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BDS4 installation manual

1. ERMINAL ED ERMINAL BLK 1 ERMINAL 1 N C SHIELD ERMINAL 8 ERMINAL C RED 2 ERMINAL 3 AL D BLK 2 ERMINAL 9 VC SHIELD ERMINAL 2 ERMINAL E RED 3 ERMINAL 10 ERMINAL F BLK 3 ER AL 4 SHIELD ERMINAL 5 ERMINAL P N C ERMINAL R RED 5 TERM 12 ERMINAL S 5 N C lt TERM 16 SHI H TERM ERMINAL T RED 6 ERMINAL U BLK 6 HI ELD CUSTOMER N C ERMOSTAT OO0K UP c mlz m NOTE 1 RESOLVER EN D JACKET AND FOLD BACK VER JACKET SHEET 3 AND 4 FOR CONNECTOR DETAILS ABLE ASSEMBLY TO BE LAB BELED GC RT 4 yy LISKA 4 PLAC CABLE LENGTH CUT OFF REMAINING PAIR 12 7MM C172 E UNDER HEAT SHRINK FROM CAB MOTOR CUT OFF REMAINING PAIR EVEN WITH CABLE JACKET CRIMP TOOL MOLEX SK CODE 155 ECN DATE APP D os TEES 4 EMIL I Kollmorgen Industrial Drives CLINE AVPLIFIER RADFORD VIRGINIA GUIDE FOR SOLV BY EWR CHK BY DATE APP D BY DATE SCALE DW G NO SHEET 12 OF 14 ISSUE
2. x DWG NO SHEET 1 OF ISSUE 93231 8054 PSR4 5 SIN LO CONNECT OR 22 EXTERNAL REGEN RESISTOR SINHI NECTOR 5 f MOTO yy nN pepa ys LE s ON PSR4 5 RESOLVER AND ieee ORIS LY FOR PSR 5 THERMOSTAT CABLE r ON 584 5 12 8 20 AMPS 2 4 cos 0 A SINGLE PHASE FILTER SEE NOTE 10 605 CONNECTOR Ci SEE NOTE 151 REF HI gt lt 4 f d 9 gt FAULT CONTACTS REF Lt EE 0 ra m SEE NOTE 2 OVERLOAD RELAY HIELD m HIELD ET 6 3 CONNECTOR PRESENT ss J SEE NOTES 45 1 C AMP amp LARGER 1 1 5 PRAT UNITS ONLY CONNECTOR C4 S PUSHBUTTON TO ENERGIZE MAIN POWER CONNECTOR C3 CONNECTOR C2 POWER 18 VDC UNREGULATED NOT REDU 1 J 1 FOR 12 PSR4 5 5 ACTO RED 20 D MAIN LL N 18 VDC UN
3. K COPY CODE 55 FCN ND DATE Kollmorgen Industrial Drives DATE APP D RADFORD VIRGINIA GE P S CX HELL 8 CLAMP 00 2 pe 1 2 M ARK BLUE WIRE MARK WHITE WIRE UJ gt MARK C BLACK WIRE MARK GND GRN YEL WIRE lt LABEL SEE SHT 2 UJ M fy Z SHIELD TO BE CUT CABLE JA FF APPROX 2 1 4 BEYOND 3 4 SECTION vs GF INSULAT AJ H SHRINK TUBING AS SHOW SHIELD TEM ID MANUF ACTURE AS DESCRIPTION PART NUMBER 33 ACTURER N 2 A PDN 4 AW 0704 nn Y M He 4 CONUCTOR 4 AWG 9 941 004 OMN 1DOAOA TBTPR FLEX DESCRIPTION ID PART NUMBER PART NUMBER MOTOR CONNECTOR AND ACCESSORIES AJ N ID MANUFACTURER s ss PA
4. LONG BUTT CONNECTOR TO BE ET AND INS SHIELD 8 BEYOND OF BUT DO NOT D THAT IS INTO 0 CUT ERTED SNI VIL DESCRIPTIO N 10 PART MANUF A CTURER 711 A NUF ACTURER PART NUMBER 7 PART NUMBER x 4 SPADE LUG 02 HOLLINGSWORTH 5520836 2 4 COND C12 AWG A 97941 012 00 003 HOLL INGSWOR B4046BF P TOOL HOLLINGSWOR HOE MOTOR CONNECTOR AN CCESSORIES SCRIPTION ANUF AC TURER TEM E 4 ID MANUFACTURER PART NUMBER NAME PART NUVBER E DESCRIPTION ils PART NUMBER NAME PART NUMBER 5 SHRINK TUB 65 15265 RAYCHEM 1 MOTOR PLUG POWELL SHRINK TUB RAYCHEM CRIMP CONTACTS CRIMP TOOL LE ASSEMBLY TO BE LAB Es HOOK MAA Y Y Y Y ELED LUA 4A AA 5 AMPLIFI 4 9zBDS4 or ER LJ CABLE LENGTH CIN METERS COPY COD is DATE APP D DATE APP
5. 11 AND 10 2 Q PIN 1 OF CONNECTOR C1 7 ON THE MASTER UNIT 8 8 8 9 9 9 9 SYSTEM SETUP 1 THE MASTER UNIT REQUIR CARD DESIGNATED THE SLAVE REQUIRES CARD DESIGNATED 2 FOR PROPER LOAD SHARING BETWEEN UNITS THE FOLLOWING ADJUSTMENT MUS DE ON THE SLAVE UNIT THE STABILITY AND COMMAND SCALE POTS NOW FUNCT 10 Q AIN ADJUSTMENTS A AD TY POT FUL SCALE L ACH UN AND SLAVE T MD ADJUST ADJUST IT S 3 MASTER SLAV TACH SYSTEMS PES OPERATION 1 INCOMPATIBLE WITH BRUSH COPY CODE 15 ECN NO DAT APP D EP Kollmorgen Industrial Drives EE RADFORD VIRGINIA MASTER SLAVE OPERATION CHK BY DATE APP D BY DATE PLOT SCALE DWG NO SHEET 3 OF 7 ISSUE iit 93231 2 ER 054 8054 CONNECTOR CONNECTOR CI DIFF HI DIFF 10 E CONNECTION SHOWN 5 F R MASTER m x 2 2 Sit 2 2 AND SLAVE DIRECTION ENABLE MASTER AND SLAVE IN OPPOSITE DIRECTION INTERCHANGE DN
6. HI J CJC0 0 gt QJ LABEL 2 6 HEATSHRINK 7 SEE SHT 2 P ONN die HEATSHR INK TUM d 2 275 4 ONG 5 LELD amp GRN YEL WIRE Ns CUT OFF VD CABLE J ET AND INSERTED OR CSTRIP RS YEL WIRE VO ARD TION OF GRN YEL 15 WILL Ro INSERTED TO OTHER END OF butt CONNECTOR 4 CRIMP CONTACTS 62 TEM T ID MANUFACTURER CRIPTION PART NUMBER PART NUMBER 2 CONDUCTOR 8 AWG 97941 008 8 M ITEM DESCRIPTION m MANUFACTURER PART NUMBER PART NUMBER 4 RING TERMINAL A 79406 002 HOLLINGSWORTH R3027BF CRIMP TOOL N A HOLL IN 6 3 BUTT CONN 004 HOLL 165 MOTOR CONNECTOR AND ACCESSORIES MANUFACTURER NAME PART NUMBER VEAM CIR 06F 32 1 S F80 J TI C SCRIPTION 1 MOTOR PLUG CRIMP REDUCER CRIMP TOOL INSERTION TOOL N A EAM GUIDE PINS N A VEAM 6 3 4 SHRINK TUB G 17634 RAYCHEM RNF 100 1 3 4 THIS CABLE ASSEMBLY TO BE LABELED GC MBA X X XX ir 3 AMPLIFIER RIV AMPLIFIER
7. E cL iua 5 8 6 zx CONNECTOR 6 SHRINK 4 LONG SHIELD amp GRN YEL WIRE BE CUT OFF cas BEYOND CAE ET AND INSERTED IN ONG OF BUT DO NOT D Esa hod 01 MANUFACTURER EN m EJ Cn U A 0 ANUFACTURER M DESCRIPTION NAME PARI PART NUMBER NAME U PART NUMBER HA 5520836 B4046BF HOE 02 HOLL 1 NGSWOR 003 HOLL INGSWOR CRIMP TOOL HOLLIN 2 4 COND C12 AWG 97941 012 C amp M 0 MANUFACTURER MO UK JN NEC IR A N 2 UK 3 gt gt 2 10N B F E R E E F P A JM PR ID MANUFACTURER co NUMBER 6 15 8 SHRINK TUB H 15577 RAYCHEM RNF 100 1 5 8 DESCRIPTION PART NUMBER NAME PART NUMBER T 1 MOTOR PLUG A 63197 BENDIX MS3106 THIS CABLE ASSEMBLY TO BE LABELED GCA M6A X X XX 4 5zBDS4 or S AMPLIFIER 5 6 CABLE LENGTH CIN METERS en CODE 155 ECN NO DATE APP D
8. RIMPED MOTOR CONNECTOR LINE RESOLVER CABLE WITH THERMOSTAT GC R Z 5 XX ARTS LIST CONNECTION CHART CABLE MOTOR CONNECTION BDS4 CI or BDS ITEM ON D MANUFACTURER TEM 5 ITEM 4 1 TEM 2 DESCRIPTION PART NUMBER NAME PART NUMBER ERMINAL A RED ERMINAL 7 NC 4 81948 BELDEN 8725 ERMINAL _ BLACK ERMINAL N C SHIELD ERMINAL 8 ERMINAL C WHT YEL ERMINAL 3 MOTOR CONNECTOR AND ACCESSORIES TET ST DESCRIPTION VC SHIELD ERMINAL 2 PART NUMBER NAME PART NUMBER u s 5 MOTOR HOUSING SOURIAU 851 0 19850 L ERMINAL F WHT BLK ERMINAL 4 7 CRIMP CONTACT SOUR 1 1758 Ve SHIELD ERMINAL 5 6 FILLER PLUG 84823 001 SOURIAU 4144A ERMINAL CRIMP TOOL SOURIAU MS3191 1 TERMINAL F N C BDS4 C2 OR BDS5 C3 AND ACCESSORIES ITEM n 0 MANUFACTURER ERMINAL R 5 EE 9 aang 11 12 POS HOUSING A 8 MOLEX 3 CRIMP PIN MOLEX ERMINAL T GREEN CUSTOMER CRIMP TODL MOLEX ERMINAL U WHITE THERMOSTAT SHIELD OOK UP SEE 5 THIS H EET 5 AND 6 FOR CONN CABLE ASSEMBLY BE ECTOR DETAI
9. SEE POSITION CODE CHART MILLIMETERS INCHES CONN QTY PIN QTY 1 CUT WIRE TO LENGTH SHOWN BELOW C TOD DTOE E TOF w 16 84 815 ar 5 2343200 5 32 111H32 48 1111234 7 48 111000 5 32 5546000 4 24 R 00 SCALE DWG USE DIMENSIDNS ONLY UNLESS OTHERWISE SPECIFIED DWG ND XX DEC PL 5 XXX DEC PLACES ANG DIM 1 ALL DIMENSIDNS MILLIMETERS UNLESS OTHERWISE SPECIFIED ISSUE ue CONN PIN WIRE LENGTH FROM CUT WIRE LENGTH SHOWN BELOW QTY QTY 108 F 1706 PEDE IRS N N 2 8 2 8 3 6 5 10000 3 16 5H32000 CAD DWG MATERIAL FINISH Y BE USED ON THIS CABLE S
10. MOTOR CONNECTOR AND ACCESSORIES VR ITEM DESCRIPTION m iu ee 4 PART NUMBER PART NUMBER a MOTOR PLUG A 97943 SEND IX 75 95 RAYC p 32085002827 3 WEIDMULLER 2 HOLLINGSWORTH 9 RAYCHEM DCPT 12 6 45 THIS CABLE BE LABELED 9 LENGTH IN M COPY CODE 155 CN NO A APP D M ete oput FP Kollmorgen Industrial Drives COLDL INE ASSEMBLY NO DATE APP D Z I a RADFORD VIRGINIA GUIDE FOR MOTOR CABLES E DIN BY DATE APP D BY DATE SCALE EWR 10 01 92 CHK BY DATE ING GS ONLY W CRIMP ONLY W CRIMP J MOTOR HOUS FILLER 7 CONTACTS 7 FIBERGLASS 9 1 8 SHRI SEE SHEET 2 FOR DETAILS 1 2 Ho N sr SHRINK T SLEEV ING 8 NK TUBING SEE SHRINK TUBING 13 LABEL TUBING SHEET 2 1 8 HEAT RESOLVER WO TACH T TUBING amp SLEEV CFOR CONNECTORS amp RELATED PAR NG PARTS IND T IVIDUAL SHEETS 10 MANUFACTURER DESCRIPTION PART NUMBER NAME PAR
11. COLDLINE MUN LORI US Kollmorgen Industrial Drives GUIDE FDR MOTC GUIDE FOR MOTOR ABLE RADFORD VIRGINIA 3 THRU 20 AMP CHK BY DATE APP D BY DATE SCALE DWG NO SHEET 6 OF 6 1550 4 THIS DRAWING CONTAINS THE INFORMATION NECESSARY FABRICATE MOTOR CABLES USED WITH BDS4 5 30 40 8 55 OR 5 30 amp 55 THE FOLLOWING D MOTORS IF THEY HAVE THREADED C F R 4 F R XS SEE SHEET 5 amp 6 5 SEE SHEET 7 8 8 FOR 0 4 CAD DWG CABLE LENGTH PART NUMBER DESCRIPTION METERS FEET COEDEINE S CABLE LENGTH 0 CABLE CIN METERS 80 W THREADED 5 0 CONNECTORS 1 1 3 0 2 4 4 5 8054 or 5 AMPLIFIER 5 S D SMART DRIVE AMPLIFIER COPY CODE c IT 2 x gt 70 70 1 DATE APP D 01 M MDB FDO Kollmorgen Industrial Drives _ GOLD RADFORD VIRGINIA GUIDE APP D BY DATE SEALE DWG MB 5 FDO 1 6 92 1 1 93539 14 CHK BY DATE E
12. gt IN M L K PLUG HE CRIMP P CONTACTS ORDING TO CONTA CTS AND TO THE PLUG THE CONNECT I THE CABLE MM C172 THEY CRIMP BODY W ON CHART TH USE STEP 6 5 NOTE 4 A THE WIRES luz m m X M lt FOR CORRECT LABEL MARKING 1 FOR CABLE ASSEMBLY GC R 4 5 XX SOLDER CONTACTS INTO THE SOLDER CUPS AN ALONG THE CABLE T URE AND SCREW BACKS NK TUBING MATE LOCATION A BELOW CONNECTION C HEAT SHRINK TUBING PICTURED ON SHEET 1 APPL SHRINK TUBING AS G UR SOLDER FIBERGLASS FAT TO SHRINK FLUG BODY PLUG BODY ED SHEET 1 5 SHOWN ON SHEET ART CA SAME AS USED ees SEE SHEET 7 OR 8 Co ECN ND DATE APP D Kollmorgen Industrial Drives RADFORD VIRGINIA GOLDL INE GUIDE EC DWN BY EWR CHK BY DATE BY DATE SCALE DWG NO Lii ISSUE PLUG BODY M III ABLE CLAMP 4 BACKSHELL TYPI
13. THERMOSTAT RESOLVER TACH THERMOSTAT RESOLVER BRAKE TACH 6 2 30 54 181 PART NUMBER DESCRIPTION 00 9 31 33 2 19 50 RXX AS XX CABLE LENGTH 012 12 4 36 2 60 201 GOLDL INE METERS XU E 3g 3 511 CABLE 015 15 39 3 21 BDS4 or 5 AMPLIFIER 5 COPY CODE 155 ND DATE APP D Kollmorgen Industrial Drives AMPLIFIER ASSEM RADFORD VIRGINIA GUIDE FOR RESOLVER 59 APP D SHEET 3 OF 14 ISSUE DW BY DATE EWR MPD DUE SCALE CHK BY DATE 05 18 02 05 18 92 PLUG BODY MY ABLE CLAMP TYPICAL TWO WIRE J SHIELDED 1 IN CABLE Di No 0 J SHEET 4 OF 14 ISSUE 03369 HEAT SHRINK 4 FOIL SHIELD CABLE OUTER 515 1 SLEP 2 STEP 3 7 cO 3 tz 11211 STEP 4 3 FH 7 Je Dese 3X FOIL S 4 5 12 7 a 50 JACKET L BACKSHELL ASS JUR
14. UUUUU 1111 UUUUUUUUU 000000000000 l STATIC SENSITIVE NDLE ACCORDINGLY 12 9 N 13 39 MAX N N N gi eren EE e e ES Sl L Ria 2 eal E tia 81 144 69 58 KOLLNORGEN Bus 2 85 C2 wal Pe 2 AIA WIDE SLOT 2 PLACES CAD DWG CODE 155 APP D ECN NO D ATE APP D 2 Kollmorgen Industrial Drives RADFORD VIRGINIA OUTL IN Qo EN DIME BDS4A 10 AMP STON DWN BY DATE CHK BY DATE 0 EWR 6 03 92 CJF PLOT SCALE 1 4 A 93572 NO ISSUE 2 ISSUE UNLESS OTHERWISE SPECIFIED ANG DIM 1 DEGREE METRIC INCHES DO NOT SCALE DWG USE DIMENSIONS ONLY X DEC PLACES ES 2 ALL DIMENSIONS ARE MILLIMETERS XX DEC PLACES UNLESS OTHERW bis J w SE
15. 5 1 BDS4 5 3 Symptoms and Corrections 5 2 5 3 1 The Motor Exhibits Very Low Torque or is Totally Inoperative 5 2 5 3 2 The Motor is Erratic or Exhibits an Improper Mode of Operation 5 2 5 3 3 BDS4 3 6 10 20 30 40 and 55 Amp Status LED S 5 2 5 3 4 PSR4 5 12 and 20 Amp Status LED s 5 3 5 3 5 PSR4 5 50 and 75 Amp Status LED s 54 5 3 6 BDS4 or PSR4 5 Reset Procedures 54 CHAPTER 6 SPARE PARTS 6 1 Introduction 6 1 6 2 Recommended Spare Parts 6 1 6 3 Ordering instructions 6 3 APPENDIX A WARRANTY INFORMATION APPENDIX B MODEL NUMBERS TABLE OF CONTENTS APPENDIX C CONNECTOR KITS amp TOOLS APPENDIX D SPECIFICATIONS APPENDIX E OPTIONS E 1 PSR4 S Electrical Options E 1 E 2 BDS4 Electrical Options E 1 E 2 1 Integrated Options E 1 2 2 BDS4 OPT2 3A Option Board E 1 2 2 1 BDS4 OPT2 3A 01 Board E 2 2 2 2 BDS4 OPT2 3A 02 Board E 3 2 2 3 BDS4 OPT2 3A 03 Board E 3 E 2 24 BDS4 and BDS4 OPT2 3A Board System Specifications E 3 E 3 BDS
16. E 7 Individual Cable Set Screw Type Thread B 5 E 4 R D Converter Speeds E 8 List Drawings BDS4 List of Drawings Motor Connection Purchase Spec for Mini Fit Jr Series Connector Purchase Spec for Mini Fit Jr Series Terminals Outline amp Dimension 5 4 5 12 amp 20 Amp Outline amp Dimension 5 4 5 50 amp 75 Amp PRS4 5 50A 75A with amp without Soft Start Simplified Schematic Outline amp Dimension BDS4 55 Amp Wiring amp Mounting DiagramER 20 Outline amp Dimension BDS4 30 amp 40 Amp BDS4 Wiring Diagram Wiring amp Mounting Diagram ER 21 Wiring amp Mounting Diagram ER 22 Wiring amp Mounting Diagram ER 23 GOLDLINE Amplifier Assembly Guide for Resolver Cables PRS4 5 12A 20A Simplified Schematic PSR4 5 Internal Schematic GOLDLINE Amplifier Assembly Guide for Motor Cables 30 40 amp 55 Amp GOLDLINE Amplifier Assembly Guide for Motor Cables 3 thru 20 Amp GOLDLINE Amplifier Assembly Guide for Motor Cables 3 thru 20 Amp GOLDLINE Amplifier Assembly Guide for Motor Cables 30 40 amp 55 Amp GOLDLINE Amplifier Assembly Guide for Resolver Cables BDS4 Direction Limit Wiring Diagram Outline amp Dimension BDS4 3 amp 6 Amp Outline amp Dimension BDS4 20 Amp Outline and Dimension BDS4 10 Amp Mounting Hole Pattern BDS4 BDS5 PSR4 5 DC Bus Cable Assembly for BDS4 5 amp PSR4 5 Mounting Hole Pattern 8
17. CKET TION oM WE is P CON APPROX 2 12 A gt BLACK O BEYOND ARK PART NUMBER 2 4 CONDUCTOR 4 A 97041 004 OMN 100404 TBTPR FLEX DESCRIPTIO MANUFACTURER PART NUMBER MOTOR CONNECT CCESSORIES DESCRIPTION MANUFAC TURER RING TERMINAL PART NUMBER MOTOR PLUG 5 17 SLATES NA jm gt 19 OU cz co 20 BUS 97 6 1 2 SHRINK TUB RNF 100 1 1 1 2 5 8 SHRINK 8 THIS CABL TO BE LABE 4 5 8094 S Z D Ts or 5 SMART DRI AMPL VE AMPL LENGTH N METERS COPY CODE 155 DATE APP D 55 NO DATE APP D Kollmorgen Industrial Drives RADFORD VIRGINIA DIN BY EWR 10 DATE 01 92 CHK DATE APP D BY DATE SHEET 9 OF 1 MPED CONNECTOR 30 A DLINE MOTOR CA OR CONNECTOR HELL amp CLAMP
18. RIMPED MOTOR CONNEC 1 11 RESOLVER CABLE WITH THE BRAKE AND TACH GC SESS CONNERTID DESCRIPTION MANUFACTURER PART NUMBER PART NUMBER 6 PAIR A 50573 CONN SSORIES DESCR MANUF ACTURER PART NUMBER PART NUMBER 5 MOTOR HOUSING IN7 7 CRIMP CONTACT 6 FILLER PLUG 10 4 7 REDUCER POWELL 0 CRIMP TOO L BENDIX 805 C2 OR BUSS 3 AND ACCESSORIES DESCRIPTION PART NUMBE MANUFACTURER R NAME 12 POS HOUSING MOLEX 3 CRIMP PIN MOLEX CRIMP TOOL MOLEX 054 AND ACCESSORIES DESCRIPTION ID PART NUMBER MANUF AC TURER NAME 20 POS HOUSING MOLEX CRIMP PIN MOLEX CRIMP TOOL MOLEX OK UP MOTOR CONNECTION CABLE BDS TEM 5 TEM 4 ERMINAL A RED 1 ERMINAL B BLK ERMINAL 1 SHIELD ERMINAL 8 ERMINAL C RED 2 ERMINAL 3 ERMINAL D BLK 2 ERMINAL 9 SHIELD ERMINAL 2 MINAL E RED 3 ERMINAL 10 MINAL F BLK 3 ERMINAL 4 N C SHIELD ERMINAL 5 ERMINAL RED 4 CUSTOMER ER AL P BLK
19. 2 CABLE M UJ gt we LABEL ID Pen 6 HEATSHRINK SEE SHT 2 N 1 LONG ges d Co MARK HEATSHRINK 6 if 1 GRNZYEL ELD CUT 0 APPROX BEYOND ABLE JACKET REMO E TION FROM O ABOVE WRAP CON CABLE ID MANUFACTURE DESCRIPTION PART NUMBER PART NUMBER JOC D MANUFACTURER PART NUMBER Orn OW AJ K 2 4 CONDUCTOR 4 A 9794 1 004 OMN 1DO404 TBTPR FLEX DESCRIPTION MOTOR CONNECTOR AND ACCESSORIES TERMINAL TEM dese beo 10 MANUF ACTURE 1 PART NUMBER PART NUMBER um IMP TOOL 1 MOTOR PLUG A 97133 VEAM 016CFZ32 1 S F80 B2 a 3 20 BUS WIRE 2 SHRINK TUB 9 8 SHRINK TUB THIS CABLE ASSEMBLY TO BE LABELE 41 4 5 BDSZ or 5 AMPLI S DzSVART DRIVE AMPL 0 1 D MM DME FP Kollmorgen Industrial Drives
20. V J COI CLAMP 5 HEATSHRINK N 4 e 5 LONG 4 2 y x ABEL 10 ce CSEE SHT 2 Z P T in HEATSHR INK quM Va s ELE 4 LONG yy ee oe LELD amp GRNZYEL WIRE Ns CUT OFF 0 CABLE J ET AND INSERTED INTO L RGE END OR CSTRIP S WIRE VO ARD OF GRN VYEL 15 WILL RS INSERTED F CABLE OTHER END OF ID MANUFACTURER SCRIPTION PART NUMBER NAME PART NUMBER ID MANUFACTURER 2 4 CONUCTOR 8 AWG 97941 008 76M DESCRIPTION PARI NUMBER MOTOR CONNECTOR AND ACCESSORIES OLL I NGSWORT TEM ID MANUFACTURER AE DESCRIPTION CRIMP TOOL OLL IN OLL I NGSW PART NUMBER PART NUMBER 3 BUTT CONN RAYCHEM MOTOR PLUG 5 3716 SHRINK TUB CRIMP CONTACTS 72 VE eu cy CRIMP TOOL THIS CABLE ASSEMBLY TO BE LABE I T S S gt gt lt lt
21. ceo Cn K COPY CODE 15 FCN ND DATE APP D cS Kollmorgen Industrial Drives e m RADFORD VIRGINIA APP D BY DATE DWN DATE EWR CHK BY DATE 0 20 02 8 78 07 00 20 96 HELL 8 4 LABEL SHT 42 X HEATSHRINK 10 d N 2 CABLE Aoc M 9 LJ oS 7 00 J TIFT 0 C 5 LELD amp GRN Y WD CABLE J JO ARD AT IS CUT OFF INTO OTHER END OF ms CO J ET AND OR CSTRIP YEL W TION WILL na WIRE TO Ns CUT OFF NSERTED OF INSERT CONDUCTOR 8 AWG A 97941 008 amp M MOTOR CONN CCESSORIES DESCRIPTION MANUFACTURER PART NU MOTOR PLUG CIR 06F DESCRIPTION MANUF AC TURER NUMBER NAME NUMBER i RING TERMINAL 9406 002 HOLL I NGSWOR T CRIMP TOOL HOLL TN 3 BUTT CONN HO
22. CODE 155 DATE APP D Kollmorgen Industrial Drives RADFORD VIRGINIA MBL Y OR CABLE DIN BY EWR DATE 0 01 92 APP D BY CHK BY DATE DATE SHEET 7 OF 1 SOLDER GOLDL INE MOTOR CAB A Bo A INEC I R HELL 8 CLAMP 2 CABLE 2 AD 2 I 7 LABEL M BLACK 6 HEATSHRINK SEE SHT 2 2 1 LONG p p 1 WIR HEATSHRINK 6 4 LONG XW T SHIELD 8 GRIVYEL WIRE BE CUT OFF D CABLE JACKET AND INSERTED INTO L RGE END UR STRIP GRNZYEL WIRE SECTION OF GRN VYEL WIR WILL BE INSERTED 00 0 ARD 5 CUT OFF IN OTHER END OF CONNECTOR 1 7 CABLE TEM ID MANUFACTURER DESCRIPTION PART NUMBER NAME PART NUMBER 2 4 CONDUCTOR 8 A 97941 008 C amp M ID MANUFACTURER DESCRIPTION PART NUMBER NAME PART NUMBER MOTOR CONNECTOR AND
23. 5 5 8 SHRINK 4 LONG NK PRA A Fan SPADE LUG S TY 4 EZ SHIELD amp GRN BEYOND CABLE JACKET AND OF BUTT CONNECTOR STR DO NOT DISCARD THE SECTI S OFF T THAT W ie BE INS INTO OTHER END BUTT CONNECTO DESCRIPTION MANUF ACTURER 4 MANUFACTURER DESCRIPTION 1 ge NAME PART NUMBER PART NUMBER 4 SPADE LUG 5520836 4 CONDUCTC 3 BUTT CONN B4046BF CRIMP TOO HOE OR CONNECTOR AND ACCESSORIES DESCRIPTION PART NUMBER 10 MANUFACTURER DESCRIPTION MANUFACTURER PART NUMBER PART MP CONT OTOR PLUG 5 3 16 SHRINK 10S F80 38 6 5 8 SHRINK TUB GUIDE PINS TOOL INSERT ION TOOL THIS CABLE ASSEMBLY BE LABELED GC EUNT S D SMA T DRM CABLE LENCTH METERS 155 DATE 0 DATE Kollmorgen Industrial D
24. NE 2 10 MANUFACTURER PART NUMBER PART NUMBER x DESCRIPTION PART NUMBER PART NUMBER MOTOR PLUG VEAM CIR 06F 22 228 5 13 16 SHRINK TUB 6 15265 RAYCHEM RNE 6 3 8 SHRINK TUB RAYCHEM RNF THIS CABLE ASSEMBLY TO BE LABELED GC M6A X X XX 3 AMPLIFIER 5 S D SMA T DRIVE AMPLIFIER CABLE LENGTH CIN METERS CAD DWC COPY CODE 155 NO DATE APP D GOLDL INE BLY 1 Kollmorgen Industrial Drives GUIDE FOR MOTOR CABLES RADFORD VIRGINIA 3 THRU 20 DATE 05 18 02 05 18 92 APP D BY DATE DIN BY EWR CHK BY DATE DWG OF 8 ISSUE USED WITH 8054 HAVE THREADED CONNECTORS FOR C MOTORS SEE SHEET 3 6A MOTORS INFORMATION NECESSARY FABRICATE MOTOR CABLES TO BE 3 THRU 20 AMP UNITS TO USE WITH THE FOLLOWING MOTORS CIF THEY 26 0 1 J SEE SHEET DWG NO SHEET 1 OF 6 ISSUE 3 7 2421402240 CAD DWG SCRIPTION CABLE LENGTH CIN METERS DASH CABLE LENGTH DASH CABLE LENGTH DASH CABLE LENGTH PART NUMBER DE NO METERS FEET NO METERS FEET NO METERS BEET GOLDLINE T 03 9 10 2 JU 51 21 170 CABLE
25. CRIMP TOOL MOLEX LK 6 ERMOSTAT OOK UP 054 AND ACCESSORIES NL H CU AJ FE SHEET 2 AND 3 FOR CONNECTOR DETAILS N P x THIS CABLE ASSEMBLY TO BE LABELED O PART NUMBER NAME 475 8054 AMPLIFIER CABLE LENGTH NOTE IN METERS 20 POS HOUSING MOLEX CRIMP PIN MOLEX 1 RESOLVER END CUT OFF REMAINING PAIR 12 7MM 172 FROM CABLE JACKET AND FOLD BACK OVER JACKET PLACE UNDER HEAT SHRINK CRIMP TOOL MOLEX MOTOR CUT OFF REMAINING PAIR EVEN WITH CABLE JACK K COPY CODE 155 DATE APP D Kollmorgen Industrial Drives CLINE AMPLIFIER 227 cs 4 m gt TT RADFORD VIRGINIA GUIDE FOR RESOLV DIN BY DATE APP D BY EWR 10 01 92 DATE SCALE DWG NO SHEET 10 OF 13 ISSUE CHK BY DATE NOC yr lt i m b e L 2201 CONNECTOR LE WITH 1 DESCRIPTION MANUFACTURER PART NUMBER 6 PAIR SORTA MO
26. ASSEMBLY 1 HAS BEEN REMOVED FROM THE CABLE STEP 4 PERFORM STEP 3 FOR EACH REMAINING PAIRS HEA JBING ONTO THE CABLE 5 SLIDE THE HEATSHRINK TUBING FROM STEP 1 ONTO THE END ACK 381MM 15 00 THIS OF THE CABLE AND SHRINK AS SHOWN ABOVE OIL SHIELDS 1 SELECT ONE OF THE WIRE WING OPERATIONS SEE NOTE 1 STEP 2 T L OW 1 3 STEP 23 5 F Ug 20 HY G2 RS TO STRIP INSULATION FROM INDIVIDUAL 1 FOR CABLE 3 FOR CABLE SEE SHEET OF THE THREE WIRES FOR CABLE GC RT 4 5 XX 5 SHEET 11 os ne FOR CABLE ASSEMBLY GC RBT 4 5 XX SEE SHEET 13 SEE SHEET 0 CO INSERT ALL PINS THIS DIRECTION AS SHOWN gt COPY CODE 155 DATE APP D EU ER Cuma r Kollmorgen Industrial Drives gt RADFORD VIRGINIA GUIDE DIN BY EWR APP D BY DATE SCALE DWG CHK BY DATE
27. m DIN BY DATE CHK BY s EWR 07 12 91 Au SEIT eee o rca Mp PWG 228 Va PAN HD SCREW QTv 2 A 93141 3 V4 LOCKWASHER QTY 2 FLATWIASHER 5 O D 2 STONDOFE SPRUCE PINE 2105 IB QTY 2 6 SET TRIP CURRENT GTY C 1 750 DIA TO 10 5 A 2 2214 4 ao Lite 16 25 17 88 CONNECT RESISTOR TO TERM BLOCK LOCATED E AT TOP PRAS we SEE NOTE 1 PS 2 _ p 7 32 DIA SAY 1 SO NOT INSTALL RESISTOR NENE VLATAMABLE MNYERIAL ES B gt SHOCK HAZARD 8 RESISTOR CONNECTED TO HIGH VOLTAGE RECOMMENDED BAWG 25 3 BOTTOM STANDOFFS ARE THREADED X 3 8 DP MOUNT HOLES FOR MOUNTING RESISTORS TO PANELS ETC 3 0UTPUT CONTACTS WIRED TO DROP MAIN LINES WHEN Kollmorgen Industrial Drives CONTACTS OPEN ON OVERLOAD j WIRING MOUNTING DIAG XX DEC PLACES 018 CE D XXX DEC PLACES t 008 ANG DIM 15 A ER 20 NEN a 5 T OTHERWISE HE METRIC CINCHES DO NOT SCALE DWG USE DIMENSI
28. 0 7 28 WIDE SLOT PLACES E 2 NS BESE 151 1111 EEEEEEEEEEJI js je Je 5 js je je ial ja js je Ie 15 le g js je fel EE 28 5 W SL ZO 11 64 1 23 APES MAX 91 2 PLACES i 3 THIS UNIT CONTAINS STATIC SENSITIVE MATERIAL RANDLE ACCORDINGLY CAD DWG COPY CODE 155 DATE APP D 55 ENNO DATE APP D 2 Kollmorgen Industrial Drives QUTLINE amp DIMENSION 7 11 96 RADFORD VIRGINIA BDS4A 20AMP DIN BY DATE CHK BY DATE IPP D BY DATE PLOT SCALE DWG NO ISSUE EWR 8 03 92 CJF 8 03 92 114 95 3 3 UNLESS SPEC IFIED X DEC PLACE XX DEC 1 DEC C INCHES PLACES PLACES DO NOT SCALE DWG 15 ALL DIMENSIONS 005 IN IN PARENTHESES 1 1 UNLESS ARE MILL IVETERS USE DIMENSIONS WITH 15 SPEC ONLY NCHES DWG 1550 E70 AS THIS UN MATERIA iL H CONT AINS
29. 1 2 Product Description 13 Features 1 4 Theory of Operation 1 4 1 PSR4 5 Power Supply Module 1 2 1 4 2 BDS4 Servo Amplifier Module 1 4 1 4 3 Brushless DC Motor 1 5 1 4 4 Power Up Down Sequencing 1 5 1 4 5 With Soft Start Circuit Standard 1 5 1 4 6 Without Soft Start Circuit or Dynamic Bus Discharge Optiona 1 6 1 5 Typical System Diagram 1 6 CHAPTER 2 INSTALLATION 2 1 Introduction asia 2 1 2 2 Safety information 2 1 2 3 Conventions 2 1 2 3 1 BDS4A vs BDS4V amp PSR4 5A vs PSR4 5V 2 2 2 3 2 Model Numbering Scheme 2 2 2 3 3 Abbreviations 2 2 2 4 Unpacking And Inspection 2 2 2 5 Installation Requirements 2 2 2 5 1 Environmental Considerations 2 3 2 5 2 2 2 2 3 2 6 Assembly cere 2 3 2 6 1 Mounting 2 3 2 6 2 Mounting the External Regeneration Resistom s 2 4 2
30. A 8 41 _ 10 MANUF AC TURER 2 CONUCTOR 8 97941 008 C amp M ITE JANUFACTURER PART NUMBER NAME PART NUMBER MOTOR CONNECTOR AND ACCESSORIES 4 2ING TERMINAL A 79406 002 HOLLINGSWORTH R3027 10 MANUFACTURER i N A HOLLIN 6 DESCRIPTION CRIMP TOO PART NUMBER NAME PART NUMBER CRIMP TOOL 3 BUTT CONN 04 HOLL INGSWOR 1 MOTOR PLUG 63197 BENDIX 53106 22 225 6 3 4 SHRINK TUB RAYCHEM RNF 100 1 3 4 THIS CABLE ASSEMBLY BE LABELED GCA MOB X X XX 4 4 5 BDS4 or 5 AMPLIFIER 5 S DzSMART DRIVE AMPLIFIER Cn K COPY CODE I ECN NO DATE APP D me Kollmorgen Industrial Drives GOLDL IN co c m RADFORD VIRGINIA GUIDE FOR M DIN BY DATE CHK BY DATE APP D BY DATE ISSUE EWR 10 01 92 1 1 AT 93539 4 COI LA LA Jn gt CRIMP CONTACTS 4 e 5 CLAMP EATSHRINK LONG ZN 4
31. T INDIVIDUAL SHEETS 10 JESCRIPTION ia Pu PART NL MANUFACTURER NAME PART NUMBER MARKEL FBRGLASS SLEEV 9 8 SHRINK TUB RAYCHEM 11 TEFLON TUB RAYCHEM 12 3 8 SHRINK TUB RAYCHEM 13 1 2 SHRINK TUB RAYCHEM 14 1 4 SHRINK TUB RAYCHEM CABLE LENGTH Ful CABLE LENGTH METERS FEET METERS FEET RIN 12 POSITION HOUS as 6 1 TEFLON fof TUBING SEE SHEET 6 FOR d DETAILS 6 e NG 1 CRIMP PINS 3 1 4 CABLE 3 11 27 9 51 171 E 6 21 30 0 54 181 9 31 33 5 191 PART NUMBER DESCRIPTION 12 4 36 90 201 5 4 5 CABLE LENGTH 15 9 53 21 EB UNE ES IN METERS 054 or 5 AMPLIFIER RB RMOSTAT RESOLVER BRAKE COPY COD DATE APP D DATE APP D RADFORD VIRGINIA Kollmorgen Industrial Drives KIT N ANOS BD FIER DLINE ESOLVER AMP OR R DIN BY EWR DATE 05 18 02 05 18 92 CHK BY DATE BY DATE SHEET 2 OF 14 5 MOTOR HOU
32. c i PIN 11 TACH 4 4 4 4 5 AND PIN 1 CONNECTOR VE UNIT 6 6 4 906170 CABLE 6 6 INPU 1 POSITIVE RESPECT TO PIN 1 MASTER TO 8 8 8 8 CLOCKWISE VIEWING FROM SHAFT END TO REVERSE 9 9 9 9 INTERCHANGE PIN 11 AND PIN 1 OF CONNECTOR C1 20 10 20 10 ON THE MASTER UNIT SYSTEM SETUP STER UNIT DESIGNATED RES SLAVE S TY SIGNATED I E 054 230 WEEN T MENT MUS ADJUSTMENTS FULLY POT FULL POT FULL E LDA YPE COMPENSATION PENSATION ADJUST T NDER LOA LIGHTLY T0 INCR STABI T0 DE ND COPY CODE 155 ECN NO DATE APP D BD CA W Industrial Drives px gt W TACH OPERATION RADFORD VIRGINIA MAST OK BY DATE BY DATE PLOT SCALE Di lil NO SHEET 4 OF 7 ISSUE 93231 ISSUE M al NOTES A THE COMMONS OF MASTER BDS4 AND SLAVE BDS5 MUST BE CONNECTED THIS IS MPL ISH
33. HE SOLDER CUPS AND SOLDER L ALONG THE WIRES TO PLUG BODY RELY STEP 3 LOCATION AS SHOWN NTO THE PLUG BODY WITH USE AND SCREW BACKSHELL ONTO PLUG NOT 1 FOR CABLE AS FOR CABLE FOR CABLE A MBLY 5 MBLY D KANTEEN ay see ee S MBLY 8 SEE K COPY CODE 155 ECN NO DATE APP D 55 DATE APP D RADFORD VIRGINIA Kollmorgen Industrial Drives gt 20 DRAWN BY EWR CHK BY DATE SA A X NINE iN UJ gt 8 CLAMP 5 J HEATSHRINK 4 e 5 LONG HEATSHRINK 8 MANUF ACTURER NAME PART NUMBER 5 LELD amp D CABLE DO 1 IN ARD 5 OFF OTHER END OF CO AND IN STOR STRIP GRA YEL SECTION WILL BE WIRE CUT OFF C amp M
34. 4 ITEM uL PART NUMBER PART NUMBER ERMINAL A ED ER N C 6 PAIR CAROL 3 ERMINAL B BL TERMINAL 7 SHIELD TERMINAL 8 ERMINAL C RED 2 TERMINAL 3 MOTOR CONNECTOR AND ACCESSORIES WE BLK 2 TERMINAL 9 DESCRIPTION SS VC SHIELD IERMINAL 2 PART NUMBER NAME PART NUMBER TTE RED 3 TERMINAL 10 MOTOR HOUSING RIAU 85 4 ce n TE TT CRIMP CONTACT SOURI AU SHIELD AL 5 FILLER PLUG 84823 001 SOURTAU ERMINAL N RED 4 CUSTOMER CRIMP TODL N A SDUR LAU MS3191 1 TERMINAL P 8054 02 OR 8055 3 AND ACCESSORIES N C SHIELD HOOK UP ID MANUFACTURER TERMINAL R DESCRIPTION E SEE I PART NUMBER PART NUMBER ERMINAL S NOTE VC 2 POS HOUSING 1 TT 12 POS HOUSING MOLEX CRIMP PIN MOLEX TERMINAL T RED 6 CUSTOMER CRIMP TOOL NZA MOLEX TERMINAL U BLK 6 THERMOSTAT SHIELD DOK UP 7 SEE SHEET 5 AND 6 FOR CONNECTOR DETAILS THIS CABLE ASSEMBLY TO BE LABELED GC RB 4 5 XX NOTE CABLE LENGTH 1 RESOLVER END CUT OFF REMAINING PAIR 12 7 1 2 FROM CABLE JACKET AND FOLD BACK OVER ae PLACE UNDER HEAT SHRINK MOTOR END CUT OFF REMA G PAIR EVEN WITH CABLE JACKET 5 K CODE 1155 ND DATE APP D Kollmorgen Industrial Drives 1015 AVPLIF IER RADFORD VIRGINIA GUIDE
35. 4 SPAD LUG 3 SPADE LUG MOTOR CONNECTOR AND ACCESSORIES I TEM ID MANUF ACTURER TOOL DESCRIPTION Mx 2 mm H PART NUMBER NAME PART NUMBER TUBING amp SLEEVING 1 MOTOR PLUG 42867 145 SOURIAU 851 06EC14 5550 ID MANUF ACTURER DESCRIPTION PART NUMBE 5 SHRINK TUB 6 15265 RAYCHEM RNF 100 1 SHRINK TUB H 19577 RAYCHEM RNF 100 1 5 78 THIS CABLE ASSEMBLY TO BE LABELED or M2A X X XX 4 5zBDS4 or 5 AMPLIFIER 5 5 5 DRIVE AMPLIFIER CABLE LENGTH IN METERS A GOLDLINE AMPLIFIE K COPY CODE 155 ECN DATE APP D Kollmorgen Industrial Drives 2000 co 2 m DATE APP D RADFORD VIRGINIA 3 THRU 20 APP D BY DATE SCALE DWG SHEET 4 OF 8 ISSUE DWN BY DATE EWR CHK BY DATE 05 18 02 05 18 92 x LU NMATING MC NUZ COMES E SE CONTACTS J 5 3 16 HEATSHRI 3 NZ Ta a5
36. AMPLIFI VE AMPLI MOA V V MLATA AZAA FIER METERS LENGTH CAD DWG COPY CODE ECN DATE APP D DATE APP D Kollmorgen Industrial Drives RADFORD VIRGINIA GOLDL INE AMP IFIE GUIDE FOR 3 THRU MOTOR EMBLY DIN BY EWR DATE 05 18 02 05 18 92 CHK BY DATE APP D BY DATE SCALE DWG ISSUE C T S VIL Ji IATAD AAD 2 pum 9 AAR E VK A MB L URK 10X x LUA S AT S GOLDLIN n 3 MATING MOTOR CONNECTOR MARK BLUE W PENA 4 Sq MAR RK W W WITS 8 3 56 HEATSHR I NK jx 5 LONG CABLE GRNVYEL WIRE GND 1 00 ONG 5 8 HEAT 6 A SPADE LUC SHRINK 4 OTY LONG CADLE END TEM ID MANUFACTURER LTEM 0 MANUFACTURER DESCRIPTION DESCRIPTION PART NUMBER 7 PART NUMBER PART NUMBER PART NUMBER 2 4 CONDUCTOR A 97941 014
37. BDS4 C2 OR BUSS C 3 AND AC CESSORIES DESCRIPTION ID MANUFACTURER PART NUMBER NAME 12 POS HOUSING MOLEX 3 CRIMP PIN MOLEX CRIMP TOOL MOLEX 054 AND ACCESSOR ES DESCRIPTION ID MANUF AC TURER PART NUMBER NAME POS HOUSING MOLEX CRIMP PIN MOLEX CRIMP TOOL MOLEX ERMINAL A ED 1 ERMINAL 7 ANC ERMINAL B BLK ERMINAL SHIELD ERMINAL 8 ERMINAL C RED 2 ERMINAL 3 AL D BLK 2 ERMINAL 9 NC SHIELD ERMINAL 2 ERMINAL E RED 3 ERMINAL 10 ERMINAL F BLK 3 ERMINAL 4 SHIELD ERMINAL 5 T 1 C CO XU CUSTOME BRAKE HC JOK UP T ERMINAL RED 5 ERMINAL BLK 5 Y TERM 4 TERM TERM AJ I 1 T W AJ US ERMOSTAT OOK UP SEE SHEET 2 AND 3 CONNECTOR D THIS CABLE ASSEMBLY TO BE LAB EL AILS 4 5 8054 FLIFIER CABLE LENGTH CIN METERS D GCA RBI X X XX K DATE ECN ND Kollmorgen Industrial Drives RADFORD VIRGINIA
38. CODE 56 NO DATE APP D INDUSTRIAL DRI VES DATE APP D RADFORD VIRGINIA A KOLLMORGEN DIVISION BY DATE UNLESS OTHERWISE SPECIFIED XX DEC PLACES DO SCALE DWG USE DIMENSIONS ONLY ANG DIM 1 DEGREE XXX DEC PLACES ALL DIMENSIONS ARE INCHES UNLESS OTHERWISE SPECIFIED 1 1 18 VDC OUTPUT 18 VDC OUTPUT COM 10 VDC OUTPUT SEE NOTE 1 3 4 BUS pes SEE NOTE 1 3 E SUPPLY REGEN 109 gt gt 4 MODELS WITH INTERNAL REGEN OMIT TERMINAL BLOCK AND 15 08 MODULE GND 7 107 141 148 150 133 R DATE APP D SS NO DATE APP D RADFORD V KOLLMORGEN DIVISION Z Z lt 2 DIN BY T LLS s 5 5 CHK BY DATE APP D DATE 4 ED W MOTORS HIS DRAWING ITH 054 IF THEY INFORMA TION BAY ET TEC ESSARY TO FABRI
39. E nu 2 CONTACTS OPEN THIS WOUL OFF ANY FAULT LEDS p ae 2 ALL MUST HAVE SHIELD CONTINUITY FOR THE FULL 5 HAS OF 75 8 5 SENGT 13 RESOLV DIVIDUALLY SHIELDED PAIRS 7 E ACTUAL APPLICATION MA INSULATED WIRE AND REFER TO SIZE FOR THE CURRENTS 11 0 1 RATED TIME DEL 14 RECOMMEND NECTION TO TERMINAL BLOCKS AND GROUND PER WIRE HOULD A 20 XTERNAL REGEN MAIN POWER AND rm SUCH AS CJ 2 4 ze m TI 35 oe A J BDS4 SHOU NNECTION AND GROUND STUD CTION AND GROUND STUD ic ALL SIGNAL AND CONTROL 5 BE 5 AW TERMINALS FOR 22 18 CONNECTORS Cl C2 CONNECTORS 51 amp C2 TERMINALS IN THE BDS4 3 AMP THRU 20 AND THE 58 5 12 AND 20 AMP IHE SCREWS IN THE POWER TERMINAL BLOCKS ARE CAPTIVE DO NOT ATTEMPT TO REMOVE THEM TO U SE LOCKING SPRING SPADE MINALS SUCH AS 54 17SF FOR 16 OMMENDED TORQUE D UND STUDS ALSO R UL STANDARD 486B FOR ONN TRICAL COL ED TORQUES FO 202 Ti ROVIDE INTERNAL TO AMPLIFIER L OVERLOAD PROTECTION DOES P TO NATIONAL ELECTRICAL CODE PROVIDED EXTERNAL REFER SIZING OF OVERLC T 5 AIH
40. H7 A CONIICTOR 88 Ww 41 10 UR 2 4 CONUCTOR 8 AWG A 97941 008 AANUF ACTURER PARI NUMBER PART NUMBER MOTOR CONNECTOR AND ACCESSORIES 4 RING TERMINAL 79406 002 HOLLINGSWORTH R3027 ITEM wara ID MANUFACTURER Ee DESCRIPTION a PART NUMBER NAME PART NUMBER a 204 HOLL INGSW 1 MOTOR PLUG A 63197 BENDIX 53106 22 225 6 3 4 SHRINK TUB 23 BUTT CONN f RAYCHEM RNF 100 1 3 4 4 5 BDS4 or 5 AMPLIF 8 S D SMART DRIVE AMPL THIS CABLE ASSEMBLY BE LABELED GCA MAB X X XX Cn K COPY CODE 15 DATE APP D CABLES me Kollmorgen Industrial Drives COLDLINE AS RADFORD VIRGINIA GUIDE FOR MOTOR co c m APP D BY DATE SCALE SHEET 4 OF 1 1550 DWN BY DATE EE wie EWR 10 01 92 CHK BY DATE COI CLAMP EATSHRI 4 e 5 NK LONG IX K f r
41. 28 00 3 8 i I O O SEE NOTES ON SHEET 1 COPY COD 995 NO DATE APP D JIS Kollmorgen Industrial Drives 1 RADFORD VIRGINIA BDSZA JS ET DIN BY DATE CHK BY DATE APP D BY DATE SCALE a ii TDG 1443 1 4 4 SEE DASH NO DO NOT SCALE DWG USE DIMENSIONS ONLY Eo SPECIFIED 080 ISSUE t N XX 55 3 8 E ALL DIMENSIONS ARE MILLIMETERS RT FOR LENGTH OF WIRE SS OTHERWISE SPEC UNLESS OTHERWISE SPECIFIED ANG DIM i ud beu 15 BETWEEN EACH CONNECTOR NO m D SEE DETAIL AY FOR 07 L Ly a T CABLE LENGTH CONFIG
42. DWG NO SHEET 4 OF 13 ISSUE 93540 5 PLUG BODY SABLE CLAMP gt HEAT SHRINK d sss N S TYPICAL 7 FOIL TWO WIRES 5 SHIELDED IN CABLE CABLE 4 CABLE OUTER l 18 JACKET BACKSHELL 8 MBLY PROCEDUR 515 1 SE ANY OUTER JACKET HAS E FOLLOWING ITEMS O JO LONG SHRINK STEP 4 FOR SOLDER CONTACTS INSERT THE WIRES INTO THE SOLDER CUPS AND SOLDER STEP 5 POSITION THE 5 8 X 1 25 HEAT SHRINK TUBING AND FIBER GLASS SLEEVING AS PICTURED ON SHEET 1 APPLY HEAT TO SHRINK TUBING B SLIDE TH C HOLD PLUG BO 4T D TIGHTEN CAB USH WITH THE FOIL SHIELD E POSITION 5 8 X 1 00 SHR ER THE END OF THE FOIL SHIELD AND SHEET 1 APPLY HEAT TO SHR SH F OUCHING STEP 6 PLACE LABEL IN APPROXIMATE LOCA Q SIR 4 3 18 1 REFER TO NOTE BELOW CONNEC IN STEP 4 A FOR CORRECT LABEL MARKING 9 10 0 STEP Z OUTER CAB S t Tes EK jx TO PLUG BODY SHELL ONTO PLUG BODY STEP 3 Tl CJ TI TUBING AS PICTURED Ao st m ON AS SHOWN ON SHEET C SAME AS US
43. E 2 2 3 BDS4 OPT2 3A 03 BOARD Electronic Encoder with Parallel Output With Drive Signals This option is similar to that discussed in Section E 2 2 2 with the exception that it also provides for a means by which the Industrial Drives 960 position controller can interface directly with the BDS4 motor controller This is accomplished by adding a small cable between Connector 32 on the BDS4 OPT2 3A board and Connector C1 of the BDS4 amplifier The 831354 motor controller signals are identified in the above table by the addition of an asterisk by the pin numbers Connector 37 on the BDS4 OPT2 3A board is located just to the left of Connector C1 mounted in the top front of the BDS4 E 2 2 4 BDS4 AND BDS4 OPT2 3A BOARD SYSTEM SPECIFICATIONS Accuracies repeatability and resolution specifications are recorded in Table E 3 E 3 APPENDIX OPTIONS E 3 BDS4 OPT D L OPTION BOARD Function The BDS4 OPT D L option board functions an interface module between the BDS4 and machine travel limit switches There are separate inputs for the CW and CCW directions of motor shaft rotation viewing the motor from the output shaft end In the event a machine limit switch 1 activated the motor will decelerate at maximum rate to zero speed and remain against the stop in a reduced current mode The BDS4 will remain fully operational with full current and torque available for movement in the opposite direction provided the oppo
44. JR CABLES 0 DATE APP D RADFORD VIRGINIA ET DIN BY DATE APP D BY DATE SCALE DWG NO SHEET 10 OF 11 ISSUE T EWR 10 01 02 93539 14 CHK BY DATE SEA SHEET 11 OF 11 ISSUE D ADEM RD OIN J N S 8 SY THREADED MOTOR CA 33A 3 7 FERRULES 1 MATING MOTOR CONNECTOR 3 W BACKSHELL 8 CLAMP MARK AQ BLUE MARK B WHITE WIRE N 2 CABLE BLACK MARK GND GRNZYEL W AN LABEL SEE SHT a mn HEATSHRINK 6 BACKSHELL EXTENSION 10 6 LONG SS 4 1 RING TERMINAL TED INTO COVERED s N SLEEVING 9 1 RING ING TERMINA SHIELD TO BE TW SINGLE CONDUCTO WITH YELLOW GR AND TERMINATED ERMINAL P 98C ARTS LIST CABLE ID MANUFACTURER SHRINK TUBING DESCRIPTION i 4 PARI NUMBER 3 MANUF AC TURER 2 4 CONDUCTOR 2 A 9 941 002 C M D TPTION i PART NUMBER NAME PART NUMBER
45. NG MOTO BLUE WAITED C BLACK E GRN LA YEL CONNECTOR 52 I N EVM Cn 1 cn ZI LHS or 3 GRN YEL WIRE GND 1 00 lox IDE LUG SPA QTY CABLE AMPLIFIER END DESCRIPTION PART NUMB 10 MANUF AC TURER ER DESCRIPTION 10 ANUFACTURER NAME U PART NUMBER PART NUMBER PART NUMBER 2 4 CONDUCTOR A 9 941 014 C amp M 4 SPADE LUG MOTOR CONNECTOR AND ACCESSORIES 3 SPAD LUG DESCRIPTION PART NUMBER 10 MANUFACTURER CRI TOOL PART NUMBER TUB ING amp SLEEVING MOTOR PLUG 14 5550 1 DESCRIPTION PART NUF ACTURER 10 T CRIMP CONTACTS A 8487 PART NUMBER CRIMP TOOL INSERTION TOOL 6 15 8 SHRINK TUB H 155 RAYCHEM RNF 100 1 5 8 FILLER PLUG THIS CABLE ASSEMBLY TO BE LABELED GC MI or A 5 BDS4 5 S D SMART DRI
46. SHIELD amp GRN YEL WIRE TO BE CUT OFF BEYOND CAB ET AND INSERTED IN MANUFACTURER EJ 711 A ID MANUFACTURER 7 DESCRIPTION PART NUMBER NAME PART NUMBER T NAME PART NUMBER CCO B4046BF HOE MOTOR CONNECTOR AND ACCESSORIES Te 3 10 MANUFACTURER TOA 1 02 HOLL INGSWOR 97941 012 C amp M 3 BUTT CONN 003 HOLL I NGSWOR P TOOL NZA HOLL TN 2 4 CONDUCTO 10 MANUF ACTURER 7S5 8 NUMBER PART NUMBER DESCRIPTION PARI NAME PARI NUMBER OTOR PLUG MP CONT 5 3 16 SHRINK TUB 6 15265 RAYCHEM 6 15 8 SHRINK TUB _ RAYCHEM 25 GUIDE PINS N A VEAM THIS CABLE ASSEMBLY TO BE LABELED GC M6A X X XX TODL 4 5zBDS4 or 5 AMPLIFIER INSERTION TOOL VEAM S D SMART DRIVE AMPLIFIER CABLE LENGTH IN METERS co 2 m home GOLBLINE Kollmorgen Industrial Drives ene RADFORD VIRGINIA TO TIRA 3 THRU DWN BY DATE CHK BY D
47. 1 2 FROM CABLE JACKET AND FOLD BACK OVER JACKET PLACE UNDER HEAT SHRINK 4 5 BD54 AMPLIFIER CABLE LENGTH iD CUT OFF REMAINING PAIR EVEN WITH CABLE JACKET 4 CIN METERS K COPY CODE 155 ECN NO DATE APP D Kollmorgen Industrial Drives SQLDLINE AMPLIFIER RADFORD VIRGINIA GUIDE FOR RESOLVER NO DATE APP D SCALE DWG SHEET 8 OF ISSUE CHK BY DATE 1 2 4 m e L SHT 9 OF 13 1551 y a Hr I 2 I gt lt gt lt P CABLE MOTOR CONNECTION CABLE 8054 C2 or 055 C3 054 Cl m DESCRIPTION M D MANUFACTURER TEM 5 TEM 4 ITEM 1 ITEM 2 PART NUMBER NAME PART NUMBER N 9 170 I J 6 PAIR 96027 004 CAROL 50573 TERMINAL BLK i RMINAL 1 WC SHIELD RMINAL 8 MOTOR CONNECTOR AND ACCESSORIES a mE 0 7 ID MANUF AC TURER x DESCRIPTION PART NUMBER NAME PART NUMBER SUUS 5 MOTO
48. BRAKE amp THERMOSTAT TO CUT ONE FOOT LONGER THAN TOTAL CABLE LENGTH STEP STEP 2 STEP DIRECTION AS S 12 OR HOWN SIR Pra OF THE THREE 20 POSIT ONNECIOR ASSEMBLY PROCEDUR RE IB INSERT ALL PINS IN THIS E IPERATIONS CONNECTOR MOVED FROM THE CABLE G ONTO THE CABLE CK 381MM 15 00 ELDS ART SELECT ONE OF THE WIRE E SEE NOTE 1 2 IN STEP 4 STEP 5 PERFORM STEP 3 J THIS OF THE CABLE AND SHR DIVIDUAL EACH REMAINI SLIDE THE HEATSHRINK TUBING NK ND PAIRS AS SHOWN ABOVE FROM STEP 1 ONTO THE END COPY CODE ECN DATE APP D DATE APP D Kollmorgen Industrial Drives RADFORD VIRGINIA GOLDL INE GUIDE 3ESOL V APP D BY DATE CHK BY DATE SCALE DWG FNIT E AA 15 JA L V SHEET 5 OF 13 RIMPED MOTOR CONNECTOR LINE RESOLVER CA WITH THERMOSTAT GC
49. DATE APP D RADFORD VIRGINIA Kollmorgen Industrial Drives MOUNTING HOLE RNC 4 BUS Bl DU PATTERN 59 4 5 DIN BY TDG APP D BY DATE DWG ND 936 ISSUE SHT OF 2 DO NOT SCALE DWG USE DIMENSIONS ALL DIMENSIONS ARE MILLIMETERS WITH INCHES IN BRACKETS UNLESS OTHERWISE SPECIFIED UNLES N OH OTHERWISE SPECIFIED DIM 1 DEGREE LE THIRD ANGLE PROJECT ION V INAL LUG LENGTH P 7 SIRI BOTH ENDS A PR STRIPPED WIRE LENGTH cy UO 3 0 45 S COD CAD DWG NO DATE 55 Kollmorgen Industrial Drives RADFORD VIRGINIA SEMBLY ISSUE an DWN BY DATE CHK BY DATE PD BY DATE SCALE 12 15 92 CJF 2 18 92 l CO ES UNLESS OTHERWISE SPECIFIED y pep EIRIC 7 ee ANG DIM 1 DEGREE Z XX DEC PLACES bis
50. EWR 10 DATE CHK BY DATE 07 02 01 9 10 13 92 APP D BY OWENS 10 13 92 DATE SHEET 1 OF 13 DWG NO SHEET 2 13 ISSUE 93540 E SS E 9 c PLUG BODY SABLE CLAMP HEAT SHRINK TYPICAL TWO WIREJ SHIELDED IN CABLE SHIELD M CABLE OUTER 1 4 5 12 7 JACKET L BACKSHELL 8 ONNECTOR ASSEMBLY PROCEDUR SOLDER CONTACTS THE WIRES INTO THE SOLDER CUPS AND SOLDER C HEAT SHRINK TUBING AND FIBERGLASS VING AS PICTURED ON SHEET 1 APPLY HEAT TO SHRINK 515 1 THE CABLE MM C172 luz m m X M SLEP 2 J 7 ALONG THE CABLE PLUG BODY URE AND SCREW BACKSHELL ONTO PLUG BODY STEP Dese 3X 3HRINK TUBING AS PICTURED ON SHEET 1 NK TUBING SIEP 6 PLACE LAB MATE LOCATION AS SHOWN ON SHEET NOTE BELOW CONNECTION CHART SAME AS USED IN STEP 4 FOR CORRECT LABEL MARKING 7 cO 3 tz 11211 STEP 4 o IN M L K J
51. 4 4 5 BDSZ or 5 AMPL 5 S D SMART DRIVE AMPL K COPY CODE 155 NO DATE APP D Kollmorgen Industrial Drives co c m DATE APP D RADFORD VIRGINIA LL DIN BY DATE APP D BY EWR 10 01 92 DATE SCALE DWG NO SHEET 3 OF 11 ISSUE CHK BY DATE MOTOR CABLE 406C MOTO N MATING MOTOR CONNECTOR JACKSHELL 8 CLAMP gt LoS 2 CABLE NS UJ gt LABEL a ACK W 6 LS SEE SHT 42 Z UTT CONN N J 4 JN G Z 3 N HEATSHRINK 6 vA LE 4 LONG y eh mee S LELD amp GRN YEL WIRE Ns CUT OEE 0 CABLE J ET AND INSERTED L RGE END TFT T1 0 STOR STRIP ERNZYEL WIE ARTS LIST 00 HE SECTION OF GRN YEL 10 ARD AT IS CUT OFF WILL BE INSERTED CABLE INTO OTHER END F BUT CONNECTOR ID MANUFACTURER CRIPTION 1 PART NUMBER NAME PART NUMBER
52. CONTACTS E PLU ONNECTION CHART Er A ARITY G BODY T WIRES INTO THE SOLDER CUPS AND SOLDER M S ay WIRES ND CRIMP D FROM THE CABLE 7MM 5 8 SHRINK 1 2 5 WITH USE ON FOLLO EAT SH HRINK TUBI ALONG SURELY HRINK RI NG ND WI THE CA NK TUBING AND AS SHOWN X X XX SEE SHEET 3 OR 4 MOA X X XX SEE SHEET 5 BLE PLUG BODY SCREW BACKSHELL ONTO PLUG BODY OR 6 TUBING AND APPLY HEAT TO SHRINK SHEETS LOCATION AS SHOWN ON COPY CODE 155 NO D ATE APP D DATE APP D Kollmorgen Industrial Drives RADFORD VIRGINIA GO LDL INE AMPLI GUID s DWN EWR DATE CHK BY DATE APP D BY DATE SCALE DWG NO CRIMPED MOTOR CONNECTOR MOTOR CABLE 40 406 MATING MOTOR CONNECTOR N S um 5 3 16 HEATSHRINK 2 J CABLE 4 e 5 LONG E un 5 8 SHR NK 4
53. GOLDL AMP GUIDE FOR RESC BY DATE CHK BY DATE SCALE DWG NO INPUT 10V MAX DIFF HI 57 4 67 1 DIFF LO C1 PIN 1 DIFFERENTIAL DO NOT USE INPUT C1 PIN 11 COMP CARD COMMAND COMMON LIMIT 67 5 CW HI 5 28VDC 67 2 CW LO 67 6 CCW HI 5 TO 28VDC 67 3 CCW LO 10 mA DIRECTION LIMIT OPTION BOARD INDUSTRIAL DRIVES RADFORD VIRGINIA KOLLMORGEN DIVISION LB cory cone CE RA E EM e nl mm 8054 DIRECTION LIMIT PLACES ons 85576 1541 94 ANG 4 DE WIRING DIAGRAM DO NOT SCALE DWG USE DIMENSIONS ONLY SCALE owe NO ISSUE ALL DIMENSIONS ARE INCHES 588 gt UNLESS OTHERWISE SPECIFIED 20 92 A 93 5 4 1 2 X DEC PLACES 4 XX DEC PLACES 4 015 IN ALL DIMENSIONS ARE MILLIVETERS WITH INCHES 3567 3 DIM 41 XX DEC PLACES 13 XXX DEC PLACES 005 IN IN PARENTHESES UNLESS OTHERWISE SPECIFIED 2 5 5 2 401 X 20 Hd 79 i 71 28 WIDE SLOT 2 PLACES BEE 157 6
54. RMS 6 0 AMPS 12 0 AMPS 20 0 AMPS 40 0 AMPS Output KVA 330 VDC BUS Continuous 1 1 2 2 3 6 KVA 7 3 45 2 0 2 2 4 4 7 3 14 5 Internal Heat 40 WATTS 65 WATTS 95 WATTS 175 WATTS Dissipation PWM Switching 10 0 KHZ 10 0 KHZ 10 0 KHZ 10 0 KHZ Frequency Motor Current Ripple 20 0 KHZ 20 0 KHZ 20 0 KHZ 20 0 KHZ Frequency 10 Resolver Excitation 7 0 KHZ 7 0 KHZ 7 0 KHZ 7 0 KHZ Frequency Speed Regulation 0 075 0 075 0 075 0 075 G Long Term TMinimum Controllable Speed Standard 12 Bit R D With 8000 RPM Max Tracking Rate 12 Bit R D With 14000 RPM Max Tracking Rate 14 Bit R D With 1 8 RPM 1 8 RPM 1 8 RPM 1 8 RPM 2000 RPM Max Tracking Rate 14 Bit R D With 1 4 RPM 1 4 RPM 1 4 RPM 1 4 RPM 3500 RPM Max Tracking Rate 16 Bit R D With 1 64 RPM 1 64 RPM 1 64 RPM 1 64 RPM 500 RPM Max Tracking Rate D 6 BDS4 APPENDIX D SPECIFICATIONS Table D 2 BDS4 Specifications Con t DESCRIPTION 8054 230 BDS4 240X BDS4 255X MAIN DC BUS Minimum 250 VDC 250 VDC 250 VDC Maximum 360 VDC 360 VDC 360 VDC Unregulated Logic Bus Input 14 5 26 VDC 14 5 26 VDC 14 5 26 VDC 0 25 AMPS 0 25 AMPS 0 25 AMPS 6 5 14 VDC 6 5 14 VDC 6 5 14 VDC 0 50 AMPS 0 50 AMPS 0 50 AMPS Fan AC Line Input 95 132 VAC 95 132 VAC 95 132 VAC 0 5 AMPS 0 5 AMPS 0 75 AMPS Output Current RMS PHASE 45 C AMB
55. WARNING 2 7 7 Connecting the External Regeneration Resistor s If an external regeneration resistor is specified connecting points are provided on the PSR4 5 Power Supply Unit refer to Notes 3 and 10 on BDS4 Wiring Diagram A 93231 BDS4 CHAPTER 2 INSTALLATION Table 2 2 BDS4 Unregulated DC Voltages C3 BDS4 PSR4 5 CONNECTOR C3 CONNECTOR C2 VOLTAGE CURRENT PINS PINS 18 V Nominal NO LOAD 17 V to 26 5 V 18 V Nominal NO LOAD 17 V to 26 5 V 10 V Nominal NO LOAD 9 V to 14 V 14 5 V MIN 1 AMP ON PSR4 5 12 OR 20 AMP UNITS 2 AMP ON PSR4 5 50 OR 75 AMP UNITS 14 5 V MIN 1 AMP ON PSR4 5 12 OR 20 AMP UNITS 2 AMP ON PSR4 5 50 OR 75 AMP UNITS COMMON 6 5 V MIN 2 AMP ON PSR4 5 12 OR 20 AMP UNITS 4 AMP ON PSR4 5 50 OR 75 AMP UNITS 18 VDC FAULT FAULT CONTACT 18 VDC CONTACT COMMON COMMON 115 V OUTPUT 115 V INPUT 10 VDC 10VDC 115 V OUTPUT 115 V INPUT Figure 2 3 BDS4 C3 amp PSR4 5 C2 Figure 2 2 PSR4 5 C1 Nominal No Load Voltages 2 7 CHAPTER 2 INSTALLATION DIFFHI DIFF LO AUX IN ENABLE ILIMIT RESET TORQUE HOLD DIFF SHIELD COMMON SHIELD COMMON SHIELD COMMON OUTPUT FAULT IMONITOR FOLD BACK SPEED MONITOR OVERTEMP DRIVE UP DRIVE UP Figure 2 4 BDS4 Connetor C1 2 7 8 Connecting the BDS4 Input Output Connector C1 The following descriptions tell the user which inputs and modes of operation are available enable the user to identify the approp
56. 6 PAIR 96027 004 CAROL 0573 TERMINAL RS co m jt m C3 MOTOR CONNECTOR AND ACCESSORIES 1 1 1 1 1 1 1 1 1 m FTI A T lt I M DESCRIPTION is MAAAC ES Ve SHIELD RMINAL 2 PART NUMBER PART NUMBER s ea L MOTOR HOUSING AU PUTET TE CRIMP CONTACT AU SHIELD RMINAL 5 FILLER PLUG SOUR I AU CRIMP TOOL NZ SQUR LAU 153191 1 TERMINAL P N C 8054 C2 OR BDS5 AND ACCESSORIES 1 D MANUF ACTURER TERMINAL R RED 5 T ERM 12 PART NUMBER NAME PART NUMBER TERMINAL S BLK 5 N C TERM 16 DESCRIPTION 12 POS HOUSING MOLEX NC 2 Jupe CRIMP PIN MOLEX SED 6 CUSTOMER CRIMP TOOL MOLEX TERMINAL U BLK 6 THERMOSTAT s HIELO DOK UP 8054 AND ACCESSORIES N C SHIELD SHEET 3 AND 4 FOR CONNECTOR DETAILS THIS CABLE ASSEMBLY BE LABELED GC RT 4 5 Xx co m m DESCRIPTION NAME PART NUMBER CABLE LENGTH NOTE 20 POS HOUSING MOLEX JACKET AND FOLD BACK OVER RESOLVER END CUT OFF REMAINING PAIR 12 7MM 172 FROM CABLE MOLEX CRIMP PIN v PLACE UNDER HEAT SHRINK MOTOR END CUT OFF
57. AND B PHASE 85 ooa QuADRATURE ENCODER JUMPER HEADER L LINES 5 COUNTS OFF ON n CD 0 6 84 6 H J dt I K L B3 K L N 11 85 1 3 M 0 82 P R G 5 5 T v U 20515 4 3 20514 4 lt lt a P0513 4 lt lt 30 60542 4 2 28 11 posoo 4 15 posos 4 17 20502 4 lt S 20503 4 20 70504 4 21 posos 4 gt 20505 4 lt lt 2 20507 4 64 Posos 4 lt lt 25 20509 4 E 20510 4 lt 27 4 lt BUSY 4 lt 12 11 CLOCK 5 43 1585 DEFAULT CONFIGURAT 1 2 3 4 7 8 9 10 11 12 ENCODER INTERFACE OPT2 3A 01 7415175 74 5175 gt ooooooooooo 1 2 74 532 oooooooooo o MARKER PULSE WIDTH SWITCHES 23 36 0 1 0 DE MARKER NARROW FGHI oooooooo lo gt Soc re ra Bee ee eee o eS e ON IS 1024 LINES W WIDE MARKER PULSE JUMPER POSITIONS ON HEADER 28 DRIVE 5 6 43538 14 16 MMC 960 INTERFACE OR RESOLVER INTERFACE ON CONNECTOR 4 VER DATA WITH SIGNALS 0PT2 3A 03 BDS4 MC1 2 CONNECTOR
58. CABLE LENGTH 06 6 20 33 33 0 60 60 200 CABLE IN METERS 09 9 30 36 63 2 0 1 Y NET e ES a ae TYPE CONN 4 5 BDS4 or 5 AMPLIFIER sue 12 40 39 30 66 66 220 M 2 T 5 50 S D SMART DRIVE AMPLIFIER xus 15 0 42 09 69 230 18 18 0 45 5 2 72 240 a E E PES SE 2 2060 21 21 18 3 200 M2B 24 24 80 51 5 70 16A 602B K OPY CODE 155 NO APP D COLDL IN BLY Kollmorgen Industrial Drives GUILD DOW JA A a ms OU J 6 51 SCM 3 EWR em RADFORD VIRGINIA 15 99 4 TDG FOO DIN BY DATE CHK BY DATE APP D BY DATE SCALE DWG SSUE M SCM EWR 08 31 92 FDO 2 1 1 i PLUG BODY ABLE CLAMP 7 10 L BACKSHELL di 5 B ES 85 93 2 SHEET 20 93421 ISSUE CABLE OUTER JACKET 515 1 C T 9 3 OIL 4 ed NE 4 STEP 4 A T WIR ND BACKSHELL AND 15 88 TOR ASSEMBLY TEMS ONTO THE REMOV 88MM ET BACK OUND THE WIRE RIP INS CT
59. TEM ID g MANUFACTURER DESCRIPTION 4 PART NUMBER NAME E PART NUMBER 4 SPADE LUG NAME PART NUMBER XSS20836 2 HOLL INGSWOR 2 4 COND C12 AWG 97941 012 C amp M 3 BUTT CONN 003 HOLLING B4046BF CRIMP TOOL NZA HOLL TN HOE MOTOR CONNECTOR AND ACCESSORIES ITEM MANUFACTURER i DESCRIPTION ITEM P 3 MANUFACTURER PART NUMBER NAME PART NUMBER DESCRIPTION PART NUMBER NAME PART NUMBER 5 SHRINK TUB G 15265 RAYCHEM 1 MOTOR PLUG SHRINK TUB CRIMP CONTACTS CRIMP TOOL THIS CABLE ASSEMBLY TO BE LABELED GCA M6A X X XX 4 5zBDS4 or 5 AMPLIFIER 5 8 CABLE LENGTH IN METERS co 2 m COPY CODE 155 ECN No DATE APP D GOLDL INE ri Kollmorgen Industrial Drives Fop Vir RADFORD VIRGINIA 3 THRU 20 CHK BY DATE APP D BY DATE SCALE DWG NO SHEET 5 OF 6 1550 SOLDERED MOTOR CONNECTOR COLDLINE MOTOR CABLE FOR 6024 602B 604 yes JMATING MOTOR CONNECTOR
60. gt lt gt lt gt lt CODE 155 DATE APP D Kollmorgen Industrial Drives RADFORD VIRGINIA DIN BY EWR 10 DATE 01 92 CHK BY DATE APP D BY DATE 5 OF 1 J S ee Ne EN h KX GOLDLINE MOTOR 606B 606C N MATING MOTOR CONNECTOR KSHELL 8 CLAMP 7 00 APEX 2 CABLE Ne UJ gt ZN O LABEL 1 9 A TSHR INK 5 80 9 2 SUTT CONN ES ANE ONG b HEATSHRINK GY GRNYEL 5 LELD amp GRN YEL WIRE TO Ns CUT ORF D CABLE J 4 LONG N Ow E J ET AND INSERTED INTO RGE END 3 OR CSTRIP RS YEL WIRE SP AES oul DO TION OF GRNZYEL 10 ARD AT IS CUT OFF WILL BE INSERTED T CABLE INTO OTHER END OF ID MANUFACTURER CRIPTION 1 PART NUMBER NAME PART NUMBER
61. 12 Position Female C3 Connector Housing 39 01 2085 A 83908 008 8 Position Female C4 Connector Housing 39 01 5 A 83908 004 4 Position Male C1 C2 C3 C4 PIN Female 39 00 0039 93105 002 18 24 AWG 2 BDS4 APPENDIX C CONNECTOR Kirs amp TOOLS Table C 4 Connector Kit PSR4 5C 200 INDUSTRIAL DRIVES CONNECTOR KIT PART NUMBER PSR4 5C 200 PSR4 5 12 20 50 and 75 MODELS CONNECTOR DESCRIPTION MOLEX PART NO 1 0 PART 10 Connector Housing 39 01 2065 ETIN 83908 006 6 Position Female Connector Housing 39 01 2085 A 83908 008 8 Position Female PIN Female 39 00 0039 A 83909 002 18 24 AWG Table C 5 Connector Tools CONNECTOR TOOLS PINS MINI FIT JR FROM MOLEX Description Engineering Order Number Number Hand Crimping Tool HTR 60622 11 01 0197 Extractor Tool HT 60630A 11 03 0038 MOLEX TELEPHONE NUMBER 708 969 4550 C 3 BDS4 APPENDIX D SPECIFICATIONS APPENDIX D SPECIFICATIONS D 1 INTRODUCTION temperatures As a general rule the failure rate of solid state components doubles for every ten degrees The Specifications for the PSR4 5 and BDS4 are Celsius rise in temperature This exponential failure provided in this appendix Derating information is rate is strong incentive for lower ambient also included for environments with high ambient temperatures D 1 APPENDIX D SPECIFICATIONS BDS4 Table D 1 PSR4 5 Specifications DESCRIPTION PSR4 5 112
62. 2 Adjust the Command Scale pot on the D L option board in the standard manner by referring to Section 4 4 1 3 or 4 4 1 4 of this manual BDS4 APPENDIX E OPTIONS Table E 1 BDS4 OPT2 3A 01 Board Specifications ENCODER RESOLUTION SELECTION MARKER PULSE WIDTH OUT A amp OUT B ENCODER JUMPER HEADER DIP SWITCH 23 amp 36 RESOLUTION 35 0 OFF 1 Encoder Encoder Quad Lines JUMPER JUMPER WIDE MARKER NARROW MARKER 1 2 0 Counts 123456789 10 1112 123456789 10 11 12 5228 EE 16 1 000000000 000000000 0 1 4 EM W X 000000000 0 1 000000000 0 1 1 This is the standard setting 12 bit These resolutions are not available on all 81354 models high resolution is also required with these resolutions APPENDIX OPTIONS BDS4 Table E 2 OPT2 3A 02 and OPT2 3A 03 Pinouts CONNECTOR 4 ICMD DIFF HI current velocity command analog ACOM DIFF LOW connected to analog common TACH TACH HI analog signal ACOM TACH LOW connected to analog common ALOCK LOCK HI analog signal ACOM ANALOG LOCK LOW analog common DRVENB Servo Drive Enable active low DCOM Digital Common DRVRDY Servo Drive Ready active low DCOM Digital Common BUSY Resolver s R to D Converter Busy active high DCOM Digital Common N C Reserved DCOM Digital Common POSOO Least Significant Bit for 12 Bit R D DCOM Digital Common POSO1 Next to Least Significant Bit for 12 Bit R D
63. 4 4 1 4 Command Scale Adjustment Automatic or Manually Operated Machines Turn the Command Scale Pot fully CCW Apply an input signal level which equals maximum desired motor speed in RPM Adjust Command Scale Pot CW for maximum desired motor speed DO NOT EXCEED THE MAXIMUM MOTOR SPEED THAT IS LISTED ON THE TL SHEET FOR THE SYSTEM Refer to the Test Limits Sheet TL to identify the maximum scaling of input signal Maximum 10 volts is standard 4 4 2 Response and Application Dependent Adjustments These adjustments allow versatility in altering the dynamic response of the BDS4 system as needed 4 3 CHAPTER 4 MAINTENANCE When altering the response system may be necessary to adjust both the STABILITY and the CURRENT LIMIT adjustments 4 4 2 1 Stability Adjustment In many cases the Stability Pot will not need to be adjusted and may be left in its fully CCW position However this pot can be used to improve the dynamic response of the servo loop by adjusting the Dynamic AC Gain To adjust the AC Gain to the proper point use an oscilloscope to monitor the internal tach signal at the SPEED MONITOR test point with respect to A COM refer to Figures 1 and 3 Use a second channel of the scope to monitor the current signal at the I MONITOR test point also with respect to A COM refer to Figures 1 and 3 Turn the STABILITY Pot fully CCW Apply a step input rapid command signal While acceleratin
64. DCOM Digital Common POSO2 One Input Bit of Resolver POSO3 One Input Bit of Resolver POSO4 One Input Bit of Resolver POSO5 One Input Bit of Resolver POSO6 One Input Bit of Resolver POSO7 One Input Bit of Resolver POSO8 One Input Bit of Resolver 5 9 One Input of Resolver POS10 Next to Most Significant Bit of the Resolver POS11 Most Significant Bit of the Resolver POS12 Next to Least Significant Bit for 14 Bit R D POS13 Least Significant Bit for 14 Bit R D POS14 Next to Least Significant Bit for 16 Bit R D POS15 Least Significant Bit for 16 Bit R D Reserved SHIELD EMI Isolated Shield Common These signals are only available on the OPT2 3A 03 option es These signals are not available on all models of the BDS4 E 6 BDS4 APPENDIX E OPTIONS Table E 3 System Specifications J GRADE R D R D CONVERTER ACCY 4 0 MIN 22 0 MIN RESOLVER 7 0 7 0 ACCURACIES H GRADE R D RESOLVER MOUNTING 3 0 MIN 3 0 UNCERTAINTY 1 Count WORST CASE ACCY 5 27 ARC 37 27 ARC MIN 0 62 DEGREES 3 5 BITS 28 55 ARC MIN 0 48 DEGREES 5 27 ARC 19 27 ARC MIN 0 32 DEGREES 1 8 BITS 13 87 ARC MIN 0 22 DEGREES 1 3 BITS 5 27 ARC MIN 0 088 DEGREES 1 0 BIT TYPICAL ACCY 2 5 BITS 5 27 ARC MIN 0 088 DEGREES 1 0 BIT RESOLUTION 212 BITS 4096 212 BITS 4096 REPEATABILITY Worst Case Analysis assu
65. Dimension 81354 55 Amp 93141 Wiring amp Mounting DiagramER 20 A 93156 Outline amp Dimension BDS4 30 amp 40 Amp 93231 BDS4 Wiring Diagram A 93314 Wiring amp Mounting Diagram ER 21 93315 Wiring amp Mounting Diagram 22 93316 Wiring amp Mounting Diagram 23 A 93369 GOLDLINE Amplifier Assembly Guide for Resolver Cables A 93408 PRS4 5 12 20 Simplified Schematic A 93409 PSR4 5 Internal Schematic A 93414 GOLDLINE Amplifier Assembly Guide for Motor Cables 30 40 amp 55 Amp 93421 GOLDLINE Amplifier Assembly Guide for Motor Cables 3 thru 20 Amp 93538 GOLDLINE Amplifier Assembly Guide for Motor Cables 3 thru 20 Amp 93539 GOLDLINE Amplifier Assembly Guide for Motor Cables 30 40 amp 55 Amp A 93540 GOLDLINE Amplifier Assembly Guide for Resolver Cables 93541 BDS4 Direction Limit Wiring Diagram A 93567 Outline amp Dimension BDS4 3 amp 6 Amp A 93568 Outline amp Dimension BDS4 20 Amp 93572 Outline Dimension BDS4 10 Amp A 93656 Mounting Hole Pattern BDS4 BDS5 PSR4 5 A 93700 DC Bus Cable Assembly for BDS4 5 amp PSR4 5 93703 Mounting Hole Pattern 81354 8 84929 81354 amp BDS5 Logic Cable Assembly 84113 BDS
66. ENABLE DRIVE READY FOLDBACK OVERTEMP OVERCURRENT OVERVOLTS UNDERVOLTS OVERSPEED Option Board D C BUS eile REGE EE Customer External Regeneration Drive Indicators Power Supply Indicators 888888 8 OVERLOAD BLOWN FUSE Resolver Connector Fault Control Power Logic Supply Connector C2 Control Voltage Output Industrial Dri BUS 92 BUS Bus amp Motor Connections La Bus amp Power Connections Lb GND Figure 1 1 BDS4 and PSR4 5 Low Current Models shown limits the voltage rise during the 15 held on for too long the shunt regulator deceleration periods power transistor fails or the shunt regulator 1080 resistor becomes shorted 6 fuse will 12and20AMP Models blow and cause the Fault Contact on the PSR4 5 to open and the BLOWN REGEN The shunt regulat
67. H G amp V UNTIL NOTE 1 FOR CABLE ASSEMBLY GCA R X X XX SEE SHEET 6 OR 7 PLUG 3 HE CRIMP CONTACTS AND CRIMP P CONTACTS INTO THE PLUG BODY WITH USE ORDING TO THE CONNECTION CHART N 1 NO APP D r Kollmorgen Industrial Drives ccr C Cx WY RADFORD VIRGINIA LUIDE DWN BY DATE CHK BY DATE APP D DATE SCALE DWG NO JE ae EWR 10 07 92 2 ING GS CONLY W CRIMP ONLY W CRIMP 5 MOTOR HOUS FILLER O 7 CONTACTS FIBERGLASS SLEEV ING 01 8 SHRINK GN SEE TUBING 8 SHRINK TUBING 12 LABEL SEE SHEET 2 7 TEFLON SHEET FOR DETAILS I o S M 02 5 8 SHRINK TUBING 1 4 RESOLVER W TUBING POSIT TACH AUN TUBING amp SLEEV PARTS NECTORS amp RELATED PART SEE CON LIST INDIV IDUAL SHEETS 10 MANUFACTURER JESCRIPTION DESCRIPTION NUMBER PART NUMBFR H457BA1000 FBRGLASS SLEEVIN SHRINK TUB 100 1 1 8 11 TEFL
68. LONG a SEE HEATSHR INK LABEL SHT 2 ZX ams 6 CABLE E ert CABLE 10 MANUF A C TURER LELD amp G VD CAB I ARD CUT INTO OTHER END OF BUTT CO RN YEL LE J WIRE Ns CUT ORF ET AND IN STRIP S YEL W SERTED SE TION OF WILL n Ih SERT VEL TED UB ES N YE NTO L RGE END RE PART NUMBER PART NUMBER 42 4 CONUCTOR 8 AWG A 97941 008 C amp M et emer P MOTOR CONNECTOR CCESSORIES PART NU JMBER NAME PART UMBER DESCRIPTION 10 PART NUMBER MANUFAC TURER 4 RING TERMINAL 2 HOLL I NGSWORT 70An6 7 9400 004 CRIMP TOOL HOLL TN BUTT MOTOR PLUG HOLL I NGSW CRI MP CONTACTS 5 SHRINK TUB 6 3 4 SHRINK TUB CRIMP TOOL RAYCHEM THIS CABLE ASSE MBLY TO BE LABE 4 A 5 BDS4 or 5 J SMART DR U I AMPL VE AMPL
69. PIN CONNECTOR 32 PIN CONNECTOR Ci DIFF LOW CMD LOW ENABLE SPD MON WIRING TABLE FOR CABLE B 93187 r a oi DOU ROW LUMBER HEADER ONG SHT 1 OF _ Tissue 02 93179 1 zi 3 22 32 AOUT DIFF LOW 58 28 2 28 0 DIFF 32 gt gt gt HEHEHE NOTE CAD GENERATED DWG 8 5 a gt 28 28 5 gt 32 BOUT ENABLE 3 7 28 288 gt 32 BOUT SPD MON GND 7 058830 DCOM 4 3 gt 32 8 5 32 6ND DRV UP DCOM 3 gt gt 32 ZOUT 0Rv ue 13 32 20UT N C DIFF LOW 15 Ts h V v DCOM lt lt co w lt lt lt lt 2 29 92992 299p 5 5 8 8 8 8 8 88 E grt 8 10 1586 6 5 44 74 532 2 8 40 44 74 532 12 74 532 PROPRIETARY INFORMATION INDUSTRIAL DRIVES DIVISION KOLLMORGEN CORPORATION INDUSTRIAL DRIVES DIVISION KOLLMORGEN CORPORATION 201 ROCK ROAD RADFORD VA BDS4 GLOSSARY G LOSSARY Acceleration The change in velocity as a function of time Acceleration usually refers to increasing velocity and deceleration describes decreasing velocity Ambient Temperature The temperature of the cooling medium usually air immediately surrounding the motor or another de
70. TION OF GRN YEL THAT AS DEF TT ILL INSERTED FIRE INTO OTHER END OF BUTT CONNECTOR PART NUMBER PART NUMBER 2 4 CONDUCTOR 8 AWG A 97041 008 C 8 M ITEM DESCRIPTION i PART NUMBER PART NUMBER 2 HOLLINGSWORTH R3027BF HOLL IN 6 HOLL ING RAYCHEM RNF 100 1 3 4 62 MOTOR CONNECTOR AND ACCESSORIES MANUFACTURER NAME PART NUMBER VEAM CIR 06F 22 228 4 RING TERMINAL CRIMP TOOL 3 BUTT CONN 6 3 4 SHRINK TUB DESCRIPTION 1 MOTOR PLUG x THIS CABLE ASSEMBLY BE LABELED 5 GC M6B X X XX A 3 AMPLIFIER RIV AMPLIFIER 4 COPY CODE I DATE APP D ceo cS Kollmorgen Industrial Drives e m RADFORD VIRGINIA APP D BY DATE DWN DATE EWR CHK BY DATE 6 78 07 00 20 96 COI CONNECTOR HELL amp CLAMP 2 CABLE
71. lt AND ACCESSORIES DESCRIPTION 10 MANUFACTURER PART NUMBER PART NUMBER MANUFACTURER RING TERMINAL A 9406 002 HOLL I NGSWORT NAME PART NU CRIMP TOOL HOLL TN BL CONN HOLL I NGSW 3 16 SHRINK TUB 3 4 SHRINK TUB VEAM VEAM VEAM THIS CABLE ASSEMBLY TO BE LABELED 4 5 BDS4 or 5 S DzSMART DRIV MER yc OD X _ AWLIF ECN NO DATE APP D Kollmorgen Industrial Drives RADFORD VIRGINIA CHK BY DATE APP D BY DATE W SOLDERED CONNECTOR 7 COLDLINE MOTOR CABLE 406C 604B 604C 606B MATING MOTOR CONNECTOR CC amp CLAMP 1 00 2 CABLE UJ gt we ZN lt x LABEL s SEE SHT 42 3 N HICKS MARK OND icio 6 2 2 SA d SHIELD 8 GRN YEL WIRE D CABLE J ET AND INSERTED ECTOR STRIP CRN YEL W RE 10 ARD SEC
72. 7 Electrical Connections 2 4 2 7 1 Recommended Torque for Electrical Conn ections u 2 ei 2 5 2 7 2 Grounding Scheme 2 5 2 7 3 Connecting the AC Input Voltages 2 6 2 7 4 Connecting the PSR4 5 Fault Output Contact Connector C1 2 6 2 7 5 Connecting the Unregulated DC Voltage to the BDS4 Connector C3 2 6 2 7 6 Connecting the Main DC Bus VOltape 2 6 2 7 7 Connecting Externa Regeneration RESIStOI S asas 2 6 2 7 8 Connecting the BDS4 Input Output Connector C1 u uuu u nu 2 8 2 7 9 Connecting the Motor 2 10 2 8 Installation Checklist 2 10 2 8 1 Checking the Motor and Resolver Wiring 2 11 2 8 2 Checking the AC Line Voltages 2 11 2 8 3 Checking tbe DC Bus Voltages 2 12 CHAPTER 3 OPERATION 3 1 Introduction eee U eere eene 3 1 3 2 Initial 3 1 3 3 Sequence of Operations 3 1 CHAPTER 4 MAINTENANCE 4 1 Introduction eee Sa reset eae 4 1 4 2 Preventative Maintenance 4 1 4 2 1 Transient Voltages 4 1 4 2 2 Surge Current 4 1 4
73. BLOCK ONLY ON EXTERNAL REGEN RESISTOR VERSION THEN R1 AND R2 ARE OMITTED 15A 100 120 100 150 00 250 00 250 008 CERE T5 INTERNAL SCHEMATIC UE K cum C 84724 2 1 0 SCALE OWS USE OIMENSIONS ONLY Wert UNLESS orueawist SECIE ALL DIMENSIONS ARE INCHES E REMOVE ALL BURRS ANO e UNLESS OTHERWISE SPECIFIED A ine ius do s Bagan ALL gman 3 RESOLVER WITH DRIVE SIGNAL OPTION 03 CONNECTOR 32 CONNECTOR 32 CUSTOMER CONNECTOR CONNECTOR 4 ENCOOER OUTPUT DRIVE SIGNALS INPUT ON 8054 Cc1 5 1 5 u DIFF HIJO O DIFF LO CMDHI 2 SPEED O O ENABLE AUX IN O ENABLE N C Oj DRY I LIMIT RESET Oj6NO 1959 SHIELD SPIN MOLEX i 8 PIN MOLEX pon SHIELD COM SHIELD OUTPUT MAXIMUM CURRENT FAULT FOLDBACK OVERTEMP 0 O O O O O O O O O O O O Of DRV UP 20 10 20 PIN MOLEX 34 34 PIN RIBBON CONNECTOR 34 PIN RIBBON MOLEX MOLEX AER CURRENT DALSO REQUIRES OPTIONAL CONNECTOR ASSEMBLY SEE DWG B 93187 MAXIMUM CURRENT 2 CONNECTOR 5 PIN COMPATIBLE WITH THE 360 SERVO DRIVE INTERFACE 312 3 INDICATES SIGNAL THAT IS AVAILABLE ON ALL DRIVE SINK SOURCE 24 NOTE DSEE D 43174 FOR PROPER JUMPER AND SWITCH SETINGS SECRET L DTH INDUSTRIAL DRIVES
74. Cl m 9 3 I J 4 6 PAIR A 96027 004 CAROL 50573 TERMINAL PLK 1 RMINAL 1 N C SHIELD RMINAL 8 MOTOR CONNECTOR AND ACCESSORIES 512 ITEM MANUEACTURER i DESCRIPTION 5 PART NUMBER NAME PART NUMBER N 720 co m C3 3 MOTOR HOUSING 7 CRIMP CONTACT 1 1 1 1 1 1 1 1 m FTI E C I M 6 FILLER PLUG gt AN espe m cz 96 C REDUCER POWELL 10 T JU I 1 T qM m anm z m CRIMP TOOL BENDIX 22520 1 01 TESMINAL 8054 C2 OR BUSS AND ACCESSORIES N C HIELD HOUK U M ID MANUFACTURER TERMINAL R B DESCRIPTION ET SEE PARI NAME ERMINAL NOTE 1 12 POS HOUSING MOLEX 3 CRIMP PIN MOLEX TERMINAL RED 6 STOMER CRIMP TOOL MOLEX CU TERMINAL U THERMOSTAT N C SHIELD DOK UP o SEE SHEET 2 AND 3 FOR CONNECTOR DETAILS NOTE THIS CABLE ASSEMBLY TO BE LABELED GUA RB X X XX 1 RESOLVER END CUT OFF REMAINING PAIR 12 7
75. D Kollmorgen Industrial Drives RADFORD VIRGINIA GOLDI GUI INE AMPLIFIER DE FOR MOTOR CABLE 3 THRU 20 AMP BY DATE CHK BY DATE DWG ISSUE GOLDL INE VD D lt MATING MOTOR J CONNECTOR E cL MOTOR 5 8 SHR NK 4 LM r LONG BEYOND OF BUT DO NOT D THAT INTO OT SHIELD 8 lt CONNECTOR TO BE ET AND INS CUT ERTED OFF N YEL IRE U A ANUF ACTURER TEM 2 10 MANUF ACTURER AME PART NUMBER DESCRIPTION eae me h PART NUMBER PART NUMBER 4 SPADE LUG 02 HOLL INGSWOR 5520836 4 COND C12 AWG 97941 012 C amp M 3 BUTT CONN 003 HOLL INGSWOR B4046BF VP TOOL HOLL TN HOE MOTOR CONNECTOR A AC CESSORIES DESCRIPTION PART 10 DESCRIPTION ANUF AC TURER NUMBER MANUFACTURER PART NUMB
76. EE TE GOLDLINE RESOLVER CAB AND TACH GC RBT 475 XX ARTS LIST ONNECTION CHART CABLE MANUFAC TURER IAME PART NUMBER 6 A 96027 004 CAROL 50573 MOTOR CONN VECTOR ND ACCESSORIES DESCRIPTION ID MANUFACT URER PART NUMBER NAME PART NUMBER 5 MOTOR HOUSING RIAU 85 7 CRIMP CONTACT SOUR I AU 6 FILLER PLUG SOUR TAU CRIMP TOOL SOUR MS3191 1 8054 C2 OR BDS5 C3 ND ACC ESSORIES DESCRIPTION MANUFACTURER PART NUMBER NAME PART NUMBER 12 POS HOUSING MOLEX 5 3 CRIMP PIN MOLEX 9 CRIMP TOOL MOLEX AND ACCESSORIES DESCRIPTION MANUFAC TURER NAME PART NUMBER 20 HOUS ING MOLEX CRIMP PIN MOLEX CRIMP TOOL MOLEX MOTOR CONNECTION CABLE BDS4 C2 8055 8054 Cl TEM 5 TEM 4 ITEM 1 ITEM 2 ERMINAL A RED 1 ERMINAL 7 ERMINAL BLK 1 ERMINAL 1 SHIELD ERMINAL 8 ERMINAL RED 2 ERMINAL 3 AL D BLK 2 ERMINAL 9 SHIELD ERMINAL 2 ERMINAL E RED 3 ERMINAL 10 ERMINAL 3 ERMINAL 4 SHIELD ERMINAL 5 AL RED 4 CUSTOMER ER AL P BLK 4 BRAKE
77. ELECTRICAL OPTIONS The standard BDS4 servo amplifier is fitted with a 12 bit R D converter which allows a maximum tracking rate of 8000 RPM and a maximum operating speed of 7500 RPM The BDS4 amplifiers are available with standard options which are discussed in the following sections These options are either integrated into the main circuit board of the BDS4 amplifier or appear as Option Boards that are mounted inside of 891354 chassis E 2 1 Integrated Options R D Converter Resolution and Tracking Rate Options Optional R D resolutions and tracking rates are available and produce higher resolution position information and or better low speed performance These options are integrated into the main circuit board motor control board within the BDS4 amplifier and are as follows Option 08 contains a 14 bit R D produces a maximum tracking rate of 3500 RPM and a maximum operating speed of 3200 RPM Option 11 contains a 16 bit R D produces a maximum tracking rate of 500 RPM and a maximum operating speed of 450 RPM Option 16 contains a 14 bit R D produces a maximum tracking rate of 2000 RPM and a maximum operating speed of 1800 RPM Accuracies repeatability and resolution specifications are recorded in the tables located in Section E 2 2 4 1 APPENDIX OPTIONS 5 2 2 BDS4 OPT2 3A Option Board The option board can support 10 12 14 16 bit R D converters mounted within 81354
78. LJ 9 a SEE HEATSHRINK 4 LONG x 2 CABLE E LABEL SHT 82 ZX Z SS CABLE 10 MANUF A C TURER amp ee ELE I ARD T CUT INTO OTHER END OF BUTT CO am WIRE Ns CUT ORF ET AND IN STRIP S YEL W TION SERTED OF GRN WILL n IN SERI RE VEL TED Li 70 GN A RGE END MOTOR PLUG CRI MP CONTACTS CRIMP TOOL 5 3 16 SHRINK T UB DESCRIPTION PART NUMBER PART NUMBER 2 CONUCTOR 8 AWG A 97941 008 C amp M TEM i9 MANUFACTURER 4 DESCRIPTION PART NUMBER NAME PART NUMBER MOTOR CONNECTOR AND ACCESSORIES ING TERMINA A 79406 002 HOLL I NCSWOR ID MANUFACTURER T H 0 U PART NUMBER PART NUMBER CRIMP 3 BUTT CONN HOLL INGSW 6 3 4 SHRINK HIS CABLE AS EMBLY LABE 4 5 o U A 5 BDS4 or 5 SMART VE AMPL AMPL U I gt lt lt
79. MODEL NUMBERS Table B 1 PSH4 5 Model Number Scheme EXAMPLE PSR 4 5 LEGEND A B Power Supply with Regeneration shunt regulation and soft start Power Supply generation indicator Standard Configuration Used with BDS4 series servo motor amplifiers Industrial Standard Configuration U L 508 listed Configuration Used with BDS4A series servo motor amplifiers AC Line Voltage L L RMS 115 VAC Single Phase not available for 50 and 75 amp models 220 VAC Single Phase or 230 VAC Three Phase D 1220 0 5 Line Current RMS Mechanical Options Standard No Option all models have side cover Use 00 for new applications previously with side cover Custom Custom Custom Custom Custom Special 12 and 20 amp PSR4 5 units only with cover without connector kit 2 axes maximum Electrical Options Standard No Options 12 and 20 Amp models contain 40 Watt Internal Regeneration Resistor 50 and 75 Amp Models require Regeneration Resistor Kit EX 2X must be ordered separately 8 8 Ohms 400 Watt External Regen 230 Volt 12 and 20 Amp Models Only Requires ER 01 External Resistor Kit 5 5 Ohms 200 Watt 115 Volt External Regen 12 and 20 Amp Models Only Requires ER 02 External Resistor Kit 5 8 Ohms 700 Watt 230 Volt External Regen 12 and 20 Amp Models Only Requires ER 03 External Resistor Kit Custom Without Soft Start 50 and 75 Amp Models Only Requires ER 2X External Resistor Kit
80. Main AC Line Input Voltage Phase Frequency 47 63 HZ Current RMS Phase Continuous Current RMS Phase Peak 2 Sec Current RMS Phase Peak 50 msec Control AC Line Input Voltage Phase Frequency Unregulated Logic Bus Output No Load 26 VDC MAX 14 VDC MAX 6 5 VDC MIN 2 AMPS External Shunt Regulator Resistor Power Model Dependant Model Dependant Internal Power Dissipation Continuous 60 W 90 W Less Shunt Regulator Soft Start Surge Current MAX 35 AMPS 35 AMPS Soft Start Charge Time MAX 0 25 SEC 0 25 SEC D 2 BDS4 APPENDIX D SPECIFICATIONS Table D 1 PSR4 5 Specifications Con t DESCRIPTION PSR4 5 220 Main AC Line Input Voltage Current RMS Phase Continuous Current RMS Phase Peak 2 Sec Current RMS Phase Peak 50 msec Control AC Line Input Voltage Unregulated Logic Bus Output No Load 26 VDC 14 VDC MAX 6 5 VDC MIN 2 AMP Internal Power Dissipation Continuous 60 W 90 W Less Shunt Regulator Soft Start Surge Current MAX 80 AMPS 80 AMPS Soft Start Charge Time MAX 0 25 SEC 0 25 SEC The XX03 Electrical Option version has a peak regulator current of 75 amps a minimum resistance of 5 8 ohms and a power rating of 700 watts D 3 APPENDIX D SPECIFICATIONS BDS4 Table 0 1 PSR4 5 Specifications Con t DESCRIPTION PSR4 5 250 Main AC Line Input Voltage 207 253 VAC Phase 3 Phase Frequency 47 63 HZ Current RMS Phase Continuous 75 AMPS Current
81. RMS Phase Peak 2 Sec 112 AMPS Current RMS Phase Peak 50 msec 150 AMPS Control AC Line Input Voltage 95 132 VAC Phase 1 Phase Frequency 47 63 HZ Current RMS 3 0 AMPS Output Power 22 5 WATTS Volts 310 VDC Unregulated Logic Bus Output No Load 26 VDC 14 VDC MAX Full Load 14 5 VDC MIN 2 AMPS 6 5 VDC MIN 4 AMPS Shunt Regulator Peak Current 100A 200A Shunt Regulator Min Resistance 4 3 OHM 2 15 OHM Less Shunt Regulator D 4 BDS4 APPENDIX D SPECIFICATIONS Table D 2 BDS4 Specifications DESCRIPTION BDS4 103X BDS4 106X BDS4 110X BDS4 120X MAIN DC BUS Minimum 125 VDC 125 VDC 125 VDC 125 VDC Maximum 225 VDC 225 VDC 225 VDC 225 VDC Unregulated Logic 14 5 26 VDC 14 5 26 VDC 14 5 26 VDC 14 5 26 VDC Bus Input 0 25 AMPS 0 25 AMPS 0 25 AMPS 0 25 AMPS 6 5 14 VDC 6 5 14 VDC 6 5 14 VDC 6 5 14 VDC 0 50 AMPS 0 50 AMPS 0 50 AMPS 0 50 AMPS Fan AC Line Input 95 132 VAC 50 60 HZ 0 5 AMPS Output Current RMS PHASE Convection Cooled 45 C AMB Fan Cooled Continuous RMS 3 0 AMPS 6 0 AMPS 10 0 AMPS 20 0 AMPS Peak 2 0 SEC 6 0 AMPS 12 0 AMPS 20 0 AMPS 40 0 AMPS Output KVA 160 VDC BUS Continuous 0 5 KVA 1 0 1 7 3 3 KVA 45 Peak 2 0 SEC 1 0 2 0 KVA 3 3 6 7 Internal Heat 30 WATTS 50 WATTS 75 WATTS 135 WATTS Dissipation PWM Switching 10 0 KHZ 10 0 KHZ 10 0 KHZ 10 0 KHZ Frequency Motor Current Ri
82. SHIELD HOOK UP T 5 D 2 d 7 FERN A S B lt TERM 16 5 s E 881 TERM 5 AJ I 1 T CUSTOMER CU AJ HIELD Cl THERMOSTAT OOK UP Y SEE SHEET 3 THIS AND 4 FOR CO CABLE ASSEMBLY BE LABELED GC NNECTOR DETAILS RBT 4 5 XX CABLE LENGTH gt DATE ND Kollmorgen Industrial Drives RADFORD VIRGINIA GOLDL I NE GUIDE BY EWR APP D BY DATE CHK BY DATE SCALE DWG NO NO SHT 14 OF 14 ISSUE 8 ERED MOTOR CONNECTOR 3369 8 GU IN FR IH THER BRAKE AND AL ARTS LIST ONNECTION CHART CABLE DESCRIPTION MANUFACTURER PART NUMBER IAME PART NUMBER 6 PAIR CAROL 50573 MOTOR CONNECTOR AND ACCESSORIES DESCRIPTION ID MANUFACTURER PART NUMBER PART NUMBER MOTOR HOUSING 851 06 014 19550 851 06 14 19550 BD
83. The card may be configured one of three ways 01 as a differential quadrature encoder interface with marker pulse 02 as a 12 to 16 bit buffered parallel resolver data interface 03 as a 12 10 16 bit buffered parallel resolver data Interface with drive control signals E 2 2 1 BDS4 OPT2 3A 01 BOARD Electronic Encoder Output When configured as a BDS4 OPT2 3A 01 board only the encoder outputs are offered The board functions only to convert the binary motor shaft position information from the R D Resolver to Digital converter located within the BDS4 amplifier to differential quadrature encoder signals with marker pulse The output interface connections are made via Connector 32 mounted on the BDSA OPT2 3A 01 Board This connector is an 8 Pin Molex MINI FIT JR connector and is located just to the left of Connector C1 mounted in the top front of the BDS4 amplifier The pin outs are as follows OUT A OUT A OUT B OUT B OUTZ OUTZ COM COM Figure E 1 Connector 32 The encoder interface option provides a differential quadrature synthesized encoder output and a E 2 BDS4 differential marker pulse output for customer use Each output pair OUT A or A phase OUT B or B phase and OUT Z or Z phase is driven by a DS8830 SN75183 differential line driver integrated circuit The voltage levels transition between 5 volts and common This interface is capable of sinking and sourcing 40 milliamps of
84. and load is obtained by selecting the coupling ratio such that the load moment of inertia referred to the motor shaft is equal to the motor moment of inertia Inrush Current The current surge generated when a piece of equipment such as a servo amplifier is connected to an AC line This surge is typically due to the impulse charging of a large capacitor located in the equipment Instability Undesirable motion of an actuator that is different from the command motion Instability can take the form of irregular speed or hunting of the final rest position Limits Motion control systems may have sensors called limits that alert the control electronics that the physical end of travel is being approached and that motion should stop Logic Ground An electrical potential to which all control signals in a particular system are referenced G 2 Loop Feedback Control A control method that compares the input from a measurement device such as an encoder or tachometer to a desired parameter such as a position or velocity and causes action to correct any detected error Several types of loops can be used in combination i e velocity and position together for high performance requirements Master Slave Motion Control A type of coordinated motion control where the master axis position is used to generate one or more slave axis position commands Motor AC A device that converts electrical alternating current into mechanica
85. current The differential outputs are designed to drive long lengths of coaxial cable strip line or twisted pair transmission lines with characteristic impedances of 50 to 500 ohms The quadrature signal is generated by the following sequence Refer to Drawing D 93179 1 Up to sixteen parallel resolver data bits are brought to the BDS4 OPT2 3A Option Board via connectors 7 and 33 These bits first pass through LS244 data buffers Next the data bits are routed to a double row jumper header component 35 At this header the quadrature resolution is selected by manipulating two jumpers The resolution can be from 16 to 16384 encoder lines in increments of power of two 2X 1 6 16 32 64 128 256 512 1024 2048 4096 8192 16384 The following jumper table shows the jumper combinations for the resolutions available After two of the twelve data bits have been selected at the jumper header block Component 35 by the two jumper selections these two signals are routed to a pair of Exclusive Or gates This is where the quadrature A Phase offset from B Phase by 90 degrees signal pair are generated After this the two quadrature signals are latched by a pair of LS175 flip flops The non inverting output from each flip flop drives an LED The inverting output from each flip flop drives a pair of DS8830 or 75183 line drivers The line driver outputs route straight across a jumper header strip this is used with other options and te
86. of the BDS4 Pin S Tach Lo should be terminated at Connector Pin 15 common of the BDS4 The tachometer is an option and is not installed on most motors 2 8 INSTALLATION CHECKLIST Refer to BDS4 Wiring Diagram A 93231 Before applying power to the 5 4 5 and BDS4 check the following items to ensure proper operation To prevent damage to the equipment the motor and resolver the AC line voltage and the DC bus voltages must CAUTION be connected as indicated by BDS4 Wiring Diagram A 93231 BDS4 2 8 1 Checking the Motor and Resolver Wiring Disconnect both the motor stator and resolver connectors from the motor Using an ohmmeter check the continuity of each motor stator lead between the motor stator connector pin and the BDS4 Using an ohmmeter check the continuity of each motor resolver lead between the motor resolver connector pin and the BDS4 The motor stator and resolver leads should be connected according to BDS4 Wiring Diagram A 93231 There are no other options for connecting the motor stator and resolver leads CHAPTER 2 INSTALLATION 2 8 2 Checking the AC Line Voltages Open the circuit breaker or remove the fuses in the Main AC lines that are connected to the PSR4 5 at L and 1 Remove Connector from the PSR4 5 and remove if present Connector C4 from the 81354 Apply only the main power Use voltmeter to check and record the 1 or 3 phase line to
87. open indicating that the BDS4 15 Inhibit mode The Input Output interface circuitry is divided into two functions A Signals to and from the motor and BDS4 BDS4 These signals are associated with the motor system resolver 7 0 kHz excitation signal is generated in the 811354 and sent to the resolver Two resolver feedback signals sine and cosine are received by the BDS4 and processed by an R D resolver to digital converter The R D unit generates a digital position word used in electronically commutating the motor and an analog velocity internal tach signal to close the servo loop B Signals to and from the signal source PLC CNC etc and BDS4 There are numerous signals that may interface between the signal source PLC CNC etc and the BDS4 These inputs and modes of operation differ with each application The BDS4 consists of a single velocity loop and three inner current loops To give precise velocity control the velocity loop is normally configured as a proportional plus an integral plus a derivative gain servo loop The output of the velocity loop is the current command for the three microprocessor based current loops The heart of the BDS4 is its microprocessor which receives and processes the current command velocity error signal from the output of the velocity loop circuit the position information from the resolver to digital converter and several other signals After receiv
88. present at the input of the BDS4 5 Command Scale Adjustment should not be fully CCW 6 Fault circuits must not be activated Fault modes are identified by red LED s located on the front of the BDS4 and PSR4 5 modules 5 3 2 The Motor is Erratic or Exhibits an Improper Mode of Operation Prerequisites for proper motor operation 1 Proper grounding scheme must provided The motor ground wire should be connected as shown by BDS4 Wiring Diagram A 93231 2 Motor armature leads must not be run in conduit or wire ducts with any signal carrying conductors 3 The resolver leads tach leads when used and motor armature leads must be wired according to BDS4 Wiring Diagram A 93231 4 The motor system resolver must be set at its Zero point refer to Section 4 4 3 3 5 Stability Adjustment should not be fully CW 6 The motor should be loaded with its specified load inertias see TL sheet for stable load inertia range Otherwise the BDS4 may become unstable 5 3 3 BDS4 3 6 10 20 30 40 and 55 AMP STATUS LED S The status of the BDS4 modules is indicated by three 3 Green and six 6 Red LED s Refer to Figure 5 1 for the LED configuration The diagnostic information indicated by these LED s is listed as follows 31354 STABILITY CURRENT LIMIT COMMAND SCALE BALANCE CONTROL VOLTS ENABLE DRIVE READY FOLDBACK OVERTEMP OVERCURRENT OVERVOLTS UNDERVOLTS OVERSPEED Figur
89. s b BDS4 COMP Compensation Board not installed or misinstalled 3 Drive Ready LED Green Not Illuminated d Defective BDS4 Foldback LED a 54 in resolver alignment test mode refer to Section 4 4 3 3 RED Illuminated b Excessive RMS current causing BDS4 protection circuit to activate Reduce motor duty cycle Overtemp LED RED Excessive heatsink temperature due to overload high ambient temperature a b Defective BDS4 Overcurrent LED a When this LED becomes illuminated an overcurrent condition RED Illuminated usually due to a shorted load motor stator winding shorted stator wiring or a shorted BDS4 power stage component is indicated If this LED becomes illuminated remove the power and disconnect the motor Reapply power If the BDS4 comes up without this LED becoming illuminated suspect a faulty motor or motor stator wiring If the BDS4 comes up with the LED illuminated suspect a faulty BDS4 power stage Overvolts LED RED a This LED will become illuminated if the Main DC Bus rises above 230 VDC for 115 VAC system 430 VDC for the 230 VAC system This can happen due to PSR4 5 fault or inadequately sized shunt regulator regeneration resistor 8 Undervolts LED RED a This LED will become illuminated if the Main DC Bus is insufficient or absent 9 Overspeed LED RED a In the event the motor obtains an excessive speed the OVERSPEE
90. set speed Stiffness Ratio of an applied force torque to change in position for a mechanical system Stator The non rotating part of a magnetic structure In a motor the stator usually contains the mounting surface bearings and non rotating windings or permanent magnets Tachometer An electromagnetic feedback transducer which produces an analog voltage signal proportional to rotational velocity Tachometers can be either brush or brushless Torque The rotary equivalent to force Equal to the product of the force perpendicular to the radius of motion and distance from the center of rotation to the point where the force is applied Velocity The change in position as a function of time Velocity has both a magnitude and direction G 3 BDS4 INDEX Underlined Text 2 2 Unpacking 2 2 Unregulated DC Voltages 2 6 Ventilation 4 2 Warning 2 1 Warranty Information see Appendix
91. technological achievements dating back to 1948 One of the finest tributes to that achievement can now be seen at the Smithsonian which has on display the first stellar inertial navigation system developed by Dr Charles Stark Draper This system contains the first models of torque motors built by the founding organization of Industrial Drives During the period of 1948 to 1960 our firsts in the industry numbered more than dozen they ranged from the simple but invaluable such as the direct drive DC torque motor and movie theater projection motors to the exotic submarine periscope drive motors for the U S Navy electric drives Curtis Wright electric brake coils and numerous other innovations For more than a decade Industrial Drives known in the early days as part of Inland Motor Division of Kollmorgen has continued to enhance its sophisticated engineering solutions to pioneer new product development The results of these and other efforts has encouraged some of the most significant innovations in the servo industry We developed the application of servo motors and drives in the Machine Tool market We were the first with water cooled servos the integral brake the flux forcing concept and the brushless motor We developed the electronically commutated electric car motor Industrial Drives pioneered rare earth magnet development for the servo motor industry Between 1974 and 1980 Industrial Drives continued to lead the
92. the identical base model number may be run on the BDS4 amplifiers If a motor having a different base motor model number is to be run on a BDS4 the BDS4 COMP compensation board must be altered or changed accordingly The 831354 must remain the same current and voltage rating 1 4 4 PSR4 5 Power Supply Module Refer to Figure 1 1 for a quick reference of the PSR4 5 and drawings A 93409 A 93408 and 93092 for precise details The 5 4 5 Power Supply Module is divided into four 4 main sections 1 The Unregulated Logic Bus supplied by the Control AC line input voltage normally single phase 115 is described in Section 4 2 2 310 140 Main DC Bus is supplied by the main AC line input voltage normally three phase 230 VAC or single phase 115 VAC 3 Soft Start Feature standard resistor limits the inrush current to charge up the Main Bus Capacitors to a specific amount as listed in Appendix D 4 Shunt Regulator regeneration section includes circuitry which monitors the main bus During deceleration profiles the motor basically operates as a DC generator and pumps energy back into the main bus causing the bus to rise The Shunt Regulator BDS4 CHAPTER 1 SYSTEM DESCRIPTION STABILITY Drive Adjustments er q hn EXTERNAL REGEN RESISTOR CURRENT LIMIT COMMAND SCALE BALANCE CONTROL VOLTS
93. 06 6 20 30 30 00 54 54 180 W THREADED 09 9 30 33 33 57 57 190 CONNECTORS 2 5 12 12 40 36 36 6 60 200 15 15 5 39 39 18 8 42 42 21 2 45 45 24 24 8 48 48 CODE 1155 COPY APP D Kollmorgen Industrial Drives D GU FLO GOLOL INE AMPLIFIER FOR MOTOR C 55 APP 0 6 SCM 3 RADEORD VIRGINIA 3 THRU 20 RD 09 15 99 4 FOO DRAWN Bi 0 BY DATE 11 6 92 0 4 lad ja FDD FOO CHK BY DATE PLUG BODY ABLE CLAMP 4 BACKSHELL DWG NO SHEET 2 OF 6 ASI O25 M FO ISSUE JACKET CABLE OUTER 515 1 C T 9 3 4 4 STEP 4 T WIRES INTO THE CRIMP INTO TH ING TO THE Co CTORS HE CRIMP CONTACTS CC e WIN THE BBMM NG BACKSHELL AND 13 88 WIRE BACK 38 OUND THE INDIV FOR CL SOM THIS END 0 RIP INSULATION 4 57MM 8
94. 1354 BDS4 amp BDS5 Logic Cable Assembly BDS4 Simplified Schematic PSR4 5 Simplified Schematic PSR4 5 Internal Schematic BDS4 OPT2 3A Pinout Options BDS4 OPT2 3A BDS4 CHAPTER 1 SYSTEM DESCRIPTION CHAPTER 1 SYSTEM DESCRIPTION 1 1 INTRODUCTION The information in this chapter will enable you to understand the product s basic functions and features These concepts will allow you to apply them to your own unique applications 1 2 PRODUCT DESCRIPTION Industrial Drives BDS4 product lines are 3 phase sine wave brushless motor controllers They are fully regenerative four quadrant bi directional velocity loop amplifiers designed to be used with Industrial Drives high performance B series permanent magnet brushless motors Although BDS4 is basically an analog servo amplifier it contains a microprocessor to implement Industrial Drives patented Torque Angle Control function for maximum system performance The BDS4 amplifier modules are available in sizes of 3 6 10 20 30 40 and 55 amps RMS phase continuous The modular design provides the flexibility for multiple axes to share a common power supply requiring no input isolation transformer The PSR4 5 Power Supply modules are available in sizes of 12 20 50 and 75 amps RMS phase continuous AC input line ratings Numerous Industrial Drives B Series motors with various diameters stack lengths and windings are also available 1 3 FEATURE
95. 2 3 Electrical Noise 4 2 4 2 4 Radio Frequency Energy 4 2 4 3 Periodic Maintenanee 4 2 4 3 1 Ventilation 4 2 4 3 2 Grounding Integrity ss 4 2 4 4 Adjustrnents 4 3 4 4 1 Set Up Adjustments 4 3 4 4 1 1 Balance Adjustment Within Position Loop 4 3 4 4 1 2 Balance Adjustment Automatic Manually Operated Machines 4 3 4 4 1 3 Command Scale Adjustment Within Position Loop 4 3 4 4 1 4 Command Scale Adjustment Automatic or Manually Operated Machines 4 3 4 4 2 Response and Application Dependent Adjustments 4 3 4 4 2 1 Stability Adjustment 4 4 4 4 2 2 Current Limit Adjustment 4 4 4 4 3 Design Tolerance Adjustments 4 4 4 4 3 1 Resolver Excitation Adjustment 4 4 4 4 3 2 Current Sensor Offset Adjustments 4 4 4 4 3 3 Motor System Resolver Alignment 4 4 4 4 3 4 Factory Only Adjustments 4 6 CHAPTER 5 TROUBLESHOOTING 5 1 Introduction ssni see 5 1 5 2 Field Serviceability
96. 20 CABLE LENGTH METERS FEET TEFLON TUBING SEE SHEET 6 FOR DETAILS 12 POSITION HOUSING 1 CRIMP PINS 3 1 44 HEAT SHRINK 2 CABLE Mss 00 11 51 171 21 54 181 00 31 57 191 PART NUMBER DESCRIPTION 012 4 90 201 GC R 4 5 XX CABLE LENGTH 015 53 211 GOLDLINE IN METERS BDS4 5 AMPLIFIER R 5 T7 RESOL VER CODE Kollmorgen Industrial Drives GOLDLINE AMPLIFIER ASSEMBLY SS APP D 2 AINE ENP VER 6 3 RADFORD VIRGINIA GUIDE FOR RESOLVER CA 7 VB 4 DWN BY OK BY PD p 6 5 EWR 03 18 92 FDO 9 OWENS 05 18 92 2209 MOTOR HOUSING FILLER PLUGS 7 CONTACTS ONLY W CRIMP FIBERGLASS SLEEVING 8 2 SEE SHEET 85 F R DETAILS W CRIMP SHRINK TUBING REN 5 8 SHRINK TUBING 3 LABEL SEE SHEET 3 1 8 HEAT SH 1 2 HEAT SHRINK pese RESOLVER TACH FOR CONNECTORS amp RELATED TUBING amp SLEEV NG PARTS LIS
97. 3 19 91 3 19 0 DWG ND ISSUE ISSUE METRIC CINOHES DO NOT SCALE DWG USE DIMENSIONS ONLY J SS WISE SPEC fuac NAE I zu Oa ae a X DEC PLACES 4 XX DEC PLACES 4 015 IN ALL DIMENSIONS ARE MILLIMETERS WITH INCHES 03112 n 3 XXX DEC PLACES 4 005 IN IN PARENTHESES UNLESS OTHERWISE SPECIFIED XX DEC PLACES 2 13 T BU u ho 160 SS MOT OR CONNECTIONS Y ELO 7 0 28 5 100 0 0 GROUND WIDE SLOT 3 94 CONNECTIONS 284 0 11 18 VIDE SLO 2 PLACES 1 18 CAD DWG THIS UNIT CONTAINS STATIC SENSITIVE ZS MATERIAL HANDLE ACCORDINGLY COPY CODE ISS NO DATE APP D ur 9 DINENCIN FOUN DEPT vsum Kollmorgen Industrial Drives OUTLINE amp DIMENSTON 87736 7 11 96 RADFORD VIRGINIA 8054 55 AMP DNE BY DATE Sed DWG NO ISSUE tet A G31 12 3 T
98. 3 1mm EMR ae Mm TT 30 microinches Gold Plated Brass AWG 18 24 051 118 1 3mm 3mm AWG 22 28 035 071 0 9 1 8mm worms eee amm 3 UNLESS OTHERWISE SPECIFIED eer 12 uu a ut ixi T poids PURCHASE SPEC FOR i owc PLACES 015 1 XXX DEC PLACES 2 008 ANG DO SCALE DWG USE OIMENSIONS ALL OIMENSIONS AWE INCHES UMLESS OTHERWISE SPECIFIED ISSUE C INCHES DO NOT SCALE DWG USE DIMENSIONS ONLY XX DEC PLACES 5 ALL DIMENSIONS ARE MILLIMETERS WITH INCHES XXX DEC PLACES IN PARENTHESES UNLESS OTHERW UNLESS OTHERWISE SPECIFIED ANG DIM 1 Ft I I COPTIONAL J M EXTERNAL REGEN RESISTOR CONNECTOR OPTIONAL ES B ES D C BUS REGEN OVERLOAD BLOWN FUSE 111 nw N jm KOLTWORGEN pim BUS OUTPUT 325V r3 PHASE POWER INPUT T 0 28 DE SLOT PLACES 3 Nx THIS UNIT CONTAINS STATIC SENSITIVE 4 9 CAD DWG 0 31 ATERIAL HANDLE ACCORDING
99. 3 Abbreviations CCW Counter Clockwise CW Clockwise DIFF CMD Differential Command D L Direction Limit GC Goldline Cable GCS Goldline Cable Set LED Light Emitting Diode NEC National Electrical Code P N Part Number R D Resolver to Digital Regen Regeneration TL Test Limits UL Underwriters Laboratories 2 4 UNPACKING AND INSPECTION Electronic components in this amplifier are static sensitive Use proper procedures when handling CAUTION component boards Upon receipt of the equipment closely inspect components to ensure that no damage has occurred in shipment If damage is detected notify the carrier immediately Carefully remove packing material and remove the equipment from the shipping container Do not dispose of shipping materials until the packing list has been checked Parts that are contained within the shipment but not physically attached to the equipment should be verified against the packing list If any parts are missing notify Industrial Drives at once 2 5 INSTALLATION REQUIREMENTS Proper installation and field wiring are of prime importance when considering the application of servo amplifiers Many problems may be avoided if installation of the equipment is done properly Users should familiarize themselves with and follow installation and wiring instruction in addition to all applicable codes laws and standards Pay special attention to the following topics when installing Industrial Drives e
100. 4 BRAKE VC SHIELD HOOK UP ERMINAL RED 5 T TERM 12 ERMINAL S BLK 5 VC 4 TERM 16 N C SHIELD UERM 5 ERMINAL T RED 6 CUSTOMER NC ERMINAL U LK THERMOSTAT 0 4 SEE SHEET 2 AND 3 HIS CABLE ASSEMBLY TO BE LABEL 4 5 8054 FOR CONNECTOR D ETAILS BCA RBT X X XX CABLE IN M LENGT ETERS H DATE ND Kollmorgen Industrial Drives RADFORD VIRGINIA GOLDLIN AMP F GUIDE FOR SOLV CHK BY DATE APP D BY DATE SCALE DW G NO Ivi Af SHEET 2 OF 13 ERED MOTOR CONNE 3540 GULDLINE RESOLVER CABLE WITH THE BRAKE AND TACH GCA ARTS LIST CONNECTIO CABLE MOTOR CONNECTION CABLE BDS4 C2 8055 C3 BDS4 CI TEM D MANUFACTURER TEM 5 TEM 4 ITEM 2 DESCRIPTION PART NUMBER n 6 PAIR 50573 NNECTOR CESSORIES DESCRIPTION MANUF ACTURER ART NUMBER PART NUMBER 5 MOTOR HOUSING 5 53106 22 145
101. 4 OPT D L Option Board E 4 APPENDIX F DRAWINGS LIST FIGURES BDS4 LisT OF FIGURES EIGURE PAGE 1 1 BDS4 and PSR4 5 Low current models 1 3 2 6 Motor Resolver Connections 2311 1 2 Typical System Diagram 1 7 2 7 Armature Motor Connections 2 12 2 1 Safety Alert Symbo s 24 5 1 BDS4 Status LED s 1 5 3 22 PSR4 S CDSs a 2 7 5 2 PSR4 5 12 20 Amp Status LED S 5 4 2 3 BDS4 C3 amp PSR4 5 C2 2 7 5 3 PSR4 5 50 75 Amp Status LED S 5 4 2 4 BDS4 Connector C1 2 8 2 5 BDS4 C2 2 10 E 1 Connector 32 2 E 2 Encoder Output Timing 9 BDS4 LIST OF TABLES LisT OF TABLES TABLE PAGE TABLE PAGE 2 1 Torque Values 2 5 B 7 Cable Model Number Scheme for 2 2 BDS4 Unregulated DC Voltages 2 7 Individual Cable Bayonet Type Thread B 7 8 Cable Model Number Scheme for 5 1 Improper Motor Operation Troubleshooting 5 5 Individual Cable Screw Type Thread B 8 5 2 BDS4 Status LED Indicator Troubleshooting 5 6 B 9 Resolver Feedback Cables B
102. 4 Simplified Schematic C 84723 PSR4 5 Simplified Schematic C 84724 PSR4 5 Internal Schematic 93185 BDS4 OPT2 3A Pinout Options D 93179 BDS4 OPT2 3A UNLESS OTHERWISE SPECIFIED XX DEC PLACES 015 IN DO NOT SCALE DWG USE DIMENSIONS ONLY rd 0 o AND DIM DEGREE XXX DEC PLACES 005 ALL DIMENSIONS ARE INCHES UNLESS OTHERWISE SPECIFIED 03244 5 REF H COS SIN HI SIN LO PIN PIN D PIN A PIN ASE BROWN LEAD PIN A N c ET SEE SA HERMOSTAT BLACK LEADS PINS T 8 TACH BLACK LEAD PIN 8 WHITE LEAD PIN AKE BLUE LEADS PINS amp P CO BLUE STATOR gt PIN E SECONDARY SEN COS LO HERMOSTAT amp DRAK MOTOR LEAD CONNECTIONS RESOLVER CONNECTION DIAGRAM LOCATED IN RESOLVER C AJ 1 ECTIONS ASSEMBLY NOTES C MOTOR ROTATION ND SEQUENCE ACTING MOUNTING 20 Z L 0 C 1 C TO 4 WITH ROTAT ENERATED ON P
103. 433UMPER 28 SELECTS THE ENCODER RESOLVER MODE s 2 054 GPZADNDUT SINIB CPOE ee 93185 2 lt 2 DCOM v DCOM DCOM 12 7489 744 42 40 11 743 AUF AUF 747 5V 2 7805 5 6 gom mw 1 JUMPER HEADER CLOCK 7415175 AOUT 45 17 o 31 1 1 8 510015 4 8 5 7415175 BOUT 17 88 49 30 5 1 4 8 bep 510ohms K ab LSB 4 B16 33 815 3343 5 814 33 2 e se OFF ON Ds ae LE SWITCH mme B SES m mS 1 8 Lo 3071 ogo 2 2 13 7 T 5 4 4 74 1 T O amp O l 4 4 5 25 6 810 74 5 4 4 8 1 3 5 12 74530 89 746 I sl 1 P42 355 15 i 3 6 3 14 7208 15 H O30 6 4 O 13 14 87 25744 12 74 830 5020 42 86 6 2 44 e ENCODER
104. 7O HI C2 40 8 5 REF LO 2 0 TC2 SIN C2 70 SIN LO 2 gt 2 NOTES ALL RXS CXS AND JX S ARE COMPENSATION COS HI C2 90 gt BOARD COMPONENTS COS LOC2 30 gt O3 INDUSTRIAL DRIVES Radford Virginia A BRON COMPONENT NO Fe ai PA EE SIMPLIFIED SCHEMATIC _ 37 7 le BI deed 8054 3 20 65 148 5 5 Wee TER COPY CODE 50 55 103 145 19 224 SHIELD 2 2 SHIELD C2 8 SHIELD 2 PPE 5 mee x UNLESS OTHERWISE MALS be wine nio reprit REMOVE ALL BURNS OND ongan ALL SHARP 66 lt E aus POWER SUPPLY REGEN CARD PSR PS2 XXX 1 Lag We Nos INTERNAL l i EXTERNAL PE REGEN RESISTOR REGEN 24 O SEE TABLE uet SpesisTOR gt INPUT TABLE BELOW V LJ CHASSIS GROUNDS GND VDC 207 NRE GUL ATED 4 e cs REGEN REGEN MODEL RESISTOR FUSE CAP 00 2 5 1650 E amo SEE gt 25 2008 2970 2 7 2 5845412 isa sa 6504 1 5 ONE z 1 8 20 aow 5845420 z5
105. 9 5 3 PSR4 5 12 amp 20 Amp Status LED B 10 Bus Bars 10 Indicator Troubleshooting 5 7 5 4 PSR4 5 50 amp 75 Amp Status LED 1 Connector Kit BDS4C 10 1 Troubleshooting 5 7 C 2 Connector Kit BDS4C 101 2 7 Connector BDS4C 200 2 6 1 BDS4 Spare Parts List 6 1 C 4 Connector Kit PSR4 5C 200 C3 6 2 PSR4 5 Spare Parts List 6 2 C 5 Connector Tools C3 1 PSR4 5 Model Number Scheme B 1 D 1 PSR4 5 Specifications D 2 B 2 ER Extemal Resistor Kit Model Number D 2 BDS4 Specifications 5 Scheme 2 D 3 Derating Data D 9 3 BDS4 Model Number Scheme 3 D 4 Environmental Specifications D 10 8 4 Compensation Model Number Designator B 4 D 5 Mechanical Specifications D 10 B 5 Cable Model Number Scheme for Individual Cable Set Bayonet Type E 1 BDS4 OPT2 3A 01 Board Specifications E 5 Thr ad santet rec ies B 5 E 2 OPT2 3A 02 and OPT2 3A 03 Pinouts E 6 B 6 Cable Model Number Scheme for E 3 System Specifications
106. A R X X XX CONNECTION CHART CABLE MOTOR CONNECTION CABLE BDS4 C2 8055 C3 D MANUFACTURER TEM 5 ITEM 4 ITEM ITEM 42 PART NUMBER NAME PART NUMBER TERMINAL RED ERMINAL 7 N C 4 PAIR A 81948 BELDE 8725 ERMINAL B BLACK VC SHIELD ERMINAL 8 MOTOR CONNECTOR AND ACCESSORIES TERMINAL TT MANUFACTURER e EMI UT DESCRIPTION NUMBER PART NUMBER ae NC SHIELD ERMINAL 2 MOTOR HOUSING ERMINAL E WHT RED ERMINAL 10 CRIMP CONTACT ERMINAL F WHT BLK AL 4 FILLER PLUG SHIELD ERMINAL 5 REDUCER POWELL ERMINAL CRIMP TOOL N A BENDIX ERMINAL F 8054 C2 BDS5 C3 AND ACCESSORIES MANUFACTURER DESCRIPTION PART TERMINAL S 12 POS HOUSING A 8 GREEN CUS TOME CRIMP PIN CRIMP TOOL WHITE ERMOSTAT SHIELD OOK UP OR DETAILS SEE SHEET 2 AND 3 0 ABELED GCA R THIS CABLE ASSEMBL A R Rh amp SA AMD 2 1 4 5 BDS4 AMPLIFIER CABLE L 7 IN METERS COPY COD DATE APP D Kollmorgen Industrial D
107. ACCESSORIES TET TT 2 ING TERMINA 79406 002 HOLL INGSWOR 3027 10 MANUFACTURER DESCRIPTION 422250 PART NUMBER PART NUMBER H MOTOR PLUG X 3106 E DAN 3 63 SEND IX 53106 22 225 am uid 6 3 4 SHRINK TUB 6 17634 RAYCHEM RNF 100 1 3 4 CRIMP TOOL HOLL 004 HOLLING OW THIS CABLE ASSEMBLY TO BE LABELED GCA MBA X X XX 4 4 5 BDS4 or 5 AMPLIFIER 5 S D SMART DRIVE AMPLIFI oEMBL Y JR CABLES DATE SCALE DWG SHEET 8 OF 11 ISSUE K COPY CODE 155 CN NO APP D Kollmorgen Industrial Drives 1 RADFORD VIRGINIA CHK BY DATE co c m APP D BY DW BY DATE EE 1 EWR 10 01 02 CU gt ELL 6 CLAMP SEE LABEL CABLE SHT 2 CABLE DESC RIPTION 10 MANUF A PART NUMBER Z Out ELD BE CUT 0 ABLE J RE
108. ATE APP D BY DATE SCALE DWG SHEET 7 OF 8 155 EWR 9342 05 18 02 05 18 92 SOLL MOTOR CABI fe oS _ MATING MOTOR CONNECTOR gt 5 3 16 V 4 e HEATSHRI 3 LONC NK 5 8 SHR EAT NK 4 AS LONG BUTT CONNECTOR JELO 8 GRNVYEL WIRE TO CABLE JACKET AND BUTT PENNEC TOR NOT Dl RD THE IJC N TIFTI N INTO R CUT OFF 1 50 7 SPADE LUG SL n 4 DESCRIPTION PART NUMBE MANUF A CTURER DESCRIPTION ANUF ACTURER PART NUMBER PART NUMBER SPADE XSS20836 4 CONDUCTO 7 41 27 94 012 3 BUTT CONN 02 HOLL INGSWOR 003 HOLL INGSWOR B4046BF CRIMP TOO HOLL TN HOE MOTOR CONNECTOR A ND ACCESSORIES DESCRIPTION ANUFACTURER
109. BDS4 SERIES INSTALLATION AND SETUP MANUAL Old Number M93100 Issue 2 New Number MB4001H THANK You Motion Technologies Group Thank you and congratulations for choosing Kollmorgen s servo products for your motion control requirements We seek to provide our customers with quality products excellent support and outstanding value In an effort to provide you with dependable and useful documentation we offer you an opportunity to critique this manual with your comments and suggestions Your feedback on this reader comments form is very important to us Please answer the questions below and return the form to Kollmorgen Motion Technologies Group Technical Manual Department 201 Rock Road Radford VA 24141 U S A FAX 540 731 0847 Name Title Company Street Address City State Zip Telephone Fax Product Manual Part Number Please check the rating that best represents your opinion on each topic Excellent Good Fair Po 1 1 Overall clarity and readability 2 Organization the manual a 3 Information completeness 4 Information accuracy 5 Installation procedures a a a 6 Ability to quickly find information you need Q a 7 Graphics 8 Figures usefulness 9 Tables usefulness a 10 Overall rating of this manual a a Please list any errors What did you like least about t
110. BIS 2 5 B c 2221 12 6 MIN 88 3 MA H 13 39 MAX 85 2 C2 5 H EB 03 OL HOR 7 28 WIDE SLOT 20 2 PLACES 79 IATERIAL HANDLE ACCORDINGLY COPY CODE 155 ECN NO DATE APP D 2 55 1 NO APP O 2 8 1 7 93 Kollmorgen Industrial Drives OUTLINE DI P 7 11 96 RADFORD VIRGINIA BDS4A 3 amp 6 AMP FTI 227 DW BY 8 04 BY DATE oe Ld EWR 8 03 92 8 03 92 1 4 93567 3 METRIC X DEC PLACES XX DEC PLACES NCHES DO NOT SCALE DWG USE DIMENSIONS ONLY Mar EOE 4 XX DEC PLACES 015 IN ALL DIMENSIONS ARE MILLIMETERS WITH INCHES ANG DIM 41 45 1 DWG XX DEC PLACES IN PARENTHESES UNLESS OTHERWISE SPECIFIED A 1 w gt gt 1111 nuu Co 1111 UU DUUUUULU T A
111. BY DATE 1 4 m 7 RIMPED MOTOR CONNECTOR RESOLVER CABLE WITH THERMOSTAT AND TACH GCA MANUF ACTURER TEM 5 PART NUMBER PART NUMBER CABLE MOTOR CONNECTION CABLE BUSY 1 DESCRIPTION 9 170 I J SORTA 3 7 5S 6 PAIR 96027 004 BN 11 C3 MOTOR CONNECTOR AND ACCESSORIES e ID MANUFACTURER PART NUMBER NAME PART NUMBER DESCRIPTION 720 co m C3 MOTOR HOUSING CRIMP CONTACT 1 1 1 1 1 1 1 1 1 m FTI A T lt I M N Ww FPS FILLER PLUG REDUCER CRIMP TOOL N A BENDIX 1 01 TERMINAL 8054 C2 OR BOSS AND ACCESSORIES ID MANUFACTURER TERMINAL F RED 5 T TERM 12 DESCRIPTION PART NUMBER PART NUMBER TERMINAL S BLK 5 N C lt TERM 16 MOLEX 17 7 1 T zu CRIMP PIN MOLEX CUSTOMER N C
112. C UNITS ATE MOTOR CABLES TO WHEN USED ON THE FOLLOWING SHEET 3 or 4 SHEET 5 or 6 SHEET 7 DASH CABLE LENGTH DASH CABLE LENGTH CABLE LENGTH PART NUMBER DESCRIPTION METERS FEET M X A ND METERS FFET NO METERS FEET 10 024 24 45 50 GOLDL TN CABLE LENGTH 20 27 90 48 60 CIN METERS 29 _ ie 4 5 BDS4 or 5 AMPLIFIER T S D SMART DRIVE AMPLIFIER 0 39 130 0 140 2 us aum APP D Kollmorgen Industrial Drives D RADFORD VIRGINIA cn SHEET 1 OF 8 ISSUE CHK BY DATE BY DATE SCALE PLUG BODY BACKSHELL DETAIL CC N NP CONNEC TOR STEP USE STRIPPING PLIERS TO STRIP INSULATION 4 5 MM 0 18 FROM EACH WIRE BOTH ENDS STEP 2 FOR CRIMP CONNECTORS SERT WIRES THE CRIMP CONTACTS AND CRIMP R ON SLEEVES ARE USED WIRES ARE ON FOLLOWING SHEETS STEP 2 A
113. CABLE LENGTH POSITION CODE CHART 111 75 4 40 EIE 75 8 34 NS BE PLACED ON WIRES DESCRIPTION CODE TH SOLID SIDE DOWN 75 PINS BE PLACED ON WIRES 00 MODULE IN THIS POSITION 0 j amp 6 AMP WITH SOLID SIDE UP 12 7MM J ROP ROT zt 1 j u 7 2 21 2 U 3 3 D 1 5 2 6 TH S i 5 USED FOR BOTH ENDS OF EACH 6 DETAIL A 90 FOR SPACING BETWEEN SEE DWG A UNITS L52 NOTE CAD DWG FOLLOW ING 15 THE AMPLIFIERS THA _ Eu pi Kollmorgen Industrial Drives P S BDS4 1018054 8055 LO BDS5 RADFORD VIRGINIA 12 4 0 3 0 2 5 00 20 0 3 0 ZS 08 _ 50 6 6 6 9 903 EWR 4 84363 EWR 2 Y E 5 Ps Sage JOB NO 8 6 6 6 84473 EWR SE CROSS REF NO 55 18 TC copy cone 84546 EWR 16 92 Z DASH NUMB EXAMPLE 84 MBER ADONE DWG
114. CAL TWO WIRE J SHIELDED L IN CABLE HEAT SHRINK 4 DWG NO SHEET 5 OF 14 ISSUE reese 04460 H SISO 08 SHI ELD CABLE Z CABLE OUTER JACKET 515 1 STEP Z STEP 3 Ao st m 11211 5 STEP 4 S t Tes EK ER JAC LOWIND LONG SHR CET HAS INK 5 43 9 5 10 0 JA DIVIDUA USH W ER THE E SH Q SIR PLUG HE CRIMP P CONTACTS ORDING TO ITEMS ONTO MSLSK CONTA TO THE PLUG THE CONNECTI CTS AND SHIELD CRIMP BODY FOIL SHIELD AND ELDS FROM TOUCHING IP INSULATION 4 5 MM 8 JNTIL THEY WITH USE ON CHART STEP 6 CONS NOTE 18 1 FOR CABLE Tan 49 SOLDER CONTACTS POSITION CLASS SLEEV SHRINK TUB B SLIDE TH C HOLD PLUG D TIGHTEN E POSITION SHEET 1 AP PLACE LABEL 1 REFER CABLE CABLE 5 INSERT THE WIRES THE KSHELL ALONG TH TO NOTE BELOW IN STEP 4 EMBLY GC RB 4 5 XX 5 8 5 8 X 1 00 S LY HEAT TO SHR N APPRO
115. CRIPTION _ NUF VC SHIELD ERMINAL 2 PART NUMBER PART NUMBER a ND FEMINA 10 5 MOTOR HOUSING A42867 1419 SOURIAU 851 06 14 1955 ERMINAL WHT BLK ERMINAL 4 N C SHIELD ERMINAL 5 ERMINAL P N C 8054 C2 08 8055 C3 AND ACCESSORIES RAS 10 MANUF ACTURER ERMINAL R SCRIPTION DESCRIPTION NUMBER NAME ERMINAL S 12 POS HOUSING A 8 MOLEX 3 CRIMP PIN MOLEX ERMINAL T GREEN CUSTOMER CRIMP TOOL MOLEX ERMINAL U WHITE THERMOSTAT N C SHIELD DOK UP SEE SHEET 5 AND 6 FOR CONNECTOR DETAILS THIS CABLE ASSEMBLY TO BE LABELED GC R 4 5 XX CABLE LENGTH S K COPY CODE 155 ECN NO DATE APP D DI SIME T Kollmorgen Industrial Drives AVP RADFORD VIRGINIA GUIDE FOR ES DWN BY EWR CHK BY DATE BY DATE SCALE DWG NO OO d DWG SHT 9 OF 14 ISSUE 9 4 gt I G2 CABLE MOTOR CONNECTION CABLE BD BDS4 0 MANUF ACTURER TEM 5
116. CTING BDS4 3 20 POINTS AMP UNITS BDS4 30 55 AMP UNITS PSR4 5 12 20 AMP UNITS PSR4 5 50 75 AMP UNITS AC Input Screws 12 Ib 20 in Ib 12 in Ib 20 in Ib DC Bus Screws 12 in Ib 20 in Ib 12 in Ib 20 in 15 Motor Connecting 12 in Ib 20 in Ib Screws External Regen 12 in Ib 20 in Ib Screws Ground Screws 5 4 5 and other equipment is accomplished by connectors supplied with the BDS4 and PSR4 5 units The input output connections are grouped by connector or terminal block They are input output motor resolver AC main power and control voltages main DC bus and unregulated DC voltages To connect the power bus of the PSR4 5 to the BDS4 amplifiers the following is suggested For PSR4 5 X12 modules use 600 VAC insulated 14 AWG larger wire For PSR4 5 X20 modules use 600 VAC insulated 10 AWG wire For PSR4 5 50 and PSR4 5 75 modules use 600 VAC insulated 8 AWG or larger wire Captive screws are used in the power terminals of the PSR4 5 X12 module PSR4 5 X20 module and the 3 amp thru the 20 amp BDS4 amplifiers Do not attempt to remove these screws to use ring terminals Use locking spring terminals similar to Hollingsworth XSS20945S or SS20947SF for 16 and 14 AWG wire and XSS20836 or SS20832F for 12 and 10 AWG wire 2 7 1 Recommended Torque for Electrical Connections Table 2 1 displays the recommended torque values for terminal block and grounding connecting po
117. CTURER ERMINAL R SCRIPTION DESCRIPTION NUMBER NAME ERMINAL S 12 POS HOUSING A 8 MOLEX 3 CRIMP PIN MOLEX ER AL T GREEN CUSTOMER CRIMP TOOL MOLEX ERMINAL U WHITE THERMOSTAT SHIELD OOK UP SEE SHEET 2 AND 3 FOR CONN THIS CABLE ASSEMBL OR AB DETAILS ELED S GCA R X X XX 4 5 8054 4 IN CABLE L GTH METERS COD N ND DATE APP D DATE APP D Kollmorgen Industrial Drives RADFORD VIRGINIA N GOLDL GUIDE FOR RESC CHK BY DATE APP D BY DATE SCALE DW 5 SHT 8 OF 13 ISSUE NEN ES C 3 C 1 G gt lt gt lt gt lt gt lt DESCRIPTIDI D 5 4 1 2 OUR Ir LUN EXC va EVITER it PART NUMBER NAME PART NUMBER MINA CABLE MOTOR CONNECTION CABLE BDS4 C2 or BDS5 C3 054
118. D fault circuit will activate latch the BDS4 in the inhibit mode and this LED will become illuminated b Miswired or intermittent resolver cable 5 6 BDS4 CHAPTER 5 TROUBLESHOOTING Table 5 3 PSR4 5 12 amp 20 Amp Status LED Indicator Troubleshooting SYMPTOM PROBABLE CAUSE 1 DC BUS LED Green a Main DC Bus insufficient or not present AC input power Not Illuminated not applied check input line fuses 2 Regen LED Yellow a Nota fault condition Indicates regeneration circuit Illuminated or Flashing activity 3 Overload LED Red a Main DC Bus voltage excessively high due to high Main Illuminated AC line input voltage b ion circui b Shunt regulator regeneration circuit overload c Defective PSR4 5 4 Blown Regen Fuse LED Red Shunt regulator regeneration resistor sized too small Illuminated b Defective PSR4 5 Table 5 4 PSR4 5 50 amp 75 Amp Status LED Troubleshooting SYMPTOM PROBABLE CAUSE 1 DC Bus LED Green a Main DC Bus insufficient or not present AC input power not Not Illuminated applied check input line fuses 2 Regen LED Yellow a Nota fault condition Indicates regeneration circuit activity Illuminated or Flashing 3 Fault LED Red Excessive heatsink temperature due to overload or high ambient Illuminated temperature b Defective PSR4 5 Consult Factory if fault occurs during hard deceleration NOTE 5 7 BDS4 CHAPTER 6 SPARE PAR
119. DIA FLAMMABLE MATERIAL 2 MOUNT HOLES NOTES 2 SHOCK HAZARD RESISTOR CONNECTED TO HIGH YOLTAGE RECOMMENDED WIRE 2 SANG 125 C 2 BOTTOM STANDOFFS ARE THREADED 1 4 20 x 3 8 DP FOR MOUNTING RESISTORS TO PANELS ETC 3 0UTPUT CONTACTS WIRED TO DROP MAIN LINES WHEN CONTACTS OPEN ON OVERLOAD UNLESS OTHERWISE SPECIFIED XX DEC PLACES 018 XXX DEC PLACES 008 ANG DIM 1 DO MOT SCALE DWG USE DIMENSIONS ONLY NO ALL DIMENSIONS ARE INCHES D UNLESS OTHERWISE SPECIFIED lt 1 7 CONTACTS NS SEE SHEET 4 F R DETAILS 5 MOTOR HOUSING FILLER PLUGS W CRIMP ONLY W CRIMP lt lt 2 FIBERGLASS SLEEVING 8 SHRINK TUBING 3 LABEL SEE SHEET 3 1 8 HEAT SHRINK 9 3 8 HEAT SHRINK Ca K TUBING CABLE 4 RESOLVER 0 TACH FOR TUBING amp SLEEV CONNECTORS amp RELATED NG PARTS LIST 5 INDIVIDUAL SHEETS DESCRIPTION 10 MANUF AC TURER FBRGLASS SLEEV A 84824 025 PART NUMBER PART NUMBER 8 H455BA1000 33 1 8 5 5 1526 EM R 10 3 8 SHRINK TUB R E TERT E 12 5 8 5 ib 13 EM RN CABLE LENG
120. ED 11211 5 STEP 4 Ue 5 INEM L K J H G 8 V UNTIL THEY 1 FOR CABLE A PLUG FOR CABLE HE CRIMP CONTACTS AND CRIMP FUR CABLE P CONTACTS INTO THE PLUG BODY WITH USE ACCORDING TO THE CONNECTION CHART E XB X X XX SEE SHEET 8 OR 9 41 SEE SHEET 10 11 SBT XZX XX SEE SHEET 12 OR 13 C oc X z 2 C zr et ed um 1 73 i C3 Cx 70 NO APP D Kollmorgen Industrial Drives c RADFORD VIRGINIA LUIDE DIN BY DATE CHK BY DATE APP D BY DATE SCALE DWG NO EWR 10 07 92 DETAIL B B DETA HEAT SHRINK TUBING CABLE OUTER JACKET DW 5 NO SHEET 5 OF 13 JAA rir LILI HEAT SHRINK TUBING L JL J F Ix es 12 20 POSITION CONNECTOR 22
121. ED THROUGH CTOR IN THE 8054 AND CONNECTOR C4 IN THE BDSS IF THEY SHARE ONE PSR4 5 B IF THE BDS5 USES THE OPTIONAL ANALOG INPUT CARD BDS5 OPTI2J THE OPTIONAL ENCODER INPUTS IN CONNECTOR ARE NOT ALLOWED THE FILTER KIT USES A FERRISHIELD SLEEVE SNAP MODEL s53 DR EQUIVILENT OR N SEE NOTE ON FILTER KITS IN B OPTIONAL IN COPTIONAL OUT A IN COPTIONAL IN OPTIONAL OUT B OUT B OUT Z OUT Z o2 COMMON 5 COMMON MASTER BDS4 WIRE THROUGH 22 STYLE DC UT MODULE TO CONNECTOR C7 PIN 9 OF SLAVE BDSS ER 54 AND SLAVE BUSS CAD DWG DATE APP D COPY CODE 15 Kollmorgen Industrial Drives BUS4 WIRING DATE APP D RADFORD VIRGINIA OPTIONAL ENCODER EQUIVALEN 1 DN 8 CH BY APP D BY DHE PLOT SCALE DWG NO SHEET 5 OF 7 ISSUE rs VA 2 19 01 1 1 PICO le vel c DWG SHEET 6 ALL WIRES TO COPPER WITH MIN RAT 03231 N
122. EN FUSE 112 120 A 80552 013 7 AMP 1 FUSE 132 REGEN FUSE 112 02 A 80552 001 10 AMP 1 120 02 FUSE 132 REGEN FUSE 212 220 A 80552 009 8 AMP 1 FUSE 132 REGEN FUSE 212 01 220 01 A 80552 002 12 AMP 1 FUSE 132 REGEN FUSE 220 03 80552 003 15 AMP 1 FUSE 132 ALL FUSES MUST REPLACED WITH EXACT SAME VALUE AND STYLE OR THEY WILL NOT BE EFFECTIVE CAUTION 6 2 31354 6 3 ORDERING INSTRUCTIONS If you need to order parts for the BDS4 and or PSR4 5 you can order them through your local distributor For a complete list of Industrial Drives representatives contact us directly at Danaher Motion Customer Support 201 Rock Road Radford VA 24141 U S A Telephone 1 800 777 3786 815 226 3100 FAX 540 731 5641 CHAPTER 6 SPARE PARTS 6 3 BDS4 APPENDIX A WARRANTY INFORMATION APPENDIX A WARRANTY INFORMATION Industrial Drives a Kollmorgen Division warrants The terms and conditions of this Warranty are that equipment delivered by it to the Purchaser will provided with the product at the time of shipping or be of the kind and quality described in the sales in advance upon request agreement and or catalog and that the equipment will be free of defects in design workmanship and The items described in this manual are offered for material sale at prices to be established by Industrial Drives and its authorized dealers A 1 BDS4 APPENDIX B MODEL NUMBERS
123. ER NAME PART NUMBER NAME PART NUMBER 6 15 8 SHRINK TUB H 15577 RAYCHEM RNF 100 1 5 8 MOTOR PLUG THIS CABLE ASSEMBLY BE LABELED 4 5 BDS4 or 5 AMPLIFI ER X X LJ CIN CABLE LENGTH METERS COPY CODE DATE APP D DATE APP D Kollmorgen Industrial Drives RADFORD VIRGINIA S0LDL I NE AVPLIFIE VE GUIDE FOR VOTOR ABLE 3 THRU 20 CHK BY DATE APP D BY DATE DWG ISSUE CRIMPED MOTOR CONNEC GOLDLINE MOTOR CABI UR DOE A ATN JMATING MOTOR CONNECTOR 1 BUTT 5 8 Ce N CONNECTOR SHRINK 4 LONG 227 amp WIRE TO BE CUT OFF BEYOND CAB ET AND INSERTED IN BUT DO NOT D THAT 10 INTO 0 MANUFACTURER EJ 711 A
124. FAN COOLED FAN COOLED FAN COOLED Continuous RMS 30 AMPS 40 AMPS 55 0 AMPS Peak 2 0 SEC 60 AMPS 80 AMPS 110 AMPS Output KVA 330 VDC BUS Continuous 45 C AMB 11 0 KVA 14 5 KVA 20 KVA Peak 2 0 SEC 22 0 KVA 29 KVA 40 KVA Internal Heat Dissipation 255 WATTS 335 WATTS 445 WATTS PWM Switching Frequency 10 0 KHZ 10 0 KHZ 10 0 KHZ Motor Current Ripple Frequency 20 0 KHZ 20 0 KHZ 20 0 KHZ 10 Resolver Excitation Frequency 7 0 KHZ 7 0 KHZ 7 0 KHZ Speed Regulation 0 075 0 075 0 075 G Long Term TMinimum Controllable Speed Standard 12 Bit R D With 8000 RPM Max Tracking Rate 12 Bit R D With 14000 RPM Max Tracking Rate 14 Bit R D With 1 8 RPM 1 8 RPM 1 8 RPM 2000 RPM Max Tracking Rate 14 Bit R D With 1 4 RPM 1 4 RPM 1 4 RPM 3500 RPM Max Tracking Rate 16 Bit R D With 1 64 RPM 1 64 RPM 1 64 RPM 500 RPM Max Tracking Rate Minimum controlled speed is defined as the minimum speed that can readily be run The standard BDS4 is configured with 12 bit R D converter for a maximum motor speed of 8 000 RPM Other resolutions and maximum motor speeds tracking rates must be ordered as specials D 7 APPENDIX D SPECIFICATIONS BDS4 Table D 3 Derating Data Derating Information Continuous Duty 60HZ 50HZ Operation In 50HZ Derating 55 C 45 Max Ambient Total Derating 55 C No Derating No Derating No Derating No Derating Based on Derating of 2 C from 45 C
125. FOR RESOLVER NO DATE APP D APP D BY DATE SCALE DWG NO SHEET 9 OF 14 ISSUE DWN BY DATE EWR CHK BY DATE 05 18 02 05 18 92 Pd C I 1 G2 CONNECTION CHART 0 MANUF ACTURER 5 4 1 2 CABLE MOTOR CONNECTION CABLE BDS4 C2 or BDS5 C3 054 Cl JESCRIPTION PNE PART NUMBER PART NUMBER TERMINAL RED RMINAL ae 6 PAIR A CAROL ERMINAL B BLK R AL 1 SHIELD RMINAL 8 AL REDZ RMINAL 3 MOTOR CONNECTOR AND ACCESSORIES DESCRIPTION i Ve SHIELD RMINAL 2 PART NUMBER PART NUMBER ES 212 MOTOR HOUSING 42867 1419 SOURIAU 851 06 14 19550 ERMINAL RMINAL 4 1 1 1 1 1 1 1 1 m E C I M Ww EXE Mt t I 4 2 24 e z m TERMINAL P BRAKE Ww BDS4 C2 OR BDSS C3 AND ACCESSORIES N C HIELD HOOK U DESCRIPTION D MANUFACTURER TERMINAL R CEE SCRIPTI
126. I BDS4A V PSR4 5 Amplifier Power Supply Input Line Fuses Adjustments Control Power and Indicators 1 115 VAC Option Connector Encoder Output Input Output 1 O or 3 O Transformer May be Optional AC Input Power 230 VAC Typical Resolver Feedback Earth Ground Servomotor with Feedback 3 O Motor Power Figure 1 2 Typical System Diagram 1 NOILLdIMOSAG WALSAS NHLdVH BDS4 CHAPTER 2 INSTALLATION CHAPTER 2 INSTALLATION 2 1 INTRODUCTION The information in this chapter will familiarize you with the safety information unpacking and inspection installation requirements assembly procedures and electrical connections for installing the BDS4 A checklist is provided at the end of this chapter to insure proper installation 2 2 SAFETY INFORMATION The purpose of this section is to alert you to possible safety hazards associated with this equipment and the precautions you can take to reduce the risk of personal injury and damage to the equipment Safety notices in this manual provide important information Read and be familiar with these instructions before attempting installation operation or maintenance Failure to observe these precautions could result in serious bodily injury damage t
127. IN 2 pE WI nel N A C bs NOTE 1 lH RESPECT CAD DWG COPY COD SS ECN NO DATE APP D s APP D Kollmorgen Industrial Drives EFE 3 RADFORD VIRGINIA CONNECTION T DIN BY DATE CHK BY DATE APP D DATE SCALE DWG NO ISSUE Sila TOG 11 03 92 11 09 92 35 MA 93908 l NOTES 1 USE DIN 83909 _ WITH CONNECTOR 2J MATERIAL UL 94Y 0 NYLON NUM BER OF CIRCUITS APPROVED VENDOR MOLEX 39 01 2 _ 5 Kollmorgen Industrial Drives EES Aran PURCHASE SPEL FOR VA D Te 17 A 83908 UNLESS OTHERWISE BSPECIFIEO xx DEC PLACES 018 XXXDEC PLACES 005 ANG DIM OO MOT SCALE DWG USE DIMENSIONS ONLY 3 ALL DIMENSIONS ARE INCHES UNLESS OTHERWISE SPECIFIED 8 3909 inches AWG 16 071 122 1 8mm 3 1mm LOOSE ae ae 225 22 28 035 071 0 9 1 8mm AWG 16 071 122 1 8mm 3 1mm LOOSE Tin Plated Phosphor Bronze 4 1 ECKEN SS AWG 16 071 122 1 8mm
128. ING THE MOTOR THERMOSTAT AUTOMATICALLY RESETS WHEN THE MOTOR 7 ALL AC LINES SHOULD 5 OLS THE CUSTOMER IS RESPONSIBLE FOR LATCHING THIS SIGNA dese INHIBIT OPERATIC MOTOR THERMOSTAT FAULT CO E USING TWISTED PA INO IG ECT THERMOSTAT OMB IN OF 4 BDS4 UM OF 4 BD NUM OF 6 BDS4 IUM OF 6 BDS4 MIXED THEN USED OULD BE TH AXIMUM GIVEN CLOSES ON APPLICATION OF CONTROL AX ANSLON ON THE PSR4 5 50 N A MAXIMUM OF 4 BDS4s OR 3 BD ER STANDS F FROM 3 TD D RELAY IS SU PSRA 5 s IZED FOR YO F THE RELAY TOR IN FAULT CON CONTROL IER PSRA 5 CONNEC THIS IS SO THAT CON MUST BE WIRED ALLY OPEN AND WILL CLOSE SOL AND MAIN POWER NUMBER AXES THAT CAN 80555 1 AMP UNITS ALSO LIMITED ITHER SIDE OF THE PSR4 5 ENGTH IN METERS CABLE N INCREMENTS OF 3 METERS RESISTOR KIT FOR SELAY INCLUDED RATING POWER WN ON S H ROUGH T JF GE ENSURE SUFF OR MAY BECOME VER LS THAT ARE FLAMMABLE 10 RED EACH 10 OBTAIN SPEC DZ a Y 4 T lt m OL VON T BE REMO
129. ION ITEM ME 2 MANUFACTURER PART NUMBER PART NUMBER DESCRIPTION PART NUMBER NAME PART NU m MOTOR PLUG A 43173 CIR 06F 18 105 5 3 16 SHRINK 6 15265 RAYCHEM 6 5 8 SHRINK TUB RAYCHEM x THIS CABLE ASSEMBLY TO BE LABELED GC M28 or 4 3 AMPLIFIER S D SMA T DRIVE AMPLIFIER CABLE LENGTH CIN METERS m COPY CODE 155 ECN DATE APP D GOLDL INE mS Kollmorgen Industrial Drives CUIDE FOR MOTOR RADFORD VIRGINIA 3 THRU 20 AMP APP D BY DIN BY DATE DATE SCALE SHEET 6 OF 8 ISSUE EWR e Fa p CHK BY DATE 05 18 02 05 18 92 CCRIMPED E 111 INE MOTOR UR 6024A 602B 6044 4 NMATING MOTOR CONNECTOR N COMES W CONTACTS 1 BN m Den C 20 cL BUTT 5 8 HEAT 6 7 p d CONNECTOR SHRINK 4 LONG
130. ION Compensation Card Bo Amplifier Base Model Number Motor Winding and Compensation Designator B 1 CABLE BUS WIRE AND MATING CONNECTOR KIT INFORMATION Extra or spare bus wire and complete cable assemblies are available from Industrial Drives Mating connector kits are available from Industrial Drives or may be purchased directly from the connector vendor B 4 BDS4 APPENDIX B MODEL NUMBERS B 2 CABLE MODEL NUMBER SCHEME FOR INDIVIDUAL CABLE SET Motor cables are designed to provide reliable and cost effective interconnection between Industrial Drives Goldline Series Motors and any BDS Series Amplifier GCS Goldline Cable Set models provide both motor stator and resolver feedback cable of equal length Cables include motor mating plugs with various termination options at the amplifier end There are 2 versions of the cable sets the GCS and the GCSA The GCS is used with motors that have MS Bayonet type connectors while the GCSA is used with motors that have MS screw type connectors To assist in ordering the model number scheme for a cable set is as follows Table B 5 Cable Model Number Scheme for Individual Cable Set Bayonet Type Thread EXAMPLE GCS M6A R LEGEND Motor Power Cable with mating plug for particular frame size B 60X X AX amp BX Motors up to 40 amps continuous B 60X X AX amp BX Motors up to 65 amps continuous B 80X X AX amp BX Motors up to 65 amps continuous B 80X X AX a
131. J m WIRE AND 155 Kollmorgen Industrial Drives RADFORD VIRGINIA DWN BY DATE CHK BY DATE APP D BY DATE 20s 13 0 NOTES ALL WIRES TO BE 15 USE CORCOM 581 SINGLE PHASE FILTER OR EGUIVILENT TEMP RATING 0 DWG NO SHEET 7 OF 7 3231 G al JG FOR CE REQUIREMENTS 16 USE SHAFFNER THREE PHASE FI MODEL MODEL MODEL MOD FO REQUIREMENTS 17 USE A SCHAFFNER THREE PHAS NO RD 7 6 12 5 FOR BDS4A 110 8 15 FOR BDS4A 120 8 2 DEL FELS IODEL NO RD 713 IODEL NO RD 71 EL NO R 37 5 100 NO RD 7137 3 NO RD 8137 0m3 2 CE REQUIREMENTS SUITABLE FOR USE ON CIRCUIT CAPABLE OF DELIVERING NOT MORE THAN 5000 COPY CODE ECN NO DATE APP D Kollmorgen Industrial Drives VIRGINIA DIN BY DATE BY DATE APP D BY DATE SCALE DWG NO SHEET 7 OF 7 i 1 03 1 1 03231 ES CA 7 89 es 2 Va PAN SCRE
132. J INCHES DO NOT SCALE DWG 4 XX DEC PLACES 015 IN ALL DIMEN XXX DEC PLACES TERS ED USE DIMENSIONS ONLY DWG NO SHT IONS ARE MILLIY IN UNLESS OTHERWISE SPECI OF 2 ISSUE THIRD ANGLE PROJECTION ae 1 25 2 LOC r 20MM BETWEEN ALL UNITS FOR COOLING mm MINIMUM FREE SPACE SHOULD BE MAINTAINED AROUND THE SYSTEM ATE THE HIGHEST CURRENT BDS4 5 AMPLIFIER NEXT TO THE PSR4 5 POWER SUPPLY AND REMAINING BDS4 5 AMPLIFIERS IN DESCENDING ORDER COD CAD DWG IS NO DATE APP D ISS ECN NO DATE APP D 2 1 20 93 CJF Kollmorgen Industrial Drives RADFORD VIRGINIA ING HOLE PATTERN BUSSA PSRA 5A DIN BY DATE CHK BY DATE APP D BY TDG 1 6 93 CJF A 03 03 2 UO 9 2 SUE 02 METRIC INCHES DO NOT SCALE DWG USE DIMENSIONS ONLY DWG 2 OF 2 ISSUE 5 4 015 IN ALL DIMENSIONS ARE MILLIMETERS u CES ANG DIM 1 DEGREE XX DEC PLACES 5 IN UNLESS OTHERWISE SPECIFIED 2 bis J THIRD ANGLE PROJECT ION METRIC 20MM BETWEEN ALL UNITS FOR COOLING 38 58 40 28 8
133. LL INGSWOR 0 3 4 SHRINK TUB RAYCHEM 1 3 4 HIS CABLE ASSEMBLY BE LABELE 4 r 5 AMPLIFIER E AMPL COPY CO APP D DATE Kollmorgen Industrial Drives RADFORD VIRGINIA CHK BY DATE APP D BY 4 CRIMP Jn gt 5 HEATSHRINK 4 e 5 AJ 1 LOND SEE SHT 2 Z UJ SHIELD TO BE DESCRIPTION PART NUMBER 10 8 MANUF ACTURE AJ MARK AQ BLUE WIRE MARK WHITE WIRE MARK C BLACK WIRE MARK GRN YEL WIRE BEYOND SECTION NS SHOWN WIRE 8 WIRE 4 CONUCTOR 4 AWG A 97941 004 OMN 100404 K TURER MOTOR CONNECTOR A ND ACCESSORIES PART NUMBER DESCR PTION 10 PART NUMBER MANUF AC TUR AJ MOTOR PLUG VEAM CIR 06F 32 17S F80 CRIMP TOOL INSERTION TOOL GUIDE PINS
134. LS LABELED WM CU R 4 5 XX CABLE LENGTH COPY CO D N ND DATE APP D DATE APP D RADFORD VIRGINIA Kollmorgen Industrial Drives GOLDLIN AMP lt GUIDE FOR C DATE 05 18 02 05 18 92 DIN BY EWR CHK BY DATE BY DATE SCALE DWG NO OO DESCRIPTION MANUF AC TURER RED MOTOR CONNECTOR 8 RESOLVER CABLE WITH THERMOSTAT GC R 4 5 XX ARTS LIST CONNECTION CHART MOTOR CONNECTION ITEM 4 TEM 5 8054 Cl 2 PART NUMBER PART NUMBER ERMINAL RED ERMINAL N C 4 PAIR A 81948 BELDEN 8725 ERMINAL B BLACK ERMINAL N C SHIELD ERMINAL 8 x S AN ME ERMINAL WHT YEL ERMINAL 3 CONNECTOR AND ACCESSORIES F AL D WHT GRN ERMINAL 9 MANUF ACTURER lt ER 2 ITE DES
135. LY 4 Kellmorgen Industrial Drives ixl d xb 2 RADFORD VIRGINIA VENS ION 20 AMP CJF DWN BY DATE CHK BY DATE APP D BY DATE SEALE 1550 T 4 FMJ 11 80 SCM 0 90 1 4 N WP UNLESS ANG DI DO NOT SCALE DWG ALL DIMENSIONS ARE MILLIMETER UNLESS OTHERWISE SPECIFIED p E cn USE DIMENSIONS ONLY WITH INCHES E METRIC THIRD ANGLE PROJECT ION GO CJ E a Q D 2 PSR EE LL 5 No Gey CORY CODE 7 0 28 0 28 DIA MOUNTING HOLES 2 PLACES GROUND TERMINALS APP D Kollmorgen Industrial Driv
136. ON iA PART NUMBER NAME TERMINAL S NOTE 12 POS HOUSING MOLEX CRIMP PIN MOLEX CRIMP TOOL MOLEX TERMINAL T RED 6 CUSTOMER TERMINAL BLK 6 THERMOSTAT N C SHIELD DOK UP SEE SHEET 5 AND 6 FOR CONNECTOR DETAILS THIS CABLE ASSEMBLY TO BE LABELED GC RB 4 5 XX NOTE CABLE LENGTH 1 RESOLVER END CUT OFF REMAINING PAIR 12 7 1 2 FROM CABLE JACKET AND FOLD BACK OVER JACKET PLACE UNDER HEAT SHRINK MOTOR END CUT OFF REMAINING PAIR EVEN WITH CABLE JACKET 5 K CODE 1155 ND DATE APP D Kollmorgen Industrial Drives 20015 1 RADFORD VIRGINIA GUIDE FOR RESOLVER N NO DATE APP D BY EWR APP D BY DATE SCALE DWG NO SHEET 10 OF 14 ISSUE 869 Q CHK BY DATE MOTOR CONNECTOR C CABLE WITH THERMOSTAT AND TACH GC 85 LIST CONNECTION D MANUFACTURER TEM 5 PART NUMBER NAME PART NUMBER CABLE MOTOR CONNECTION CABLE BUSY 1 9 3 I J
137. ON Depending on the continuous current ratings of the BDS4 and PSR4 5 modules a total of six 6 amplifiers may be mounted with a single power supply However the maximum number of BDS4 amplifiers mounted on either side of the 5 4 5 power supply module must not exceed four 4 Mounting combinations for the PSR4 5 and 81354 modules are as follows e PSRA 5 X12 a maximum of four 4 BDS4 amplifiers sequentially or split mounted amplifiers are mounted on both sides of the PSR4 5 at either side of the PSR4 5 in descending order of continuous current ratings e 5 4 5 20 a maximum of four 4 81354 amplifiers sequentially or split mounted at either side of the PSR4 5 in descending order of continuous current ratings e 5 4 5 50 a maximum of six 6 BDS4 amplifiers split mounted only to either side not to exceed four 4 amplifiers on a side mounted in descending order of continuous current ratings e PSR4 5 X75 a maximum of six 6 BDS4 amplifiers split mounted only to either side not to exceed four 4 amplifiers on a side mounted in descending order of continuous current ratings Refer to The drawing of your model system in Appendix F for the Mounting Hole Pattern NOTE information Allow sufficient clearance for the large regenerative heat producing resistor s The internal resistors are mounted at the upper edge of the PSR4 5 unit The CAUTION externally mounted regen shunt re
138. ON REFERENCED E qe APER SIGNAL SCALED FOR 8 VOLTS AT MAXIMUM 20 10 DRIVE UP RELAY THE SYSTEM SPEED AS STATED DN TACH MONITOR ee Ps 2 2 CONNECTOR C1 S7 DRIVE UP RELAY RESISTOR IN LINE RELAY ACTS CIRCUIT DR I VE UP RELAY CAN DRIVE UP TO 1 2 AND THE CONTACTS ARE RATED FOR 115 VAC THE RELAY MUST DERATED FOR INDUCTIVE LOADS N T c 20 ee gt TO COPY CODE 155 Kollmorgen Industrial Drives BD RING DIA SS APP D 11 RADFORD VIRGINIA C1 CUSTOMER 1 0 m BY DATE CHK BY DATE APP D BY DATE PLOT SCALE SHEET 2 OF 7 1550 2 22 2 20 91 1 1 3 3 12 BUSZ CONNECTOR C1 DIFF HI 11 i i m CONNECTION SHOWN 5 FOR MASTER ao m y A ig AND SLAVE TO ROTATE IN SAME DIRECTION ENABLE MASTER AND SLAVE ROTATE TT TEE IN OPPOSITE DIRECTION INTERCH Tus PIN 11 AND PIN 1 OF CONNECTOR C TUNE 3h ila THE SLAVE UNIT J ROTATE ING FROM EVERSE
139. ON TUB TFLI6 5 8 SHRINK TUB RNF 100 1 5 8 13 1 2 SHRINK TUB RNF 100 1 172 178 HEAT 5 CABLE LENGTH 5 GTH DASH CABLE LENGTH METERS FEET TI P1 NO METERS FEET 20 POSIT 10 10 HOUSIN CRIMP PIN l HOUSING 3 OF 13 ISSUE SEE SHEET 43 FOR DETAILS SEE SHEET 3 FOR DETAILS NUMBER DESCRIPT ION CABLE 3 10 Oa an 05 70 9 19 YU 051 31 170 2 20 30 00 54 180 3 33 10 97 19 8 40 3t 20 0 0 200 GOLDL IN GCA RXX Z AT AN CABLE LENGTH METERS AMPLIFIER 4 5 054 RI THERW zTHERMOST AT RESOL T RESOL 21 45 THERM 2 48 6 RBT THERM CODE APP D DATE APP D Kollmorgen Industrial Drives RADFORD VIRGINIA GJ FIER ASSEM CUIDE FOR RESOLVER CABLES DIN BY EWR DATE 10 07 02 01 9 CHK BY DATE APP D BY DATE SHEET 3
140. ONS ONLY DIG 0 ISSUE 2 X DEC PLACES 4 4 XX DEC PLACES 015 IN ALL DIMENSIONS MILLIMETERS WITH INCHES ANG DIM XX DEC PLACES 4 13 DEC PLACES 005 IN IN PARENTHESES UNLESS OTHERWISE SPECIFIED AT 3932150 QNIN gt gt POSSIBLE 4 PE BOARD CONNECTORS S 2 PLACES ILI EH CA B noo n EH 05 226 0 EH C2 p BUS S CONNECTIDNS 284 0 11 18 WIDE SLOT 3 15 CONNECTIONS n 2 PLACES S UNIT CONTAINS STATIC SENSITIVE S TAL HANDLE ACCORDINGLY CAD DWC COPY CODE 159 ECN ND DATE APP D Kollmorgen Industrial Drives DU LINE amp DIMENSION 106 8 6 91 CJF L RADFORD VIRGINIA 54 30 amp 40 AMP 8 Q av Sm DIN BY DATE CHK BY DATE APP D BY DATE SCALE DWG NO ISSUE 87736 7 11 96 4 EWR 107 12 01 CJF 07 17 91 1 4 93156
141. ORS TU UL CRIME CONTACTS e TORS THE SOLDER CUPS AND 38 1MM INDIV FOR CL SOM THIS END 0 ULATION 4 57MM 18 INTO THE PLUG LE 2 EDU SHRINK DUA ARITY CABLE D CR BODY CHART 0M THE CABLE 2 7MM 1 2 5 THIS D TIGH L WIRES POS TU STEP 6 NOTE NOTE 1 FOR CAB FOR CABLE CABLE ASSE IMP WITH USE SOLDER BLY ALONG SURELY AND ON FOLLOW EAT SHRI HRINK TU 5 SCREW BACKSHELL ONTO PLUG V V NA NK TUBING AND TUBING AS SHOWN BLE TO PLUG BODY ING AND s SEE SEE SEE SHEET SHEET SHEET CAD DWG APPLY HEAT SHRINK SHEETS LOCATION AS SHOWN ON COPY CODE ee JE 1155 APP D DATE APP D RADFORD VIRGINIA Kollmorgen Industrial Drives GOLDI AMPLIFIER GUID FOR MOTOR EMBLY DWN BY EWR DATE 05 18 07 VIT 107 9 CHK BY DATE BY DATE SCALE DWG NO SHEET 2 OF 8 ISSUE GUNNE D a FILLER PLUG
142. PROBABLE CAUSE Incorrect Direction of Motor a Invert input command signal at Connector C1 1 and 11 Shaft Rotation DO NOT ATTEMPT TO REVERSE DIRECTION OF ROTATION BY INTERCHANGING MOTOR LEADS AND OR RESOLVER LEADS CAUTION Motor Drifts Slowly with Zero a Adjust balance Pot for zero speed in position loop for zero Input Following Error or zero input signal Uncontrolled Excessive Motor and or resolver leads incorrectly connected Speed a b BDS4 backwards in position loop motor shaft turns in wrong direction c Incorrect alignment of system resolver refer to Section 4 4 3 3 d Defective BDS4 COMP Board Motor Erratic a Motor and or resolver leads incorrectly connected tach signal when used and or resolver signals c Incorrect compensation Check BDS4 COMP Board against TL Sheet 5 5 CHAPTER 5 TROUBLESHOOTING BDS4 Table 5 2 BDS4 Status LED Indicator Troubleshooting SYMPTOM PROBABLE CAUSE 1 Control Volts LED Control AC line input voltage out of spec or had a momentary Green Not llluminated interruption b Unregulated logic bus not applied to BDS4 from PSR4 5 due to defective wiring or being miswired fuses inside of PSR4 5 may be blown c Defective logic bus supply in BDS4 or PSR4 5 or blown logic bus fuse d Defective BDS4 2 Enable LED a Enable input circuit not pulled low Green Not Illuminated b Defective 8054 a 8 4 faulted see Red LED
143. R MAX mm FLAMMABLE MATERIAL NOTES 2 5HOCK HAZARD 8 RESISTOR CONNECTED TO HIGH VOLTAGE RECOMMENDED WIRE 2 DAWG 2 STANDOFFS ARE THREADED Y 3 8 DP FOR MOUNTING RESISTORS TO PANELS ETC 3 OUTPUT CONTACTS WIRED TO DROP MAIN LINES WHEN CONTACTS OPEN OVERLOAD UNLESS OTHERWISE SPECIFIED mmm emp DATE WI XX DEC PLACES 018 DG 5 e DEC PLACES 008 2 w ANG DIM 5 DO NOT SCALE DWG USE DIMENSIONS ONLY ALL DIMENSIONS ARE INCHES Dav UNLESS OTHERWISE SPECIFIED B EN SS RR Qd ua n yt RE e YER ARR Aat may PAR CURAS RIT SR RATED TOTAL RESISTANCE 2 25 0 SET awa A 23315 TRIP CURRENT TO 21 AMPS SCALE i 1000 W 2 3 DIA MOUNT HOLES LSIKIB COPY CODE RADFORD VIRGINIA A 93315 RING amp MOUNTING DIAG 4 4 x V2 PAN HD SCREW GTY 95 ou ta posu Va LOCKWASHER QTY 93316 FLATWASHER 2 V4 2O x Va THREADED STUD QTY 4 RATED POWER EONO W 3l CEE STAND OFF SPRUCE PINE 5 QTY C TOTAL RESISTANCE 2 2 4 4 OHM RESISTOR 1000 W QTY 2 SET TRIP CURRENT TO AMPS 3 CONNECT RESISTOR TO TERM BLOCK LOCATED PSRA 5 SEE NOTE 1 CAUTION DO NOT INSTALL RESISTOR NEAR 1 38
144. R HOUSING G 10158 BENDIX MS3106E 22 14S RMINA RED 3 RMINAL 10 1 1 1 1 1 1 1 1 1 m FTI E C I M G ae C3 I 1 m 8054 C2 OR BUSS AND ACCESSORIES N C HIELD HOUK U M ID MANUFACTURER TERMINAL R z piy DESCRIPTION SEE PART NUMBER TERMINAL 5 NOTE ve 1 12 POS HOUSING MOLEX 3 CRIMP PIN MOLEX TERMINAL T RED 6 CUSTOMER TERMINAL U BLK 6 ERMOSTAT CRIMP TOOL MOLEX N C SHIELD 00K UP OLVER END CUT OFF REMAINING PAIR 12 7MM C172 FROM CABLE SEE SHEET 2 AND 3 FOR CONNECTOR DETAILS ET AND FOLD BACK OVER JACKET PLACE UNDER HEAT SHRINK THIS CABLE ASSEMBLY TO BE LABELED CCA RB X X XX MOTOR END CUT OFF REMAINING PAIR EVEN WITH CABLE JACKET iis 4 IN METERS K COPY CODE 155 DATE APP D Kollmorgen Industrial Drives CLINE AVPLIFIER NO DATE APP D RADFORD VIRGINIA GUIDE FOR RESOLV APP D BY DATE SCALE DWG NO SHEET 9 OF 13 TSSL CHK
145. REGULATED 6 amp 12 BDS4 s AND OR 1 COMMON xi BDS5 5 2 7 2 SEE NOTE 8 2 10 VDC UNREGULATED 5 7 FILTER H SEE NOTE 16 TERM TERMINAL 4 MACHINE 59 BUS ih EARTH T x GND GROUND SEE NOTE 4 SCREW S SI Sk 3 PHASE OR SINGLE PHASE SUPPLIED iL REFER SEE NOTES 2 OF OVERLDAD PROTECTION IT IS poe e NA m ED CABLE USE PROPER SIZE WIRE USE 5 NOTES ON LAST PAGE IND EXAMPLE MODEL NER USE BE PROV IDED EX TERN nw ND TOR 9 50 ROM NEC FOR WIRE SIZE 0 DATE APP D Kollmorgen Industrial Drives 155 7 CJF RADFORD VIRGINIA 8 B oe WE mom wt PLOT SCALE D
146. REMA 2 PAIR EVEN WITH CABLE JACKET CRIMP TOOL MOLEX S K COPY CODE 155 ND DATE APP D Kollmorgen Industrial Drives SQDLINE AMP ECN NO DATE APP D RADFORD VIRGINIA GUIDE FOR RESC DIN BY EWR APP D BY DATE SCALE DWG NO SHEET 11 OF 14 ISSUE CHK BY DATE OLDERED MOTOR CONNECTOR 8 50 SOLVER CABLE WITH THERMOSTAT AND TACH GC F ARTS LIST CONNECT ION CABLE DESCRIPTION MANUF AC TURER PART NUMBER NAME PART NUMBER b 6 PAIR A 96027 004 CAROL MOTOR ND ACC ESSORIES DESCRIPTION MANUFACTURER PART NUMBER MOTOR HOUSING 8 51 06 14 19550 221 WVULUG 199504 054 C2 OR BUSS C3 AND ACCESSORIES DESCRIPTION PART ID MANUFACTURER NAME PART NUMBER 12 POS HOUSING MOLEX 3 CRIMP PIN MOLEX CRIMP TOOL MOLEX 054 ACCESSORIES DESCRIPTION PART NUMBER MANUF AC TURER NAME 20 POS HOUSING MOLEX CRIMP PIN MOLEX TEM 5 MOTOR CONNECTION 1
147. RT NUMBER NAME PART NUMBER 66 3 47 SHRINK TUB RNF 100 1 3 4 ALPHA 207 1 MOTOR PLUG 43828 VEAM 06 32 1765 RAYCHEM RNE 100 1 5 8 THIS CABLE ASSEMBLY BE LABELED GCC M8B X X XX S4 or 5 AMPLIFIER SVART DRIVE AMPLIFIER K COPY CODE 155 DATE APP D Kollmorgen Industrial Drives e m DATE APP D RADFORD VIRGINIA APP D BY DATE DWN DATE EWR CHK BY DATE 0 20 02 8 78 07 00 20 96 THIS DRAWING CONTAINS THE INFORMATION NECESSARY TO FABRICATE MOTOR CABLES 10 BE USED WITH BDS4 5 3 6 10 8 20 OR S D 3 10 amp 20 AMP UNITS WHEN USED ON THE FOLLOWING MOTORS IF THEY HAVE CTORS FOR 10X amp 20X EXC 206D MOTORS SEE SHEET 3 or 4 T U 2 8 40X EXC MOTORS SEE SHEET 5 6 0 MOTORS SEE SHEET 7 or 8 DASH CABLE LENGTH DASH CABLE LENGTH DASH CABLE LENGTH PART NUMBER DESCRIPTION METERS FEET METERS FEE NO METERS FEE 03 3 10 30 30 00 57 57 190 GOLDL INE
148. Response and Application Dependent Adjustments These adjustments add versatility to the BDS4 and allow it to be tailored to specific applications accessible at the front of the BDS4 Stability Adjustment Current Limit Adjustment 3 Design Tolerance Adjustments Factory set and sealed adjustments should never require customer adjustment internal adjustments Current Sensor Offset Adjustments Pots AZ and CZ Resolver Excitation Adjustment Pot OSCG FACTORY ONLY ADJUSTMENTS Pots R DTR R DG and R DZ 4 4 1 Set Up Adjustments At equipment start up make these adjustments CHAPTER 4 MAINTENANCE 4 4 1 1 Balance Adjustment Within Position Loop If a monitor or readout displays Following Error adjust Balance Pot for zero Following Error at zero speed Optional Monitor DIFF CMD HI with respect to DIFF CMD LO with a DC voltmeter Command zero speed from the Numerical Controller Adjust Balance Pot for zero volts on the meter 4 4 1 2 Balance Adjustment Automatic or Manually Operated Machines Monitor DIFF CMD HI with respect to DIFF CMD LO with a DC voltmeter With the input signal at Zero volts or with the input shorted to common adjust Balance Pot for zero speed 4 4 1 3 Command Scale Adjustment Within Position Loop If the following error is displayed by monitor or readout command a slow feed rate and adjust Command Scale Pot for the proper amount of Following Error at that speed
149. S Highlighted design features are e Modular construction maximizing serviceability e Two part plug connectors interfacing between the BDS4 PSR4 5 and other equipment e Routine adjustments accessible from the front of the BDS4 e High frequency 20 kHz motor current ripple for quality servo performance higher efficiency and less audible noise e Differential velocity or current command input e Voltage programmable current limit input e Aremovable compensation board containing all the components that make the BDS4 compatible with a particular motor Protection against thermal overload indicates any overtemperature conditions The BDS4 is protected against peak current overloads by a current foldback circuit Also it is protected 1 1 CHAPTER 1 SYSTEM DESCRIPTION from logic bus out of tolerance conditions and motor stator short circuit conditions both line to line and line to ground e Drive Up contact closes indicating the amplifier is ready for input command signal opens on fault conditions e Standard PSR4 5 Power Supply units contain a Soft Start function and a dynamic bus discharge function e The 12 and 20 amp 5 4 5 units have as standard 40 watts of internal shunt regulation There are optional versions available having no shunt regulator Other options have externally mounted power resistance allowing shunt regulation of up to 700 watts The shunt regulator is protected from excessive
150. S4 C2 OR BUSS C 3 AND AC CESSORIES DESCRIPTION ID MANUFACTURER PART NUMB ER 12 POS HOUSING MOLEX 3 CRIMP PIN MOLEX CRIMP TOOL MOLEX ACCESSOR IES DESCRIPTION MANUFACTURER PART NUMBER NAME POS HOUSING MOLEX CRIMP PIN MOLEX CRIMP TOOL MOLEX MOTOR CONNECTION CABLE 8054 C2 or 8055 C3 BDS4 TEM 5 TEM 4 ITEM 1 ITEM 2 ERMINAL A RED ERMINAL 7 NC ERMINAL B BLK ER AL SHIELD ERMINAL 8 ERMINAL RED 2 ERMINAL 3 E AL D BLK 2 ERMINAL 9 NC SHIELD ERMINAL 2 ERMINAL E RED 3 ERMINAL 10 ERMINAL F BLK 3 ERMINAL 4 N C SHIELD ERMINAL 5 ERMINAL RED 4 CUSTOMER ER AL P BLK 4 BRAKE VC SHIELD HOOK UP R RED 5 T TERM 12 ERMINAL S BLK 5 N C TERM 16 N C SHIELD 5 ERMINAL RED CUSTOMER NC U LK 6 THERMOSTAT HIELD CU AJ OOK UP SEE THIS SH EET 3 AND 4 FOR CONNECTOR DETAILS CABLE ASSEMBLY TO BE LA BELED GC RBT 4 5 XX CABLE LENGTH COPY COL DATE DATE APP RADFORD VIRGINIA Kollmorgen Industri
151. SING LABEL 2 POSITION HOUS ABEL 12 POSITION HOUS 6 FILLER PLUGS ONLY W CRIMP SEE SHEET 3 CRIMP Ni 7 CONTACTS W CRIMP 5 8 SHRINK TUBING TEFLON TUBING THY X SHEET 6 DETAILS FIBERGLASS SLEEVING 8 9 3 16 SHRINK TUBING o f sss 3 3 RESOLVER W TACH SEE SHEET 85 F R DETAILS 2 TENET Hg S 7 DINK TUBING CABLE 47 ber 12 5 8 SHRINK TUBING CABLE 4i 3 16 HEAT SHRINK 9 SEE SHEET 46 FOR DETAILS BING amp SLEEVING PARTS LIS yee FOR CONNECTORS amp RELATED PARTS Ste INDIVIDUAL SHEETS MANUFACTURER PART NUMBER NAME PART NUMBER ee dins MARKEL H457BA1000 RAYCHEM RNF 100 1 1 8 RAYCHEM TFL16 RNF 100 1 5 8 DESCRIPTION FBRGLASS SLEEVING 1 8 SHRINK TUB C 32 tt T EN CO 20 x CABLE LENGTH METERS FEET 31 171 DASH CABLE LENGT METERS FFE METERS FEET dE UC br C EE m
152. SPACING WITH BDS4 MBLY MUST BE USED ONLY FIERS 155 NO DATE APP D BY FDO Koll morgen Industrial Drives RADFORD VIRGINIA VP D BY JOB ND AA 7 Ulo 805 AN 2 Y 8055 8 0 PLOT SCALE UNLESS OTHERWISE ORC PLACES t 919 MAX DEC PLACES t 00 ANG Om t i NOT SCALE DWG USE OIMENSIONS ONLY ALL OIMENSIONS ARE INCHES UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED 60 owe REMOVE ALL BURRS AND sue C 84 I3 BREAK ALL SHARP COSES CURRENT LIMIT 12 o ZERO TEST 10K ut eio RES 20K 2 c pr TC3 1 5 2 3 3 COMMON 1 5 S COMMAND mg COMMON CI I SCALE COMMON 1 17 8 C33 AUX IN BALANCE 25 SPEED MONITOR 9 12 20K 7 OUTPUT FAULT ENABLE Ci gt 202 4 1 9 OVER TEMP f 20K L 5 RESET C1 30 gt gt O C 1 8 FOLD BACK SHIELD R24 20K SHIELD 1 5 SHIELD 6 ABSOLUTE SPEED 15 C34 50 2 E DEVE 15 C3260 12 REE TC2 1 omm C 1 20 COM C3 3
153. SPECIFIED THIRD ANGLE PROJECT ION 20 TYPICAL 88 106 20 Wii LN O O BDS4 BDS4 10 AMP 20 AMP 1 25mm MINIMUM FREE SPACE SHOULD BE MAINTAINED AROUND SYSTEM 2 LOCATE THE HIGHEST CURRENT BDS4 5 AMPLIFIER NEXT TO THE 5 POWER SUPPLY AND REMAINING BDS4 5 AMPLIFIERS IN DESCENDING ORDER COD IS Ss NO DATE APP D JIS C DATE APP D Kollmorgen Industrial Drives RADFORD VIRGINIA e c DIN BY DATE BY DATE APP D BY DATE TDG 11 06 92 UNLESS OTHERWISE SPECIFIED ANG DIM 1 DEGREE METRIC X DEC XX DEC PLACES PLACES 4 XX DEC bis J XXX DEC oO NOT SCALE DWG ALL DIMENSIONS ARE MILLIMETERS UNLESS OTHERWISE SPECIFIED USE DIMENS IONS ONLY 2 ISSUE THIRD ANGLE PROJECT ION M SEE NOTES ON SHEET 1 20 TYPICAL 38 58 140 COD CAD DWG ND APP D 15
154. T NUMBER FBRGLASS SLEEVING A 84 MARKEL 55BA1000 9 SHRINK TUB RAYC 10 3 8 SHRINK TUB RAYCHEY WF 100 1 3 8 11 TEFLON TUB TFLI6 5 8 SHRINK TU NF 100 1 57 8 1 GD tt tt TT 13 1 2 SHRINK T 100 1 1 2 CABLE LENGTH METERS FEET DASH CABLE LENGTH NO METERS FEET SHRINK 9 HEAT SHRINK 19 12 TEFLON TUBING SEE SHEET 43 FOR i DETA ILS 5 96 POSITION HOUS CRIM PI NG NS 3 NUMBER DES ION a Aa 10 YU 051 1 170 20 30 00 34 180 3 33 10 S 57 190 4 3 20 06 200 GOLDLIN GCA RXX V N M An CABLE METERS IN LENGTH R RT THERb AT RESOL T RESOL 21 45 THERM 4 48 6 RBT THERM 2054 AMPLIFIER COPY CODE DATE APP D Kollmorgen Industrial Drives RADFORD VIRGINIA GJ FIER ESO VER CAB DIN BY On S co Ro
155. TION OF ROTATION BY INTERCHANGING MOTOR LEADS AND OR RESOLVER LEADS If the motor is commanded to move and does not respond turn the command scale NOTE adjustment several turns CW 3 2 BDS4 If the servo system performed properly then read Chapter 4 Maintenance for adjustments and other information that may be helpful in adapting your system to your own applications BDS4 CHAPTER 4 MAINTENANCE CHAPTER 4 MAINTENANCE 4 1 INTRODUCTION The information in this chapter will enable you to maintain the systems components ensuring smooth efficient operation of the motor Adjustments to the system are broken in three 3 categories Set Up Response and Application Dependent and Design Tolerance These adjustments allow the user to tailor the BDS4 to their specific applications 4 2 PREVENTATIVE MAINTENANCE Preventative maintenance to this equipment must be performed by qualified personnel familiar with the construction operation and CAUTION hazards involved with the application Electronic components in this amplifier are static sensitive Use proper procedures when CAUTION handling component boards Preventative maintenance should be performed with the BDS4 system out of operation and disconnected from all sources of power 4 2 1 Transient Voltages All transient producing devices must be properly suppressed Solid state controls of the BDS4 may be affected by tran
156. TOR CO CESSORIES DESCRIPTION MANUFACTURER PART NUMBER MOTOR HOUSING MS3106E 22 14 BDS4 ACCESSORIES DESCRIPTION MANUFACTURER PART NUMBER 12 POS HOUSING CRIMP PIN CRIMP TOOL ACCESSORIES DESCRIPTION MANUFACTURER POS HOUSING CRIMP PIN CRIMP TOOL MOTOR CONNEC TEM 5 db 20 20 I AJ CO U2 2U C Ww ED A 1 RE RMINA B m m m T NOTE 1 RESOLVER END JACKET AND Fi MOTOR END CU K COPY DATE APP D c cn 1 2 227 cs 4 m gt TT RADFORD VIRGINIA DIN BY EWR 10 CHK BY DATE CUT OFF REMA JLD BACK OVER JACKET T OFF_REMAINING PAIR Kollmorgen Industrial Drives w APP D BY
157. TS CHAPTER 6 SPARE PARTS 6 1 INTRODUCTION 6 2 RECOMMENDED SPARE PARTS The information in this chapter will enable you to It is recommended by Industrial Drives that you have obtain spare parts for your Industrial Drives available for use in your BDS4 and PSR4 5 the parts equipment Use these tables to order any parts that listed in Tables 6 1 and 6 2 It is also very important have become defective or that are required for to note that there are no user serviceable parts on specific configurations Ordering instructions are either component other than those fuses and also provided connector kits listed Table 6 1 BDS4 Spare Parts List QUANTITY DESCRIPTION PART NUMBER PER UNIT Connector Kit BDS4C 100 3 6 and 10 amp models BDS4C 101 20 amp model 0 4 200 30 40 and 55 amp models 6 1 CHAPTER 6 SPARE PARTS BDS4 Table 6 2 PSR4 5 Spare Parts List PSR4 5 QUANTITY DESCRIPTION MODEL PART NO PER UNIT CONNECTOR KIT ALL PSR4 5C 100 1 12 AND 20A CONNECTOR KIT ALL PSR4 5C 200 1 50 AND 75 2 CONTROL VOLTS ALL A 78896 008 1 5 AMP FUSES 12 AND 20A FUSE 99 102 A 78896 012 4 AMP FUSE 126 CONTROL VOLTS ALL 50 AND A 78896 012 4 AMP USES 75 FUSE 64 65 A 78896 016 8 AMP FUSE 24 SOFT START 115 VAC 80552 007 5 AMP 1 FUSE 12 AND 20 AMP FUSE 121 SOFT START ALL 230 A 80552 001 10 AMP 1 FUSE 12 and 20 AMP FUSE 121 SOFT START ALL 50 AND 75 AMP A 78896 017 10 AMP 1 FUSE IN LINE REG
158. W 2 LOCKWASHER 2 V4 FLATWOSHER 5 2 STANDOFF SPRUCE PINE 2109 15 GT 2 1000 W CONTINUOUS 4 4 OHM RESISTOR SET TRIP CURRENT GTY 1 1 750 DIA TO 45 AMPS CONNECT RESISTOR To TERM BLOCK LOCATED gt QS A 5 me SEE NOTE 1 DO NOT INSTALL RESISTOR NEAR 7 32 DIA FLAMMABLE 1 1 NOTES 5 HAZARD 8 RESISTOR CONNECTED HIGH VOLTAGE SEE RECOMMENDED WIRE SANG 125 C 2 BOTTOM STANDOFFS ARE THREADED VA 2O 3 8 DP FOR MOUNTING RESISTORS TO PANELS ETC 3 OUTPUT CONTACTS 2 NIRED TO DROP MAIN LINES WHEN CONTACTS OPEN ON OVERLOAD UNLESS OTHERWISE SPECIFIED IHE BR MOUNTING DIAG C MDDNT HALES ANG DIM 1 PLACES 018 DWG 35 95514 DO NOT SCALE DWOG USE DIMENSIONS ONLY ALL DIMENSIONS ARE INCHES UNLESS OTHERWISE SPECIFIED 4 20 x Ve HD SCREW QTY 2 V4 LOCKWASHER QTY 2 V4 FLATWASHER QTY 2 V4 2O x Va THREADED STUD QTY 4 STAND OFF SPRUCE PINE 2165 1 QTY 0 4 5 OHM RESISTOR QTY 2 T UE 5 00 I MAX l TT p 6 250 N CONNECT RESISTOR TO TERM BLOCK LOCATED AT 65 lt 2 5 SEE NOTE 1 CANUTION N DO NOT INSTALL RESISTOR NEA
159. WG NO 5 0 VA 1 09 91 0 0 6 01 91 C J F 6 01 91 EAST ANALOG INPUT DIFFERENTIAL VELOCITY OR CURRENT pipe LO COMMAND INPUT SCALED FOR 10 VOLTS E FULL SCALE DERI HI 0 SEE CIRCUIT TO THE RIGHT ANALOG DIFF LO i INPUT 01UF 2 16 2k DIFF HI ADDITIONAL SINGLE ENDED INPUT TO THE US VELOCITY LOOP ESISTOR jm X ra AN EXTERNA USED TO PROG OF THE 1 75 OF 8 6K ohm OF PEAK WITH 3 5K ohm OR A POSITIVE VOLTAGE FROM O VDC 7 5 VDC MAY BE USED TO ADJUST THE PEAK MO 15 5 CURRENT FROM 7 5 TO 1007 OF ITS RATING COMMON SHIELD mme 5 COMMON 6 SHIELD A FOLDBACK gt T 29 SHIELD O QUE HOLD OUTPUT FAULT 2 OPEN COLLECTOR MAXIMUM COMMON MAX I MUM MONITOR 15 COMMON REFERENC SIGNAL SCALED FOR FULL CURR 8 MON ES VOLTS THIS S 1 7 1 MONITOR 18 8 OVERTEVP gt GNAL HAS E RESISTOR IN L C AND 25 TACH MONITOR 1S A COMM
160. WR 10 01 92 PLUG BODY CABLE CLAMP BACKSHELL DETA IL AWA DWG 0 MEE CONNECTOR ASSEMBI Y PROCEDUR S U N LW U 5 ID X U S WIA USE STRIPPING PLIERS TO STRIP FROM EACH WIRE BOTH ENDS STEP 2 INSERT WIRES INTO THE CRIMP CONTAC 215 AND STEP NSULAT ION WHEN CRIMP REDUCTION SLEEVES ARE US TO BE INSERTED IN VE FIRST INSERT THE CRIMP CONTACTS INTO THE PLUG BODY OF GUIDE PINS CONNECT AS SHOWN ON FOLLOWING THE AND SCRE STEP 3 SLIDE TO PLUG HOLD PLUG BODY SEC C TIGHTEN CABLE CL D PLACE LABEL IN FOLLOWING SHEETS THE BACKSHELL ALONG UREL Y OCATION AS SHOWN ON 4 57MM BODY BACKSHELL ONTO PLUG BODY WIRES ARE WITH USE SHEETS NOT 21 FOR CABLE 08 CABLE 08 CABLE FOR CABLE ASSEMBLY BB X X XX PRESS B 9 SEE SEE SHEET SHEET SHEET SHEET COPY CODE 155 APP D DATE APP D 2 98 FDO Kollmorgen Industrial Drives RADFORD VIRGINIA ee DRAWN BY DATE CHK BY DATE BY DATE EWR 10 01 92 SCALE AS N N EM P A
161. Without Soft Start and Regeneration 12 and 20 Amp Models Only Without Regeneration 12 and 20 Amp Models Only With 240 V logic supply unit withou regen with soft start XXYY Omit when there are no options B 1 APPENDIX MODEL NUMBERS BDS4 Table B 2 ER External Resistor Kit Model Number Scheme EXAMPLE ER 01 XX LEGEND A B C LEGEND DEFINITION LM External Resistor Kit for PSR4 5 Resistor Rating 8 8 ohms 400W 5 5 ohms 200W 5 8 ohms 700W 4 5 ohms 500W 50 or 75 amp 230V models only 4 4 ohms 1000W 50 or 75 amp 230V models only 2 2 ohms 1000W 75 amp 230V models only 2 2 ohms 2000W 75 amp 230V models only Options None Available at this Printing 12 or 20 amp 230V models only 12 or 20 amp 115V models only 12 or 20 amp 230V models only B 2 BDS4 APPENDIX B MODEL NUMBERS Table B 3 BDS4 Model Number Scheme EXAMPLE BDS 4A 2 03 H XC YY 20A Z LEGEND LEGEND DEFINITION Brushless Drive Sinewave Servo Amplifier Amplifier generation indicator Original Standard Configuration no letter designation Industrial Standard Configuration U L 508 listed configuration Maximum Output Voltage 115VAC Nominal 230VAC Nominal 03 06 10 20 30 40 55 Output RMS Current Per Phase Continuous R D Converter Standard Accuracy 22 Arc Min Maximum Special Accuracy 8 Arc Min Maximum Required for 01 02 03 El
162. XIMA JNN FOR CORRECT LAB i 1 25 HEAT S NG AS PICTURED ON SHEET 1 CTION CHART SHOWN ON 13 0 HE SAME A INTO THE SOLDER CUPS AND SOLDER SHRINK TUBING APPLY HE AND FIBER AT TO PLUG BODY SHELL ONTO PLUG BODY PICTURED ON SHEET AS USED SEE SHEET 9 OR 10 SEE SHEET SEE SHEET 5 12 14 c NO DATE APP D Kollmorgen Industrial Drives RADFORD VIRGINIA GOLDL INE GUIDE DWN BY EWR CHK BY DATE BY DATE SCALE ND Lii 91 HEAT SHRINK 2 1 TUBING 12 OR 20 2 POSITION CONNECTOR OUTER JACKET 2118 2 HEAT SHRINK 2 TUBING L JL J Et 22 BRAKE 8 THERMOSTAT DETAIL B B DETAIL C C CUT ONE FOOT LONGER THAN TOTAL CABLE LENGTH IN 27 A x Z ENN gt
163. ain DC Bus Voltage output at with respect to on the PSR4 5 terminal block according to Section 2 1 Check and record the unregulated DC voltage levels at Connector C3 of the PSR4 5 They should be 17 to 26 5 and 9 to 14 5 VDC per Section 2 7 5 Remove power Note the model number of the PSR4 5 and refer to Section 2 1 to confirm DC voltage levels If the voltage levels are within the specifications listed in Appendix D proceed CHAPTER 2 INSTALLATION WAIT FOR THE BUS TO BLEED DOWN and reconnect the B and B leads to the power terminal block of the PSR4 5 Be careful to reconnect the leads with the proper polarity Re install Connector C2 on the PSR4 5 1 Failure to observe correct polarity will result in damage to the PSR4 5 and BDS4 CAUTION 2 13 31354 CHAPTER 3 OPERATION CHAPTER 3 OPERATION 3 1 INTRODUCTION The information in this chapter will enable you to become familiar with system components and their dependence upon one another Also it will help you ensure each component is configured and functions properly At this point all safety stops and other precautions should be in place and working properly Be prepared to stop the machine if necessary 3 2 INITIAL START UP You should now be ready to supply power to test the servo systems functions and features Work with only one axis section at a time Confirm all other BDS4 amplifiers are inhibited meaning the enable cir
164. al Drives GOLDLIN GUIDE DWN BY EWR 05 18 02 05 18 92 CHK BY DATE APP D BY DATE SCALE DWG NO UNLESS OTHERWISE SPECIFIED ANC DIM 1 DECREE METRIC PLACES PLACES DEC XX DEC DO NOT ALL DIMENS SCALE DWG USE DIMENSIONS ONLY 15 ARE MILLIMETERS WITH INCHES UNLESS OTHERWISE SPECIFIED ISSUE NOT R esl RE 3 TH RE RMINAL BLOCK SISTOR MO GEN ONLY GEN ONLY DELS NO INTER PROV IDED ONLY ON EXTERNAL REGEN RESISTOR ESE VALUES FOR INTERNAL ESE VALUES FOR EXTERNAL AL REGEN RESISTOR PROVIDED ON EXTERNAL FAULT TABLE T DS LOGIG SUPPLY TRANSFORMER MIN A EGEN CARD DE BUS REGEN FUSE REGEN 7 SEE TABLE OVERLOAD INTERNAL J BUS SEE REGEN RESISTOR 2 SEE TABLE mulo EXTERNAL REGEN RESISTOR SEE TABLE 5155 E C1 5 i 5 nm 115VAU 2 2 INPUT 2 M um Ae m N Ts C1 6 o e S
165. ator connector at the motor The motor thermostat switch is an automatic resetting device and should be connected directly into CAUTION latched locked out power down type circuit Incorrect motor resolver phasing can cause erratic operation runaway or WARNING damage to the system Terminate Pins A B C D E and F of the resolver connector at Connector C2 on the BDS4 as shown by Figures 2 5 and 2 6 Also see the BDS4 Wiring Diagram A 93231 and the appropriate motor HD hook up drawing or Motor Connection Diagram A 63542 Use cables with three 3 independently SIN HI SIN LO SIN SHIELD COS SHIELD COD HI COS LO REF LO REF HI SPARE SHIELD REF SHIELD N C N C Figure 2 5 BDS4 C2 2 10 BDS4 shielded pairs for the resolver The leads of the three phase synchronous motor are brought out to Pins A B and C of the motor connector Pin D is ground for the motor Refer to Figure 2 7 for pin connections Terminate Pins A B and C of the motor connector to Ma Mb and Mc respectively on the power terminal block located on the front of the BDS4 amplifier Terminate Pin D at the BDS4 chassis ground screw Refer to Wiring Diagram A 93231 and the appropriate motor HD hook up drawing The optional integrally mounted tachometer is brought out to Pins R and S on the resolver connector for both the B and BR series motors Pin R Tach Hi should be terminated at Connector 1 Pin 12 Aux In
166. ch may be ordered either from Industrial Drives or purchased directly from the connector vendor Ordering information is as follows Table C 1 Connector Kit BDS4C 100 INDUSTRIAL DRIVES CONNECTOR KIT PART NUMBER BDS4C 100 BDS4 3 6 and 10 AMP MODELS CONNECTOR DESCRIPTION MOLEX PART NO PART NO Connector Housing 20 39 01 5 83908 020 Position Female Connector Housing 39 01 2085 A 83908 008 8 Position Female i 2 Housing 12 39 01 2125 83908 012 Position Female C1 C2 PIN Female 39 00 0039 A 83909 002 18 24 AWG 1 APPENDIX KITS amp TooLs BDS4 Table C 2 Connector Kit BDS4C 101 INDUSTRIAL DRIVES CONNECTOR KIT PART NUMBER BDS4C 101 8054 20 AMP MODELS CONNECTOR DESCRIPTION MOLEX PART NO PART NO Connector Housing 39 01 2205 A 83908 020 20 Position Female 2 Housing 39 01 2125 83908 012 12 Position Female C3 Connector Housing 39 01 2085 A 83908 008 8 Position Female C4 Connector Housing 39 01 2045 A 83908 004 4 Position Male C1 C2 C3 C4 PIN Female 39 00 0039 A 83909 002 18 24 AWG Table C 3 Connector Kit BDS4C 200 INDUSTRIAL DRIVES CONNECTOR KIT PART NUMBER BDS4C 200 8054 30 40 and 55 AMP MODELS CONNECTOR DESCRIPTION MOLEX PART NO PART NO Connector Housing 39 01 2205 A 83908 020 20 Position Female Connector Housing 39 01 2125 A 83908 012
167. cuits are open high Incorrect servo to position loop phasing can cause excursion oscillations or CAUTION runaways Appropriate precautions should be taken to stop the machine if necessary Limit switches and safety devices should be in place Unloaded motors compensated for a large mismatch may become unstable when the system is activated Refer to the test limits TL sheet for CAUTION stable load inertia range If the system becomes unstable remove the power immediately 3 3 SEQUENCE OF OPERATIONS This section contains a basic start up sequence that should be followed the first time the servo system is initialized READ THIS ENTIRE SECTION BEFORE PERFORMING ANY OF THESE PROCEDURES When you apply power to the system pay special attention to the LEDs on the BDS4 front panel The CONTROL VOLTS and DRIVE READY green LEDs should be illuminated This indicates that the system is functioning properly Should a FAULT red LED remain on for more than a instant immediately disconnect power and consult Chapter 5 Troubleshooting 1 Apply power Enable only one 31354 Observe the action of the machine If the direction of the motor shaft rotation is reversed 3 1 CHAPTER 3 motor shaft turns in the wrong direction remove power Reverse the input to the BDS4 at DIFF CMD Hl and DIFF CMD LO at Connector C1 Pins 1 and 11 DO NOT ATTEMPT TO REVERSE DIREC
168. d 4 2 3 Electrical Noise The low levels of energy the BDS4 control circuits may cause them to be vulnerable to electrical noise Sources of electrical noise are those pieces of equipment that have large fast changing voltages and currents when they switch on and off These devices have the capability of inducing critical current and voltage transients on their respective power lines These transients must be accommodated for with noise immunity provisions Electrical noise is prevented with the same methods as Surge Current and Transient Voltages However there are other methods of preventing electrical noise Such as Maintain physical separation between electrical noise sources and the BDS4 amplifier Maintain physical separation between electrical noise sources and the BDS4 control wiring This can be accomplished by using separate conduits or wiring trays for control wiring and power wiring 4 2 BDS4 Use twisted pair wiring for control circuits the BDS4 Follow good grounding practices when wiring the PSR4 5 and BDS4 Be careful not to create a grounding loop with multiple ground paths Follow the NEC s provisions on grounding 4 2 4 Radio Frequency Energy This equipment generates radio frequency energy NOTE This equipment uses and can radiate radio frequency energy and must be installed and used in accordance with this installation and service manual in order to prevent possible interfe
169. d per TL Test Limits Sheet to make the BDS4 compatible with the motor Before beginning the troubleshooting process consider the following points L There are four 4 distinct areas within which a fault may occur 5 1 CHAPTER 5 TROUBLESHOOTING A External Interface Circuitry external to but connecting to the BDS4 B BDS4 Amplifier Module C PSR4 5 Power Supply Module 1 Main DC bus voltage 2 Control DC bus voltages 3 Shunt Regulator Regeneration Circuitry 4 Soft Start Dynamic Bus Discharge Circuitry D Motor 1 Resolver 2 Tachometer Optional H There are only two 2 basic fault characteristics to be considered A The motor exhibits very low torque or is totally inoperative B The motor is erratic or exhibits an improper mode of operation 5 3 SYMPTOMS AND CORRECTIONS If the motor does not respond or responds in a manner other than with smooth operation remove power and troubleshoot the system with the following guidelines Also refer to Table 5 1 for more improper motor operation symptoms 5 3 1 The Motor Exhibits Very Low Torque or is Totally Inoperative Prerequisites for motor movement 1 The BDS4 and PSR4 5 must be wired correctly per BDS4 Wiring Diagram 93231 2 power must be present 5 2 BDS4 3 The BDS4 must be in the Enable mode as indicated by the green CONTROL VOLTS ENABLE and DRIVE READY LED s 4 A command signal other than zero volts must be
170. dback units required for a motor s shaft to rotate one complete revolution Resolver A position transducer utilizing magnetic coupling to measure absolute shaft position over one revolution RMS Current Root mean square current In an intermittent duty cycle application the RMS current is equal to the value of steady state current which would produce the equivalent resistive heating over a long period of time Rotor The rotating part of a magnetic structure In a motor the rotor is connected to the motor shaft Servo Amplifier Servo Drive An electronic device which produces the winding current for a servo motor The amplifier converts a low level control signal into high voltage and current levels top produce torque in the motor Servo System An automatic feedback control system for mechanical motion in which the controlled or output quantity is position velocity or acceleration Servo systems are closed loop systems Shunt Resistor A device located in a servo amplifier for controlling regenerative energy generated when braking a motor This device dissipates of dumps the kinetic energy as heat Single Point Ground The common connection point for signal grounds in a control wiring environment Slew In motion control the portion of a move made at a constant non zero velocity Speed Regulation For a speed control system speed regulation is the variation in actual speed expressed as a percentage of
171. e 5 1 BDS4 Status LED s Approximately second after all power 15 applied the green CONTROL VOLTS LED on the front of the BDS4 module should become illuminated to indicate that the Control AC line input voltage is applied When the Enable input circuit the BDS4 15 closed the green ENABLE LED should become illuminated indicating that the BDS4 is now in the enabled mode No fault red LED s should be illuminated The green DRIVE READY LED may or may not be illuminated depending on whether or jumper 721 15 installed on the BDS4 COMP Board The red FOLDBACK LED will become illuminated during any situation where the RMS current exceeds the continuous rating of the BDS4 peak current is allowed for only 2 0 seconds The LED indicates that the peak current of the BDS4 is automatically being reduced to the RMS continuous rating Once the current demand is reduced the FOLDBACK CHAPTER 5 TROUBLESHOOTING circuit will reset and the LED will turn off This LED acts only as an indicator If the red OVERTEMP LED becomes illuminated the BDS4 will become latched in the Inhibit mode indicating an overheated BDS4 heatsink When the red OVERCURRENT LED becomes illuminated it indicates an overcurrent condition usually due to a shorted load motor wiring or BDS4 power stage transistor The BDS4 will become latched in the Inhibit mode If the red OVERVOLTS LED becomes illuminated the BDS4 will become la
172. e resolver should not be disturbed Loosen but do not remove the two servo clamp screws holding the resolver stator secure DO NOT MOVE THE POSITION OF THE MOTOR SHAFT Apply power If necessary repeat Step 3 above Enable the BDS4 Slowly rotate the resolver stator outside element while a colleague watches the FOLDBACK LED on the front of the BDS4 amplifier If the LED does not become fully illuminated turn the resolver stator in the opposite direction Continue to rotate the resolver stator until the LED becomes fully illuminated If the correct alignment position is passed the LED will blink more slowly When the LED becomes fully illuminated discontinue turning the resolver stator and tighten the two servo clamp screws Inhibit the BDS4 Remove power Repeat Steps 3 and 4 above Inhibit the BDS4 Remove power Remove the jumper from the test points Replace the motor end cover 4 4 3 4 Factory Only Adjustments Do not adjust Pots R DTR R DG and Pot R DZ These pots are set and sealed at the Factory and cannot be adjusted in the field If these pot seals are ever broken WARNING return the complete BDS4 amplifier to the Factory for alignment 4 5 31354 CHAPTER 5 TROUBLESHOOTING 5 1 INTRODUCTION The information in this chapter will enable you to isolate and resolve common system hardware problems The troubleshooting methods in this manual isolate each component from the system u
173. ecognized 2 3 1 8054 vs BDS4V vs BDS4A amp PSR4 5 vs PSR4 5A The BDS4 BDS4V and the BDS4A differ in according to the following BDS4 Original Standard Configuration BDS4V Industrial Standard Configuration BDS4A U L 508 Approved Configuration The BDS4 is the original amplifier developed by Industrial Drives It was followed by a value analysis version the BDS4V The BDS4A was later developed and submitted to UL for approval In a similar manner the PSR4 5 and PSR4 5A follow this scheme PSR4 5 Original Standard Configuration PSR4 5A UL 508 Approved Configuration This indicates that the BDS4A and PSR4 5A meet all the safety standards set by the Underwriter Laboratories Where differences occur between models special instructions will be indicated in this manual For the purpose of referencing all amplifiers and power supplies the nomenclatures BDS4 and PSR4 5 will be used Check your model number to verify your model 2 3 2 Model Numbering Scheme All Industrial Drives components contain a model and serial number printed on a black and gold tag on the front panel The model number identifies how the equipment is configured Refer to Appendix C for the model number scheme tables These tables explain what the model configurations are You should verify that the model numbers represent the equipment desired for your application Also verify the compatibily between components of the servo system 2 2 BDS4 2 3
174. ectrical Options or Motors with Nmax gt Mechanical Options Standard Unit No Options Side Cover Option Custom Custom Custom Custom Custom Custom Side Cover Option w Cover No Conn Kit Electrical Options Standard Unit No Options Electronic Encoder Output Requires Type J R D Converter Electronic Encoder with Parallel Output Requires Type J R D Converter Electronic Encoder with Parallel Output and Drive Signals Requires Type J R D Converter Custom Custom Same as 01 Except Configured for LSB on Channel B Refer to Section E 2 2 1 14 Bit R D with 3500 RPM Tracking Rate Requires Type J R D Comp Card Without Components Custom Custom Custom Custom Same as 01 Plus 08 Direction Limit Option Board 14 Bit with 2000 RPM Tracking Rate Requires Type R D Converter B 3 APPENDIX MODEL NUMBERS BDS4 Table B 3 BDS4 Model Number Scheme Continued LEGEND DEFINITION 14 Bit R D with 3500 RPM J Grade W Direction Limit Option Custom 16 Bit R D 600 RPM J Grade R D Custom Custom Custom Custom Custom Custom Custom Custom Custom 12 Bit R D 14k RPM J Grade with encoder equivalent option Motor and Winding Designator Compensation Designator 0 5 X Jm 5 20 X Jm XXYY Omit when there are no options Table B 4 Compensation Card Model Designator EXAMPLE CMP BDS4 203H 204A2 LEGEND A B LEGEND DEFINIT
175. ed a soft start circuit charges the Main DC bus capacitors in the PSR4 5 through a current limiting resistor b The shunt regulator regeneration circuitry is switched from dynamic bus discharge to regular mode c The undervoltage fault in the BDS4 is now cleared after approximately 3 4 sec delay and if jumper J21 is installed on the BDS4 COMP Board the Drive Ready LED will become illuminated and the Drive Up contact in the BDS4 between Pins 10 and 20 of Connector C1 will close The BDS4 is ready to be enabled and will enable once the enable input is activated Only the Main AC line input voltage is removed a Approximately 30 msec after the Main AC line input voltage is removed the shunt regulator is switched from regulate to the dynamic bus discharge mode and the main DC bus power is discharged b The shunt regulator circuit is deactivated 1 5 CHAPTER 1 SYSTEM DESCRIPTION Drive Up contact within BDS4 will open due to Bus undervolts 4 Only the Control line input voltage is removed The Drive Up contact in the BDS4 will open BDS4 is immediately disabled Operation of the soft start dynamic bus discharge and other circuits within the PSR4 5 will not be affected The PSR4 5 fault contact will open 1 4 6 Without Soft Start Circuit or Dynamic Bus Discharge Optional 1 6 1 Only the Control AC line input voltage is applied a log
176. es m Pad sd C 24 IT CPM SCM RADFORD VIRGINIA P DUTLIN ler SEE NOTE 1 m JU Mm rm gt 18VDC e 1 5 AMPS gt 18 00 8 1 5 AMPS LOGIC POWER SUPPLY COMMON 04 4 0 gt gt 1006 e 6 AMPS AND bl N A 4 SS FAULT FAULT SEE NOT SCR GATING CIRCL CONTROL TRY M X THERMOSTAT ISSUE gt EXTERNAL REGEN RESISTOR DC 8 5 325 06 NOMINAL J US NTROL AC LINE NOTES MOV TRANS SUPPRESSION LENT WITHOUT SOFT START POWER DIODE SCR BRIDGE SEE NOT DC BUS D 38 0 38 5 CODE ECN ND DATE APP D DATE APP D INDUSTRIAL DRIVES RADFORD V RGINIA DIVISION PRS4 5 A WITH amp WITHOUT SOFT START SIMPLIFIED SCHEMATIC BY FDO APP D BY DHE i MP
177. f a position control loop with proportional gain only Friction A resistance to motion caused by surfaces rubbing together Friction can be constant with varying speed coulomb friction or proportional to speed viscous friction or present at rest static friction Full Load Current The armature current of a motor operated at its full load torque and speed with rated voltage applied Full Load Speed The speed of a motor operated with rated voltage and full load torque Gain The ratio of system output signal to system input signal The control loop parameter that determines system performance characteristics GLOSSARY BDS4 HP Horsepower One horsepower is equal to 746 watts Since Power Torque x Speed horsepower is a measure of motor s torque and speed capability e g 1 motor will produce 35 Ib in at 1800 rpm Input Output The reception and transmission of information between control devices In modern control systems has two distinct forms switches relays etc which are in either an on or off state or analog signals that are continuous in nature such as speed temperature flow etc Inertia The property of an object to resist changes in velocity unless acted upon by an outside force Higher inertia objects require larger torques to accelerate and decelerate Inertia is dependent upon the mass and shape of the object Inertial Match An inertial match between motor
178. g and decelerating the motor at approximately 25 of maximum speed adjust the STABILITY Pot CW and notice the tach and current wave forms at the SPEED MONITOR and MONITOR test points Watch for indications of instability 1 ringing in the wave forms while accelerating and decelerating the motor Turn the STABILITY Pot CCW until the tendency to go unstable disappears 4 4 2 2 Current Limit Adjustment The maximum peak current limits are set at the factory and can not be increased above the level listed on the Test Limits sheet TL Although the peak current limits cannot be increased above the specified value they may be decreased To reduce the peak current limit level apply a step input command signal Use an oscilloscope to monitor the I MONITOR test point refer to Figures and 3 Accelerate and decelerate the motor Adjust the CURRENT LIMIT Pot for desired peak current limit The current scale factor at the I MONITOR test point is 8V Peak RMS rating of the BDS4 refer to Section 2 2 for Peak Rating and Section 4 1 for more information on this signal 4 4 BDS4 4 4 3 Design Tolerance Adjustments Factory Set and Sealed These adjustments should not be made in the field They have been factory set and sealed and should never NOTE require adjustment The following procedures are to be followed only if the seals are broken 4 4 3 1 Resolver Excitation Adjustment Inhibit the BDS4 by opening the Enab
179. gen Information in this document is subject to change without notice and does not represent a commitment on the part of Danaher Motion Kollmorgen Therefore information contained in this manual may be updated without notice due to product improvements etc and may not conform in every respect to former issues This product is covered by U S Patents 4 447 771 4 479 078 4 490 661 Other foreign patents pending U L is a trademark of Underwriter s Laboratories N E C is a trademark of the National Electric Code Kollmorgen GOLDLine BDS4 BDS5 and PSR4 5 are trademarks of Danaher Motion Kollmorgen Dangerous voltages currents temperatures and energy levels exist in this product and in the associated servomotor s Extreme caution should be exercised in the application of this equipment Only qualified individuals should attempt to install setup and operate this equipment Ensure that the motor drive and the end user assembly are all properly grounded per NEC requirements Danaher Motion Kollmorgen KOLLMORGEN Phone 1 800 777 3786 or 815 226 3100 Motion Technologies Group Technical Support Fax 540 731 5679 BDS4 FOREWORD The commitment to quality at Industrial Drives is our first priority In all aspects of our business research development product design and customer service we strive to guarantee total quality This pledge is founded on a solid history of innovative
180. gulator power resistor s are mounted above the PRS4 5A unit 2 3 CHAPTER 2 INSTALLATION 2 6 2 Mounting the External Regeneration Resistor s External regenerative resistors are a shock hazard Mount these resistors properly Enclose these WARNING resistors to protect personnel and equipment L n External regeneration resistors can become extremely hot Allow safe clearance around CAUTION the resistor s enclosures Proper ventilation must be provided Some models of PSR4 5 use an externally mounted regen shunt regulator resistor The resistor kit includes mounting hardware and depending on the model a thermal overload relay to be wired in with the resistors A suitable enclosed location outside the equipment cabinet needs to be set aside for mounting these components while observing the heat and shock requirements of these resistors 2 7 ELECTRICAL CONNECTIONS Dangerous voltages currents temperatures and energy levels exist in this product and in the associated servo motor s Extreme caution should be exercised in the application of this equipment Only WARNING qualified individuals should attempt to install set up and operate this equipment Ensure that he motor drive and the end user assembly are properly grounded per NEC requirements n Hd 2 4 BDS4 To facilitate wiring the BDS4 amplifiers must be mounted next to the 5 4 5 power supply
181. h to Motor 3 to 75 Meters 3 Meter Increments B 8 BDS4 APPENDIX B MODEL NUMBERS B 4 SPECIAL CABLES FOR RESOLVER FEEDBACK AND INTERFACE The GC specials are designed to eliminate the need for the customer to make crimp connections for BDS4 input output connector C1 and BDS4 resolver connector C2 These cables are terminated at C1 and C2 on the BDS4 and are unterminated at the opposite end The unterminated end is intended to be connected into a customer supplied terminal block To assist in ordering the model number schemes for these special cables are as follows Table B 9 Resolver Feedback Cables GC RF 4 5 XX Resolver feedback flying lead cable not terminated at the motor XX length in 3 meter increments 03 09 etc GC IOF 4 XX flying lead cable not terminated at customer s interface XX length in meter increments 03 09 etc B 5 SPECIAL CABLES FOR LOGIC POWER SUPPLY Special logic power supply cables are available to accommodate the various physical sizes of BDS4 and PSR4 5 modules and are designed based on standard module spacing requirements Refer to drawing B 84929 for information concerning decoding the model numbers of special logic bus cables To assist in ordering the model number scheme for this cable is GC LOGIC XXXXXXX B 9 BDS4 APPENDIX C CONNECTOR Kirs amp TOOLS APPEND x C CONNECTOR KITS amp TOOLS C 1 INTRODUCTION Mating connectors are customer furnished items whi
182. his manual What did you like most about this manual How would you improve this manual Signature Date European Community Declaration Conformity We Kollmorgen Corporation Industrial Drives Division 201 Rock Road Radford Virginia USA declare under sole responsibility that this equipment is exclusively designed for incorporation in another machine The operation of this equipment is submitted to the conformity of the machine in which it is incorporated following the provisions of the EC Electro Magnetic Compatibility EMC directive 89 392 EEC Copyright 1993 Danaher Motion Kollmorgen rights reserved Printed in the United States of America NOTICE Not for use or disclosure outside of Danaher Motion Kollmorgen except under written agreement All rights reserved No part of this book shall be reproduced stored in a retrieval system or transmitted by any means electronic mechanical photocopying recording or otherwise without the written permission from the publisher While every precaution has been taken in the preparation of this book the publisher assumes no responsibility for errors or omissions Neither is any liability assumed for damager resulting from the use of the information contained herein This document is proprietary information of Danaher Motion Kollmorgen furnished for customer use ONLY No other uses are authorized without written permission from Danaher Motion Kollmor
183. ic bus comes up b Apower up reset pulse is generated in the BDS4 c If no faults other than main bus undervolts are present after the power up reset pulse is generated a delay of one second then the drive is ready to be enabled However there can be no motor movement until the main AC line input voltage is applied The Main AC line input voltage is applied a The soft start circuit charges the Main DC bus capacitors in the PSR4 5 through a current limiting resistor BDS4 b The shunt regulator regeneration circuitry is switched from dynamic bus discharge to regular mode The undervoltage fault in the BDS4 is now cleared after approximately 3 4 sec delay and if jumper J21 is installed on the BDS4 COMP Board the Drive Ready LED will become illuminated and the Drive Up contact in the BDS4 between Pins 10 and 20 of Connector C1 will close The BDS4 is ready to be enabled and will enable once the enable input is activated Only the Main AC line input voltage is removed The DC bus will bleed down slowly after approximately five minutes The shunt regulator is deactivated The Drive Up contact within the BDS4 will open 4 Only the Control AC line input voltage is removed The BDS4 will be immediately disabled The BDS4 Drive Up contact will open The PSR4 5 fault contact will open 1 5 TYPICAL SYSTEM DIAGRAM Figure 1 2 illustrates a typical system with all of the major components L
184. industry in servo application innovations Our commitment to engineering excellence never waivered In fact that commitment grew stronger with the development of brushless submarine and submersible motors visiting the Titanic graveyard multi axis electronic drives and antenna pedestal drives delivering unprecedented accuracy and revolutionizing the entire industrial automation process The decade of the 1980 s brought continued advancements in technology and penetration of new markets requiring precise motion control Already in the fifth generation of brushless products Industrial Drives continues to lead the way with digital servo positioning capability and our newest motor offering the GOLDLINE Series incorporating the very latest high energy rare earth magnets neodymium iron boron Once again we are setting the standards that others only hope to duplicate Recently acknowledged by the Frost and Sullivan Foundation a leading market specialist in the motion control industry Industrial Drives and its parent Kollmorgen Corporation continue to rank first in servo technology Other achievements Yes too many in fact to mention Each achievement stands as a testimony to the committed quality and excellence in design technology This constancy of purpose is unyielding in an era of rapidly changing technology BDS4 TABLE OF CONTENTS CHAPTER 1 SYSTEM DESCRIPTION 1 1 Introduction
185. ing the velocity error the microprocessor generates three sinusoidal current commands These current commands are forwarded to the three proportional plus integral current loops one for each of the three motor phases The microprocessor is the key element in the Industrial Drives patented torque angle technique The microprocessor varies the phase of the currents with respect to motor BDS4 flux and significantly improves the motor speed vs torque profile 4 outputs from the three current loop circuits are converted into 10 KHz pulse width modulation scheme The modulation is such that the 10 KHz PWM results in 20 kHz current ripple in the motor resulting in very quiet motor operation The PWM switching signals are optically coupled to the power stage gate drive hardware for complete electrical isolation The BDS4 uses IGBT s Isolated Gate Bipolar Transistors for the output power stage allowing high frequency operation 1 4 3 Brushless DC Motor The Industrial Drives B Series brushless motors feature the latest in permanent magnet technology utilizing high energy Neodymium Iron Boron alloys These brushless motors consist of permanent magnet rotors and three phase Y stator windings This places the heat producing member on the outside where it can best dissipate heat These motors depending on size are either four or six pole motors Since they are brushless motors there are no commutators or associated br
186. ints torques are measured with the wire or terminal lug underneath the screw head 12 in Ib 20 in Ib 12 in Ib 20 in Ib 2 7 2 Grounding Scheme To prevent shock hazard to personnel and to ensure proper operation of the servo system the BDS4 5 4 5 and the servo motor must be grounded according to NEC specifications Each BDS4 and PSR4 5 have at least two grounding screws on the front of the chassis Provisions of the National Electrical Code with respect to grounding should be followed These precautions generally deal with the NOTE ground loop currents arising from multiple ground paths Only one ground path should be used One of the screws on the chassis of the PSR4 5 should go to earth or machine ground The other should be connected to the adjacent BDS4 ground screw along with the ground wire from the motor The free ground screw on the BDS4 chassis should then be connected to the next BDS4 etc For grounding to machine or earth ground a screw lug should be attached to the ground screw or stud on the PSR4 5 or BDS4 A torque of 12 in Ib for ground screws and 20 in lb for ground studs is recommended Also refer to the National Electrical Code NEC or UL standard 486B for recommended torque s 2 5 CHAPTER 2 INSTALLATION 2 7 3 Connecting the Input Voltages The Main AC Input Voltage either single or three phase should be connected at L L and L on the power terminal block l
187. l energy Requires no commutation devices such as brushes Normally operated off commercial AC power Can be single or multiple phase Oscillation An effect that varies periodically between two values PLC Programmable Logic Controller Also known as a programmable controller these devices are used for machine control and sequencing Power The rate at which work is done In motion control Power Torque x Speed Pulse Rate The frequency of the step pulses applied to a step per motor driver The pulse rate divided by the resolution of the motor drive combination in steps per revolution yields the rotational speed in revolutions per second Ramping The acceleration and deceleration of a motor May also refer to the change in frequency of the applied step pulse train Rated Torque The torque producing capacity of a motor at a given speed This is the maximum continuous torque the BDS4 GLOSSARY motor can deliver to a load and is usually specified with a torque speed curve Regeneration The action during motor braking in which the motor acts as a generator and takes kinetic energy from the load converts it to electrical energy and returns it to the amplifier Repeatablity The degree to which the positioning accuracy for a given move performed repetitively can be duplicated Resolution The smallest positioning increment that can be achieved Frequently defined as the number of steps or fee
188. le input circuit Using an oscilloscope monitor REFERENCE HIGH at TC2 1 refer to Figure or 3 Adjust Pot OSCG inside the BDS4 for 12 volts peak to peak This signal should be 7 0 kHz 500 HZ 4 4 3 2 Current Sensor Offset Adjustments Using a digital DC voltmeter monitor TC4 1 Adjust Pot AZ inside the BDS4 for minimum voltage level Using the digital voltmeter monitor TC4 3 and adjust Pot CZ inside the BDS4 for minimum voltage level Refer to drawing C 84113 4 4 3 3 Motor System Resolver Alignment This procedure applies only to the system resolver not the application position loop NOTE resolver The motor system resolver is properly aligned at the factory and should never require realignment However this procedure is included here in the event motor repair etc the resolver should ever need realignment In order for the following test to be valid the motor and resolver phasing must be correct If there is any doubt as to whether the motor and resolver are wired correctly refer to Section 4 6 and check the motor and resolver wiring BDS4 The motor system resolver alignment can be confirmed by conducting the following test 1 Remove power Disconnect the motor shaft from any mechanical load Connect a small jumper between TC1 3 and TC1 4 refer to Figures 1 and 3 While in this mode resolver zeroing test mode the FOLDBACK LED will become the resolver alignment indicator Apply po
189. line voltage at the circuit breaker or fuse holders Remove power Note the model number of the 5 4 5 and refer to Appendix B to confirm the correct Main AC voltage level SIN HI SIN LO SHIELD SHIELD COS HI COS LO REF LO RESOLVER CONNECTOR REF HI SHIELD Figure 2 6 Motor Resolver Connections CHAPTER 2 INSTALLATION 5 a ARMATURE MOTOR CONNECTOR BDS4 Shield POWER TERMINAL BLOCK ON 8 54 Figure 2 7 Armature Motor Connections Apply only the AC control power Use an AC voltmeter to check and record the single phase voltage at Connector C1 of the PSR4 5 Remove power Note the model number of the PSR4 5 and refer to Appendix B to confirm correct Control AC voltage level If the voltage levels are within the specifications listed in Appendix B proceed with the Check Out procedure Close the circuit breaker or re install the fuses for the Main AC input power Re install Connectors C1 and C4 if present 2 8 3 Checking the DC Bus Voltages 2 12 Allow sufficient time after removing power from the system for the voltage to bleed down before connecting WARNING or disconnecting wires at the bus Remove power Remove the Bus and Bus leads from the PSR4 5 power terminal block Remove mating Connector C2 from the PSR4 5 Apply power BDS4 Check and record the M
190. mes all errors add together do For 12 bit systems only For 14 bit systems the uncertainty drops to 1 32 arc min and for 16 bit systems the uncertainty drops to 0 33 arc min Therefore the worst case and typical accuracies will be reduced slightly for 14 and 16 bit systems E APPENDIX OPTIONS BDS4 Table E 4 R D Converter Speeds R D CONVERTER MAXIMUM SPEED MAXIMUM R D RESOLUTION TRACKING RATE OPERATING SPEED 233 33 RPS 8000 RPM 133 33 RPS 8000 RPM 33 33 RPS 2000 RPM 15 0 RPS 900 RPM 13 33 RPS 500 RPM 58 33 RPS 3500 RPM E 8 BDS4 APPENDIX OPTIONS One Encoder One Quadrature pe Line o Encoder Count OUT A OUT A cast ree A LEADS B by 90 Degrees for Clockwise Rotation OUT B OUT B OUT Z Standard Marker Pulse OUT Z Standard Marker Pulse 21241 22 Figure 2 Encoder Output Timing APPENDIX F DRAWINGS DRAWING 63542 Motor Connection A 83908 Purchase Spec for Mini Fit Jr Series Connector 83909 Purchase Spec for Mini Fit Jr Series Terminals 84385 Outline amp Dimension PSR4 5 12 amp 20 Amp A 93031 Outline amp Dimension 5 4 5 50 amp 75 Amp 93092 PRS4 5 50 75 with amp without Soft Start Simplified Schematic 93112 Outline amp
191. module in descending order according to their continuous current ratings Refer to Section 2 6 In order to adhere to suitable engineering practice the AC control voltage 115 for the logic bus must be applied first to activate the NOTE controland fault logic circuits prior to applying the main AC voltage Follow these precautions 1 Observe all notes wiring diagram 2 All motor stator leads signal input leads resolver leads encoder leads and tachometer leads must be shielded 3 Twist all AC leads to minimize electromagnetic emissions noise 4 Avoid running signal leads must be shielded in close proximity to power leads motor stator leads or other sources of electromagnetic noise 5 Minimize lead lengths as much as possible 6 Connect the BDS4 system according to the System Wiring Diagram pay close attention to the grounding scheme T Provide adequate stress relief for cables The notes on BDS4 Wiring Diagram A 93231 give specific wiring details NOTE Thermal overload protection for the motor is not provided within the PSR4 5 or the BDS4 and must be provided externally Refer to the National Electrical Code for proper sizing of overload protection With the exception of the hook up of the motor the main input voltage and the main Bus and Bus DC voltage all interface wiring between the BDS4 BDS4 CHAPTER 2 INSTALLATION Table 2 1 Torque Values CONNE
192. mp BX Motors up to 115 amps continuous Motor Feedback Option Cable with Mating Plug System Resolver Only System Resolver Brake Tachometer Amplifier Termination BDS4 or BDS5 3 20 Amp Models BDS4 or BDS5 30 55 Amp Models Not Terminated Cable Length to Motor 3 to 75 Meters in 3 Meter Increments B 5 APPENDIX MODEL NUMBERS BDS4 Table B 6 Cable Model Number Scheme for Individual Cable Set Screw Type Thread EXAMPLE GCSA LEGEND LEGEND DEFINITION Motor Power Cable with mating plug for particular frame size B 40X X AX amp BX Motors up to 40 amps continuous B 60X X AX amp BX Motors up to 40 amps continuous B 60X X AX amp BX Motors B 80X X AX amp BX Motors B 80X X AX amp BX Motors up to 115 amps continuous up to 65 amps continuous up to 65 amps continuous Motor Feedback Option Cable with Mating Plug System Resolver Only System Resolver Brake Tachometer Amplifier Termination BDS4 or BDS5 3 20 Amp Models BDS4 or BDS5 30 55 Amp Models Not Terminated Cable Length to Motor 3 to 75 Meters 3 Meter Increments B 6 BDS4 APPENDIX B MODEL NUMBERS B 3 CABLE MODEL NUMBER SCHEME FOR INDIVIDUAL CABLE Individual cables can be provided by GC Goldline Cable Models To assist in ordering the model number scheme for an individual cable is as follows Table B 7 Cable Model Number Scheme for Individual Cable Bayonet Type Connect
193. n OUT A and OUT B can be jumpered for resolutions between 16 to 16384 lines in binary 2X increments The OUT Z Marker Pulse can be switch selected for either a narrow pulse width or a wide pulse width in relation to the particular resolution selected Note that any other marker pulse width can be selected as it has no direct effect on the selected resolution of the encoder equivalent signal STANDARD 12 BIT CONFIGURATION Place two jumpers on header 35 JUMPER PINS I J JUMPER PINS K L Adjust the Dip Switch 423 amp 36 to SWITCH A OFF SWITCH B OFF SWITCH C OFF SWITCH D OFF SWITCH E OFF SWITCH F ON SWITCH G ON SWITCH H ON SWITCH I ON SWITCH J ON SWITCH K ON SWITCH L ON Double Row Header 28 JUMPER 1 2 APPENDIX E OPTIONS JUMPER 3 4 JUMPER 5 6 JUMPER 7 8 JUMPER 9 10 JUMPER 11 12 See Schematic Drawing D 93179 E 2 2 2 BDS4 OPT2 3A 02 BOARD Electronic Encoder with Parallel Output Without Drive Signals The parallel resolver data option provides 12 16 bits of buffered resolver data output The signals are output on one 34 pin ribbon cable connector The mating connector for the ribbon cable connector is a Berg P N 66900 234 or equivalent The ribbon cable pinouts are listed in Table E 2 and on drawing C 93185 POSOO POS15 are sequenced to agree with PMC 960 positioner board signal names for a 12 bit configuration Due to this POS12 POS15 will appear to be out of sequence
194. n200W 129704 INPUT UNREGULATED LAMP 5845 25 1 8 7504 l65QuF se 400 5845 20 1880 i2A 2570 02 4 NOTE 20 3 2ow 584542 5 215 56 500 sa 650 UNREGULATED 2AMP 200 5420 5 2556 5004 2970 m E i5 000LF e E SS E TERN E 0 1 BLOCK PROVIDED ONLY ON EXTERNAL REGEN RESISTOR MODELS NO INTERNAL REGEN RESISTOR PROVIDED ON EXTERNAL eee EER RESISTOR MODEL 2 THESE VALUES FOR INTERNAL REGEN ONLY 3HHESE VALUES FOR EXTERNAL REGEN ONLY REG 5 7 COPY CODE nc PSR475 SIMPLIFIED SCHEMAT PART S WENS 96 27 1 84723 C1 gus BUS LA t O GND 115 VAC ea 115 nf 107 3 85 6 8 85 85 2 85 4 A NOT SCALE 096 USE DIMENSIONS ONLY TL 6 6 415 UNLESS OTHERWISE SPECIFIED vus uwy ny C 84724 95 1 95 VDC OUTPUT 18 OUTPUT POWER SUPPLY REGEN CARD PSR PS2 XXX cory cge 95 5 95 95 4 10 0 OUTPUT 7 305 Rt ISEE NOTE 1 0 L I D 1 306 R2 V NOTES wove TERMINAL
195. nput circuit 2 O K to Enable Drive Up Mode JR21 is installed on the BDS4 COMP Board Standard Apply power When there are no faults present the internal Drive Up contact will be closed and the green Drive Ready LED will be illuminated indicating that the BDS4 is OK TO ENABLE However if there is a fault present the Drive Up contact will be open and the Drive Ready LED off indicating that the BDS4 is ina fault mode In this case activating the Enable input circuit will not enable BDS4 Pin 12 Aux IN This is an additional single ended input to the velocity loop This input may be used in adaptive CHAPTER 2 INSTALLATION mode applications or used as the tach input for integrally motor mounted tachometer generators Pin 13 I Limit The Current Limit input allows access to the Current Limit circuitry providing a means by which inputs may be applied for adaptive control applications This single ended input may also be used to adjust the peak current limit of the amplifier from 7 596 to 10096 of its rating A positive voltage from 0 VDC to 7 5 VDC corresponds to 7 596 to 100 respectively Also a resistor to common may be used to program the current limit with 75 of I peak 8 6 Ohm 5096 of I peak 2 3 3 K Ohm The Current Limit Adjustment Pot may also be used to adjust the peak torque of the motor to the desired level Pin 14 Torque Hold BDS4 may be converted from a constant velocity amplifier t
196. nt regulator regeneration circuit is active No fault is indicated The red FAULT LED when illuminated indicates an excessive heatsink temperature within the unit due to an overload condition and may also indicate excessive ambient temperature Faults occurring within the PSR4 5 will cause its Fault Output contact to open More diagnostic information about the PSR4 5 50 and 75 Amp LED s is listed in Table 5 4 5 3 6 BDS4 or PSR4 5 Reset Procedures To reset the OVERVOLTS and OVERCURRENT fault latches within the BDS4 and all fault latches within the PSR4 5 power supply units remove all AC line input voltage for at least five 5 minutes or until the power stage capacitors are fully discharged All other fault latches within the BDS4 amplifiers may be reset by toggling the RESET input circuit to common or by removing and reapplying the input voltage as described previously The thermal overload relay with the PSR4 5 50 and 75 amp modules External Regen Resistor s is normally furnished and set for HAND reset operation In the event of excessive shunt regulator activity its auxiliary contact will open THIS CONTACT MUST BE WIRED INTO THE E STOP STRING OR AN EQUIVALENT SHUNT DOWN CIRCUIT The thermal overload relay may be reset by pushing in the reset rod located in the top of the unit Figure 5 3 PSR4 5 50 75 Status LED s BDS4 CHAPTER 5 TROUBLESHOOTING Table 5 1 Improper Motor Operation Troubleshooting SYMPTOM
197. ntil the problem is resolved 5 2 FIELD SERVICEABILITY Dangerous voltages exist in this equipment Also motor temperature may exceed 100 C Extreme caution should be exercised when troubleshooting this equipment Only qualified CAUTION individuals should attempt to install setup operate or troubleshoot this equipment The BDS4 and PSR4 5 are designed to promote minimum down time situations Due to the compact package size and to the fact that there are few user serviceable components on the modules it is recommended that they be replaced if they cease to function properly Return the modules in their entirety to Industrial Drives for repair CHAPTER 5 TROUBLESHOOTING The only user serviceable items on the PSR4 5 are the output line fuses in the control DC voltage supply and in the 12 and 20 amp units the shunt regulator regeneration load resistor fuse preserve the level protection for the product as designed replacement fuses must the exact same style CAUTION ampere rating as those originally installed The BDS4 modules may be interchanged provided the following guidelines are adhered to 1 The BDS4 modules must be the same rating 2 The motors being controlled must bear same model number 3 In event motors have different model numbers the BDS4 COMP Board must bear the model number of the motor being controlled or the BDS4 COMP Board must be altere
198. o a constant torque amplifier at stall only by closing a circuit between Pin 14 and common via internal 20 K Ohm pull up resistor The velocity loop operational amplifier is maintained at unity gain while in this mode of operation Pin 18 I Monitor There is a direct relationship between the signal appearing at this output and actual motor current A DC voltmeter placed between Pin 18 and common calibrated in either current or torque can be used to estimate the constant load levels placed on the motor The current scale factor at Pin 18 is 8V Peak RMS current rating of the BDS4 3 K Ohm output impedance This output is for reference only Its accuracy decreases as current decreases 4 at peak current 9 at continuous current 12 at 1 2 continuous current Pin 19 Speed Monitor There is a direct relationship between the signal appearing at this output and actual motor speed A DC voltmeter or other instrument placed between Pin 19 and common calibrated in RPM can serve as a means by which speeds may be monitored Refer to the TL Sheet for the scale factor in volts RPM 8 volts maximum speed as listed on the TL Sheet for the particular motor amplifier combination 3K Ohm output impedance 2 9 CHAPTER 2 INSTALLATION 2 7 9 Connecting the Motor B SERIES MOTORS have a thermostat switch wired to the resolver connector at the motor BR SERIES MOTORS have a NOTE thermostat switch wired to the st
199. o the equipment or operational difficulty The safety alert symbols are illustrated in Figure 2 1 When you see these symbols in this manual be alert WARNING CAUTION NOTE Figure 2 1 Safety Alert Symbols to the potential for personal injury Follow the recommended precautions and safe operating practices included with the alert symbols Warning refers to personal safety They alert you to potential danger or harm Failure to follow warning notices could result in personal injury or death Caution directs attention to general precautions which if not followed could result in personal injury and or equipment damage Note highlights information critical to your understanding or use of these products 2 3 CONVENTIONS To assist you in understanding the material in this manual conventions have been established to enhance reader comprehension Explanations of these conventions are as follows e Safety warnings cautions and notes present material that is important to user safety Be sure to read any safety notices you see as they could prevent equipment damage personal injury or even death to you or a co worker e Bold text highlights other important information that is critical to system operations 2 1 CHAPTER 2 INSTALLATION e CAPITALIZED text stresses attention to the details of the procedure e Underlined text emphasizes crucial words in sentences that could be misunderstood if the word is not r
200. ocated on the front of the PSR4 5 unit The 5 4 5 is not line phase sensitive When using the 12 or 20 amp PSR4 5 with single phase main power the input lines may be connected to any two 2 terminals L or Le The Control AC input voltage should be wired to Connector C1 Pins 2 and 3 on the PSRA 5 and from Connector C1 Pins 5 and 6 of the PSRA 5 to Connector C4 Pins 1 and 2 fan units only on the 81354 4 is present only on BDS4 Amplifiers that have continuous ratings of 20 amps NOTE and above 2 7 4 Connecting the PSR4 5 Fault Output Contact Connector C1 Pins 1 4 Fault Contact The Fault Output Contact closes when power is applied to the PSR4 5 This contact opens on a fault condition within the PSR4 5 only The pinouts for C1 are listed in Figure 2 2 Refer to Note 2 of the BDS4 Wiring Diagram A 93231 for further information concerning the PSR4 5 Fault Output Contact 2 6 BDS4 2 7 5 Connecting the Unregulated DC Voltage to the BDS4 Connector C3 The wiring between the BDS4 Connector C3 and the PSR4 5 Connector C2 unregulated voltage is in Table 2 2 and the pinouts are in Figure 2 3 2 7 6 Connecting the Main DC Bus Voltage Refer to notes 4 and 6 on BDS4 Wiring Diagram A 93231 for details concerning the hook up of the Bus and Bus circuits between the PSR4 5 and the BDS4 amplifiers Failure to observe correct polarity will result in damage to the PSR4 5 and BDS4
201. or EXAMPLE GC M2 4 5 LEGEND A B LEGEND DEFINITION Goldline Cable With Bayonet Type individual cable Motor Power Cable with Mating Plug or Feedback Option Cable B 10X Motors B 20X Motors B 40X Motors B 60X X AX amp BX Motors up to 40 amps continuous B 60X X AX amp BX Motors up to 65 amps continuous B 80X X AX amp BX Motors up to 65 amps continuous B 80X X AX amp BX Motors up to 115 amps continuous System Resolver Only System Resolver Brake Tachometer Application Resolver Amplifier Termination BDS4 or BDS5 3 20A Models BDS4 or BDS5 High Current Models Not Terminated ID Cable Length to Motor 3 to 75 Meters in 3 Meter Increments B 7 APPENDIX MODEL NUMBERS BDS4 Table B 8 Cable Model Number Scheme for Individual Cable Screw Type Connector EXAMPLE M4 4 5 03 LEGEND A B C D LEGEND DEFINITION Goldline Cable with screw type connector individual cable Motor Power Cable with Mating Plug or Feedback Option Cable B 40X Motors up to 40 amps continuous B 60X Motors up to 40 amps continuous B 60X Motors up to 65 amps continuous B 80X Motors up to 65 amps continuous B 80X Motors up to 115 amps continuous System Resolver Only System Resolver Brake Tachometer Application Resolver Amplifier Termination BDS4 or BDS5 3 to 20 A Models BDS4 or BDS5 High Current Models Not Terminated Cable Lengt
202. or regeneration resistor FUSE LED to become illuminated load is fuse protected If the shunt regulator 1 3 CHAPTER 1 SYSTEM DESCRIPTION WARNING The shunt regulator also includes a duty cycle limit circuit to protect against excessive load resistor heating If the average duty cycle limit is exceeded the regeneration circuitry will become disabled the Fault Contact will open and the OVERLOAD LED will become illuminated To reset this fault remove and reapply all input line power bus capacitors must completely discharge 50 and 75 AMP Models The thermal overload output contacts must be connected into a shut down circuit E Stop string etc to drop the main power or a possible fire hazard will exist Refer to Drawing A 93231 The shunt regulator regeneration resistor is protected by a thermal overload relay If the resistor rating is exceeded or if the shunt regulator transistor fails the thermal overload output contacts will open indicating an IMMEDIATE need to remove the main power 1 4 2 8054 Servo Amplifier Module Refer to Figure 1 1 for a quick reference of the BDS4 s features The BDS4 Servo Amplifier is divided into four 4 main sections 1 4 1 Fault Diagnostics monitor various signal leads When a fault condition occurs the fault circuit will become latched the BDS4 will become internally inhibited the appropriate red LED will become illuminated and the Drive Up contact will
203. peak current by fuse It is also protected from excessive duty if duty cycle exceeds a preset limit by shunt overload shutdown circuit e The 50 and 75 amp PSR4 5 shunt regulation is accomplished with externally mounted power resistor s with ratings from 500 to 2000 watts as standard Special units may be ordered for even higher power The shunt regulator is protected from excessive peak current by a thermal overload relay It is also protected from excessive duty if duty cycle exceeds a preset limit by shunt overload shutdown circuit e Diagnostic LED indicators located on the front panel on both the BDS4 and the PSR4 5 modules e Either 12 Bit Parallel Position Information Card or an Encoder Equivalent Output Card as available options 1 4 THEORY OF OPERATION The BDS4 brushless servo system consists of three main components 1 PSR4 5 Power Supply Module 2 BDS4 Amplifier Module 3 B Brushless Motor 1 2 BDS4 of the compensation components necessary to match a BDS4 amplifier to a particular motor such as current loop compensation velocity loop compensation and torque angle compensation are located on the removable BDS4 COMP compensation board located inside the BDS4 amplifier The TL Test Limits and Modification Sheet contains the compensation component values and such information as maximum operating speed peak current limits etc that are assigned to each BDS4 system Only motors having
204. pple Frequency 20 0 KHZ 20 0 KHZ 20 0 KHZ 20 0 KHZ 10 Resolver Excitation 7 0 KHZ 7 0 KHZ 7 0 KHZ 7 0 KHZ Frequency Speed Regulation 0 075 0 075 0 075 0 075 G Long Term TMinimum Controllable Speed Standard 12 Bit R D With 8000 RPM Max Tracking Rate 12 Bit R D With 14000 RPM Max Tracking Rate 14 Bit R D With 1 8 RPM 1 8 RPM 1 8 RPM 1 8 RPM 2000 RPM Max Tracking Rate 14 Bit R D With 1 4 RPM 1 4 RPM 1 4 RPM 1 4 RPM 3500 RPM Max Tracking Rate 16 Bit R D With 1 64 RPM 1 64 RPM 1 64 RPM 1 64 RPM 500 RPM Max Tracking Rate Minimum controlled speed is defined as the minimum speed that can readily be run The standard BDS4 is configured with a 12 bit R D converter for a maximum motor speed of 8 000 RPM Other resolutions and maximum motor speeds tracking rates must be ordered as specials D 5 APPENDIX D SPECIFICATIONS BDS4 Table D 2 BDS4 Specifications Con t MAIN DC BUS Minimum 250 VDG 250 VDG 250 VDG 250 VDC Maximum 360 VDC 360 VDC 360 VDC 360 VDC Unregulated Logic 14 5 26 VDC 14 5 26 VDC 14 5 26 VDG 14 5 26 VDG Bus Input 0 25 AMPS 0 25 AMPS 0 25 AMPS 0 25 AMPS 6 5 14 VDC 6 5 14 VDC 6 5 14 VDC 6 5 14 VDC 0 50 0 50 0 50 0 50 Fan Line Input 95 132 VAG 50 60 HZ 0 5 AMPS Output Current RMS PHASE Convection Cooled 45 C AMB Fan Cooled Continuous RMS 3 0 AMPS 6 0 AMPS 10 0 AMPS 20 0 AMPS Peak 2 0 SEC
205. quipment BDS4 2 5 1 Environmental Considerations The environment that this equipment is placed in can have dramatic effects on its operation Industrial Drives recommends that the BDS4 and PSR4 5 be operated and stored under the following conditions Operating Temperature 0 C to 45 9 Storage Temperature 20 C to 70 C e Humidity 10 to 90 Non Condensing 2 5 2 Enclosures It is suggested that the BDS4 and PSR4 5 be mounted in a cabinet or other suitable enclosure to protect them from physical and environmental damage Refer to Appendix D for complete system dimensions Allow sufficient clearance for the large regenerative heat producing resistor s mounted at the upper edge of the PSR4 5 unit and the CAUTION externally mounted regen shunt regulator power resistor s 2 6 ASSEMBLY The BDS4 and PSR4 5 are both constructed prior to shipping from the factory The only assembly required is the mounting of the devices 2 6 1 Mounting Refer to the drawing of your model system in Appendix F for outline and dimensions Be sure to look at the proper drawing for mounting measurements The PSR4 5 and BDS4 modules should be mounted in the vertical position To minimize cross talk and enhance air flow maintain a minimum of 20 millimeters 0 75 in on either side of each unit and at least 40 millimeters 1 5 in of unobstructed space above and below the units CHAPTER 2 INSTALLATI
206. rence with radio communications or other electronic equipment 4 3 PERIODIC MAINTENANCE Periodic maintenance must be performed by qualified personnel familiar with the construction operation and hazards involved with the BDS4 and its application Power should be disconnected during all maintenance procedures 4 3 1 Ventilation The 5 4 5 and BDS4 should be mounted vertically to allow maximum ventilation of the components This configuration allows the heat generated by the components to vent through the top and draft in cooler air through the bottom The top and bottom of the components are vented to allow this drafting to occur These ventilation passages should be kept open If the PSR4 5 requires auxiliary cooling with fans inspect the fans on a regular basis 4 3 2 Grounding Integrity The method employed for grounding or insulating the equipment from ground should be checked to assure its integrity on a regular basis This check should be performed with the power off and the testing equipment grounded 81354 4 4 ADJUSTMENTS Adjust pots with proper adjustment tool NOTE DO NOT FORCE The adjustments are classified into three categories 1 Set Up Adjustments Adjustments that are necessary at installation accessible at the front of the BDS4 Motor System Resolver Phasing and Alignment Should be checked the first time if LD cables are not used Balance Adjustment Command Scale Adjustment 2
207. riate connecting points on Connector C1 and help the user decide which inputs and modes of operation to use The pinouts are listed in Figure 2 4 Pins 15 16 17 Common These pins provide commons returns between external equipment numerical controls etc and the 811354 Pins 4 5 6 5 16 1 2 8 BDS4 These pins provide termination points for cable shields To insure there are no ground loops in the shield common connect only one end butt and insulate the other end 11 DIFF CMD HI Pini DIFF CMDLO Differential velocity or current command input 10 V full scale 20 K Ohm input impedance Should be shielded Pin2 Enable Allows the BDS4 to be enabled or disabled without removing the main power When a circuit is closed between Pin 2 and common the BDS4 will be put into the Drive Up mode Opening the circuit puts 6 81354 into the Inhibit mode internal 20 Ohm pull up resistor to 12 VDC Green LED indicated Pin 3 Reset Allows any latched fault circuit except OVERVOLTS or OVERCURRENT faults to be reset by toggling Pin 3 to common It has a 20 K Ohm pull up resistor to 12 VDC Pin7 Output Fault Open collector signal logic low to indicate that either an overcurrent or overvoltage fault has occurred in the Power Stage of the amplifier 25 ma sink capabilities 30 VDC Max red LED indicated Pin 8 Foldback Open collector signal logic low to indicate that the amplifier has started
208. rives GOLDL IN GUIDE DATE APP D FOR RESC RADFORD VIRGINIA CHK BY DATE APP D BY DATE SCALE DW G NO SHEET 6 NO SHEET 7 OF 13 ISSUE RED MOTOR CONNECTOR 99940 1 RESOLVER CABLE WITH THERMOSTAT GCA R X X XX ARTS ST CONNECTION CHART CABLE MOTOR CONNECTION CABLE 8054 C2 or 8055 C3 BDS4 C TEM 0 MANUF ACTURER TEM 5 4 ITEM 1 TEM 2 if OUR Ir I LUN EEREN dcs YE E PART NUMBER PART NUMBER ERMINAL A RED ERMINAL 7 4 PAIR 81948 BELDEN 8725 ERMINAL BLACK ERMINAL N C SHIELD ERMINAL 8 MOTOR CONNECTOR AND ACCESSORIES ERMINAL C WHT YEL ERMINAL 3 ID MANUFACTURER WHIT CEN O DESCRIPTION EE AL D WHT GRN ERMINAL 9 NE VC SHIELD ERMINAL 2 5 MOTOR HOUSING G BEND 53106 22 145 ERMINAL WHT RED ERMINAL 10 ERMINAL F WHT BLK ERMINAL 4 SHIELD ERMINAL 5 ERMINAL 8054 C2 OR 8055 C3 AND ACCESSORIES ITEM deeem e ID MANUF A
209. rives RADFORD VIRGINIA AMPLIFI 3 THRU 20 AMP CHK BY DATE APP D BY SHEET 5 OF 8 ISSUE REU us Cry DAD 2 AD 0 M 1 1 IN UA 1 J K LUO X A edi DE 4 LUG QTY 4 ATN MATING MOTOR 5 3 16 HEATSHRINK 2 CABLE 4 5 LONG v ae BUT EN 5 8 HEAT 6 Es Dd lt CONNECTOR SHRINK 4 LONG IELD amp GRN YEL WIRE TO BE CUT OFF 1 50 YOND CABLE JACKET AND INSERTED INTO BUTT CONNECTOR EL WIR NOT Di RU THE A Z ITI CABLE TEM 10 MANUFACTURER DESCRIPTION 10 517 MANUFACTURER PART NUMBER XSS20836 DESCRIPTION TORIO PART N NU MBER NAME NUMBER HA SPADE LUG 02 HOLL I NGSWOR A 97941 012 C amp M 3 BUTT CONN 003 HOLL INGSWOR B4046BF 2 4 CONDUCTO CRIMP TOOL NZA HOLLIN HOE MOTOR CONNECTOR AND ACCESSORIES 10 MANUFACTURER DESCRIPT
210. rminate at customer Connector 32 The marker pulse signal is generated by the following sequence All sixteen parallel resolver data bits are brought to the BDS4 OPT2 3A Option Board These bits first pass through LS244 data buffers Next the data bits are routed to a bank of DIP switches consisting of Components 23 and 26 At these switches the marker pulse width is selected For a minimum pulse width all switches should be closed As more switches are 31354 opened from the LSB to the MSB pulse width will become wider The marker pulse width selected has no effect on the quadrature resolution selected although these two types of signals are normally related on a standard encoder The jumper switch table that follows shows the wide and narrow marker pulse selection with each of the eleven encoder equivalent resolutions available After the dip switch the selected signals are Anded together then Anded with all of the MSB data lines that were not switch selectable Note that the combination of the two Nand gates feeding into an Or gate results in the equivalent of a large Nand gate The output of the Or gate feeds into a LS175 flip flop The non inverting output of the flip flop drives an LED The inverting output of the flip flop drives 058830 or 75183 line driver The line driver outputs route straight across a jumper header strip this is used with other options and terminate at customer Connector 32 The encoder resolutio
211. sient voltages These voltages are in excess of the specified voltage for any given circuit When these peak voltages occur even for less than a second permanent damage to the BDS4 can occur In order to help avoid transient voltages that may interfere with electronic circuit functions within the PSR4 5 and BDSA all switched inductive devices their wiring solenoids relay coils starter coils etc must be suppressed 220 ohm 1 2 watt resistor in series with a 0 5 micro farad 600 volt capacitor or equivalent is suggested 4 2 2 Surge Current Excessive current greater than that of the specified limits of the PSR4 5 and BDS4 can cause permanent damage to the system Current limiting means are recommended to protect from these currents 4 1 CHAPTER 4 MAINTENANCE If the short circuit inrush current generated by the power source is in excess of 5000 amps RMS symmetrical current an isolation transformer line inductor must utilized the CAUTION incoming power circuit Failure to observe this precaution could result in damage to or destruction of the PSR4 5 and BDS4 Input transformers step up or step down input voltage and can be either autotransformers or isolation transformers Isolation transformers help eliminate the following Damaging AC line voltage transients reaching the PSR4 5 and BDS4 Damaging currents which may develop if a point inside the PSR4 5 or BDS4 becomes grounde
212. site limit switch 15 not activated Wiring Reference to Drawing A 93541 will assist in wiring the D L option board The speed command position error to the BDS4 amplifier must be wired to 1 and 4 of the special differential input terminals on 13 1 option board NOT TO THE STANDARD INPUT OF THE BDS4 In order to initiate restricted movement the customer must provide 5 to 28 VDC through limit switches on the machine to the CW and CCW inputs of the D L option board The 5 to 28 VDC supply must be capable of sourcing 20 ma of current E 4 BDS4 Board Configuration The D L option board is shipped from the factory configured so that the absence of input 5 to 28 VDC from either of its CW or CCW inputs activate the direction limit mode If it is desired that direction limit be activated by the presence of voltage remove Jumper 26 located between Pins 2 and 3 on the board and install it between Pins 1 and 2 Direction Limit Indication When the Direction Limit mode is activated a red LED will become illuminated The LED is located Just behind option board Connector 3 and can be seen through the opening in the front of the BDS4 Adjustments There is only one adjustment on the D L option board It is the Command Scale Pot and is located next to option board Connector 67 Perform the adjustment procedure in the following manner 1 Adjust the Command Scale in the front the BDS4 fully CCW
213. tched in the Inhibit mode indicating the presence of excessive main DC bus voltage When the red UNDERVOLTS LED becomes illuminated the BDS4 will be put into the Inhibit mode but not latched indicating the main DC Bus is insufficient or absent If the red OVERSPEED LED becomes illuminated the BDS4 will become latched in the Inhibit mode indicating that the motor has obtained an excessive speed or the resolver cable is miswired or has an intermittent connection The Fault Output contact located within the PSR4 5 power supply module will not be affected by any faults occurring within the BDS4 More diagnostic information about the BDS4 is listed in the Table 5 2 5 3 4 PSR4 5 12 and 20 Amp Status LED s The status of the 5 4 5 12 and 20 amp modules is indicated by one 1 Green one 1 Yellow and two 2 Red LED s Refer to Figure 5 2 for the LED configuration The diagnostic information indicated by these LED s is as follows Approximately 0 25 seconds after the main power is applied the green DC BUS LED will become illuminated to indicate the presence of voltage on the main DC bus capacitors Voltage indication may range in magnitude from over 300 VDC during normal operation with AC line voltage applied to below 50 VDC 5 3 CHAPTER 5 TROUBLESHOOTING BUS REGEN OVERLOAD BLOWN FUSE Figure 5 2 PSR4 5 12 20 Status LED s when the line voltage is removed but the bus capacitors have not comple
214. tely discharged The yellow REGEN LED is for monitoring purposes only When this LED becomes illuminated the shunt regulator regeneration circuit is active No fault is indicated The red OVERLOAD LED will become illuminated in the event the shunt regulator regeneration circuit experiences an overload condition The Fault Output contact will also open The red BLOWN REGEN FUSE LED will become illuminated and the Fault Output contact will open in the event the shunt regulator regeneration fuse blows Faults occurring within the PSR4 5 will cause its Fault Output contact to open More diagnostic information about the PSR4 5 12 and 20 Amp LED s is listed in Table 5 3 5 3 5 PSR4 5 50 and 75 Amp Status LED s The status of the PSR4 5 50 and 75 amp models is indicated by one 1 Green one 1 Yellow and one 1 Red LED Refer to Figure 5 3 for the LED configuration The diagnostic information indicated by these LED s is as follows Approximately 0 5 seconds after the main power is applied the green DC BUS LED will become illuminated to indicate the presence of voltage on the main DC bus capacitors Voltage indication may range in magnitude from over 300 VDC during normal operation with AC line voltage applied to below 50 VDC 5 4 BDS4 when the line voltage is removed but the bus capacitors have not completely discharged The yellow REGEN LED is for monitoring purposes only When this LED becomes illuminated the shu
215. to 55 C Consult Factory for Derating Above 55 C D 8 BDS4 APPENDIX D SPECIFICATIONS Table D 4 Environmental Specifications Operating Temperature 0 45 Storage Temperature 20 C to 70 C Humidity Non Condensing 10 to 90 Table D 5 Mechanical Specifications WEIGHT x BDS4 255X PSR4 5 X75 D 9 31354 APPENDIX OPTIONS Options are brought into existence from time to time to satisfy specific needs and to add versatility to the product Refer to the Model Number Schemes in Appendix B The BDS4 and PSR4 5 may be ordered with various mechanical and electrical options standard or custom designed for particular applications Ifa feature is desired which is not covered here consult the Industrial Drives Sales Staff for information on custom designed options E 1 PSR4 5A V ELECTRICAL OPTIONS 12 and 20 AMP Models OPTION 01 400 watts external regeneration resistor kit for 230V systems refer to Section 4 7 02 200 watts external regeneration resistor kit for 115V systems refer to Section 4 7 03 700 watts external regeneration resistor kit for 230V systems refer to Section 4 7 80 without Regen or dynamic brake 81 with 240 V logic supply without Regen dynamic brake 50 and 75 AMP Models OPTION 20 with undervolt fault 50 without soft start circuitry E 2 BDS4
216. to reduce peak current due to excessive loading 25 ma sink capabilities 30 VDC max red LED indicated Pin 9 Overtemp This output will transition low to indicate the 881354 amplifier is being subjected to an excessive temperature condition Open collector logic low 25 ma sink capability 30 VDC max red LED indicated Pins 10 20 Drive Up BDS4 The Drive Up contact closure internally indicates to the outside world that the BDS4 amplifier is in the Drive Up mode or when the contact is open it indicates the Inhibit mode The contact is rated at 115 VAC at 2 amps green LED indicates Drive Ready The Drive Up relay acts in conjunction with the Enable circuit in one of two possible modes of operation as determined by optional jumper J21 To determine which mode of operation is being utilized refer to J21 on the TEST LIMITS SHEET 1 Drive Up Mode 21 is not installed on the BDS4 COMP Board Apply power When the Enable input circuit is activated pulled low the internal Drive Up contact will close and the green Drive Ready LED will become illuminated However when the Enable input circuit is not activated or a fault occurs the internal Drive Up contact will be open and the green Drive Ready LED will be off indicating that the BDS4 is in the Inhibit Mode If fault occurs within the BDS4 the Drive Ready LED will turn off and the Drive Up contact will open and remain open regardless of the state of the Enable i
217. ushes The motors run as synchronous motors meaning the rotor speed is the same as the speed frequency of the stator s rotating magnetic field The feedback device 15 a brushless resolver mounted internally as part of the overall motor construction Another available option is the integral brush tachometer For more information refer to the Installation and Service Manual B Series Brushless Motors M 89031 1 4 4 Power Up Down Sequencing First apply the 115 VAC control voltage Second apply the main AC voltage Third check for faults and then enable the BDS4 The AC line input voltages may be removed in any sequence 1 The BDS4A V sine wave controller allows a wider range speed because it has the ability to electronically change the angle between the rotor flux and the stator flux commonly referred to as torque angle Industrial Drives A Kollmorgen Division Patented Numbers 4 447 771 4 479 078 and 4 490 661 1 CHAPTER 1 SYSTEM DESCRIPTION 1 4 5 With Soft Start Circuit Standard Only the Control AC line input voltage is applied a logic bus comes up b Apower up reset pulse is generated in the BDS4 c If no faults other than main bus undervolts are present after the power up reset pulse is generated a delay of one second then the drive is ready to be enabled However there can be no motor movement until the main AC line input voltage is applied The Main AC line input voltage is appli
218. vice Amplifier Electronics which convert low level command signals to high power voltages and currents to operate a servo motor Brushless Servo Drive A servo drive used to control a permanent magnet synchronous AC motor May also be referred to as an AC Servo Drive Drive This is the electronics portion of the system that controls power to the motor Drive Analog Usually referring to any type of motor drive in which the input is an analog signal Drive Servo A motor drive which utilizes internal feedback loops for accurate control of motor current and or velocity Efficiency The ratio of output power to input power Encoder Absolute A digital position transducer in which the output is representative of the absolute position of the input shaft within one or more revolutions Output is usually a parallel digital word Encoder Incremental A position encoding device in which the output represents incremental changes in position Encoder Marker A once per revolution signal provided by some incremental encoders to specify a reference point within that revolution Also known as Zero Reference signal or index pulse Encoder Resolution A measure of the smallest positional change which can be detected by the encoder Feedback A signal which is transferred from the output back to the input for use in a closed loop system Following Error The position error during motion resulting from use o
219. wer DO NOT ENABLE THE 8054 If necessary have a colleague observe the FOLDBACK LED The FOLDBACK LED will be either off or slowly blinking Slowly rotate the motor shaft until the FOLDBACK LED blinks at its fastest rate rotate slowly then pause giving the circuitry time to react The closer the resolver is to being correctly aligned the faster the LED will blink The LED should be somewhere between one pulse per second and fully illuminated when it blinks at its fastest rate Remove hand from motor shaft before enabling The e shaft will jerk into position CAUTION with some force Enable the BDS4 by pulling Connector 2 on the BDS4 to common The internal software of the BDS4 will cause phase M to have zero current The M and M phases will have equal but opposite currents causing the motor shaft to align itself in a neutral position The FOLDBACK LED should be fully illuminated indicating correct alignment of the resolver No further attempt at alignment is necessary Resolver alignment is correct If however the LED does not become fully illuminated as indicated in Step 4 above proceed with the alignment procedure Inhibit the BDS4 Remove power Remove the end plate cover from the rear end of the motor The shaft mounted frameless resolver will be in sight CHAPTER 4 MAINTENANCE The frameless resolver rotor is slid forward onto the motor shaft and secured by a large lock nut This part of th

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