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Installation and Service Manual

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3. 1 8 2 2 us 550 450KHz With scope monitor TP73 at the Modulation Hybrid The waveform should appear as shown in section 6 10 24 With an oscilloscope monitor TP79 with channel 1 Monitor TP77 with channel 2 Have a colleague rotate the motor shaft with a constant smooth movement for one complete revolution The following waveforms should be present D i 1 TP79 3 l _ 1 77 5 OV To check the Hall Effect Current sensors do the following Open the Remote Inhibit input circuit With a DVM monitor TP36 2 on the Comp 3 board with respect to common The voltage level should be zero volts 0 010V Monitor TP45 2 on the Comp 3 board The voltage should be zero volts 0 010V If necessary readjust the zero offset pots per section 6 12 the Torque Hold input circuit close the Remote Inhibit circuit Run the motor at a low speed 100 to 500 R P M With an oscilloscope monitor TP36 2 and TP45 2 on the Comp 3 card A sinewave whose frequency varies with speed should be present 8 0 SPEED AND CURRENT MONITORING INFORMATION The Tach Voltage may be observed at TP113 on the BDS2 MC2 board The waveform appearing at TP113 is a multiplexed composite of the resolver and brushless tach feedback signals Therefore there is a direct relationship between this waveform and the actual motor speed D C voltmeter wired into the mating connector 233 at Pin
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8. 14 with respect to Pin 16 or 17 calibrated in R P M or IN MIN etc can serve as a means by which motor speeds may be monitored Refer to the TL sheet for the system for the scale factor in volts R P M 25 The Current Monitor waveform may be observed at TP55 on the BDS2 MC2 board The waveform appearing at TP55 is a combination of the three phase stator currents and represents a RMS composite current A D C voltmeter wired into the mating connector 233 at Pin 15 with respect to Pin 16 or 17 calibrated in either current 1b ft can serve as a means by which constant load levels placed on the motor may be monitored Refer to the TL sheet for the system for the scale factor in Amps Volt average 26 e Ss qu 9 0 SPARE PARTS LIST BDS2 RECOMMENDED SPARE PARTS LIST BDS2 1 208 MODEL NUMBER DESCRIPTION BDS2 MC2 Motor Control Board A 80286 Diff Input and Current Limit Hybrid 80287 Interface Hybrid A 80288 Modulation Hybrid BDS2 Comp3 Compensation Board 80294 8 Bit Eprom 80293 R D Converter DHE1 Dual Hall Effect Board 79776 09 Prom 4 Pole Brushless Tach 238 A 79711 001 Prom 256x4 Open Collector A 79776 12 Prom BDS2 6 Pole 4 5 A 78899 013 Fuse 5 amp 125V BDS2 102 Connector Kit with crimp terminal A 80550 002 Cable Clamp Assembly 15 Position A 80550 003 Cable Clamp Assembly 25 Position A 80629 002 Receptacle Shell 15 Position A 80629 003 Receptacle Shell 25 Position A 80
9. Installation and Service Manual BDS2 1 Series Brushless Motor Controller M 8408 Issue 3 Caution Dangerous voltages exist in this equipment Do not attempt connecting or probing in this equipment with power on Should any question arise regarding any step outlined in this manua please cali the factory INDUSTRIAL DRIVES KOLLMORGEN DIVISION 4 6 0 0 TABLE OF CONTENTS DESCRIPTION l 1 1 1 2 3 Rating Standard Features Self Protection MOUNTING WIRING 3 1 Grounding Scheme 3 2 Signal Inputs and Modes of Operation PRELIMINARY CHECKS 4 4 1 22 Checking the Power Input Checking the PSRI Output Checking the Brushless Motor Phasing Checking the Resolver Phasing leroing the System Motor Resolver Brushless Tach Phasing Final Check Out Before Connecting Motor to Load CONNECTING THE N C OR C N C FINAL ADJUSTMENTS 6 6 6 1 2 3 4 Power Supply Adjustments Regen Level and Overvolts Adjustments Located on PSR1 Speed Scale Factor Adjustment With or C N C Speed Scale Factor Adjustment Manually Operated Velocity Loop Zero Adjustment 13 14 14 14 14 14 15 7 8 0 6 10 6 11 6 12 6 13 A C Gain Adjustment Current Foldback Zero Adjustment Overspeed Adjustment R D Oscillator Adjustment Triangle Wave Adjustment F V Scaling Adjustment A and Phase
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11. HECS or Hall Effect Current Sensor Board d ACS REG1 or ACS REG2 Regen Board 581 3 Heat Sink Power Stage a Thermostat b Power Transistor Paks II There are only two basic fault characteristics to be considered 1 The motor exhibits very low torque or is totally inoperative 41 2 There is motor movement but exhibits an improper mode of operation Please use caution when troubleshooting the BDS2 The recommended procedure for troubleshooting the unit is with the understanding that the Main Bus and Control Bus power supplies are functioning properly Check these sections first The Motor Exhibits Very Low Torque or is Totally Inoperative The prerequisites motor movement under full torque mode are I Fault circuits must not be activated as displayed by the LED bar graph 274 1 The correct 15V and 5V DC control voltage levels must be present at 13 23 and TP31 respectively 2 300 325VDC 10 main bus level must be present at 4 with respect to 5 of the power terminal block on the BDS2 3 The Remote Inhibit input circuit must be pulled low 4 The Direction Limit input circuits must be pulled low 5 The Thermostat mounted on the heat sink must be closed 6 There must not be a current Foldback or Overspeed Fault 7 The Option Fault input circuit if used must be pulled low 8 The Torque Hold input circuit must be pulled low 9
12. approximately 1 5 volts and 20 msec in with should occur Remove power Remove the jumper from the Regen board Check the BDS2 BD1 or VFS2 BD1 board the following manner First check the ribbon cable Note the arrows marked on both halves of the connectors The arrows should be aligned and the plugs securely in place Open the circuit breaker on the PSRI unit Apply only the 115V AC power to the BDS2 amplifier DO NOT APPLY THE MAIN BUS VOLTAGE With a DC voltmeter monitor the positive side of C14 with respect to the GND TP on A Bottom base drive circuit of the BDS BD1 board Refer to drawing C M80152 1 and Figure 2 The voltage should be 8 0V 5V Monitor the negative side of C13 The voltage should be 8 0V 5V If a VFS2 BD1 board is used monitor the positive side of C13 and negative side of C14 in the A TOP circuit Refer to drawing C 80386 1 Repeat for each of the other five base drive circuits Close the Remote Inhibit input circuit leaving the Torque Hold input circuit open Using a manual input command source battery box etc apply 1 0 volt to the input of the BDS2 22 With an oscilloscope A TOP to the GND TP of if VFS2 BD1 base drive A Bottom The waveform should appear as follows accordingly LG Have a colleague rotate the motor The waveform should vary in duty cycl the other five monitor fuse clip 10 on A Bottom Connect the scop
13. Axes Output L L RMS Voltage Output RMS Current per Phase Mechanical Configuration Panel Mount w o DB Contactor Panel Mount w DB Contactor High Powered Panel Mount w o DB Contactor Panel Mount w Cold Plate Check with Factory For Combinations of Current Ratings and No Option Connector Kit w Insulation Displacement Terminal Connector Kit w Crimp Terminal Screw Terminal Strips EXAMPLE BDS2 1 208 25 40 60 75 90 130 D 01 03 11 21 Panel Configurations E 100 101 102 103 Motor Compensation vi MODEL NUMBER SYSTEM EXAMPLE PSR1 208 040 01 BC PSRI s S Power Supply and Regen Module 805 and VFS Systems A 208 Amplifier L L RMS Voltage when using this Power Supply B 040 100 DC Output Current 40A 100A Regen Capability 0 4 5 Ohm 1000W Fused for 30 40A EXAMPLE PSR1 230 130 01 e AB 5 5 1 Power Supply and Regen Module for BDS and VFS Systems A Amplifier L L RMS Voltage when using this Power Supply 130 AC RMS Input Current 130 A RMS C Regen Capability 01 2 25 Ohm 2000 W 2 Parallel 4 5 1000 W Fused for 60 A vill POMA uos E DESCRIPTION The Industrial Drives Division BDS2 1 product lines are sinewave brushless D C
14. Control Card with an oscilloscope Adjust Pot 62 for a 7 volt peak sinewave as shown below 350 400usec 2 85 2kHz T F 6 10 Triangle Wave Adjustment Inhibit the 052 1 Open the PSRI circuit breaker Monitor TP73 with an oscilloscope Adjust Pot 118 for 9 5 volts peak Center triangle waveform around zero volts as shown below T 450 550us F 2 22 1 82Khz TP73 a For amplifiers using BDS2 MC1 or BDS2 MC2 Revision 1 Motor Control Card adjust triangle waveform as shown below T 450 550 us F 2 22 1 83 Khz P7 6 11 F V Scaling Adjustment Not on some units See Fig 1 Monitor TP95B with DC digital voltmeter Run motor to 250 RPM Adjust Pot 83A for 0 25 volt Increase motor speed 500 RPM Adjust Pot 83A for 0 5 volt Increase motor speed to 1000 RPM Adjust Pot 83A to 1 0 volt The voltage level at TP95B is scaled at 1 0 volt KRPM 6 12 A and C Phase Current Sample Offset Adjustments WARNING DO NOT ADJUST THE CURRENT FEEDBACK GAIN POTS ON THE HALL EFFECT BOARD THESE ARE FACTORY SET AND SEALED ADJUSTMENTS ONLY IF A SEAL IS EVER BROKEN RETURN THE HALL EFFECT BOARD THE FACTORY FOR ALIGNMENT OR ORDER REPLACEMENT BOARD Open the Remote Inhibit circuit Monitor TP36 2 located on the Comp 3 Card with respect to common with a DVM Adjust pot 17 located on the Dual 1 board for zero volts 0 010V If the single 5 is used adjust Pot 2 of the
15. The External Current Limit input circuit must be pulled low 10 The Green Drive Up LED 32 must be illuminated 11 Acommand signal must be present at the input of the BDS2 The Motor is Erratic or Exhibits an Improper Mode of Operation Although improper operation may be brought about by any one of almost an infinite number of possible fault modes the following troubleshooting hints will aid in locating some of the most probably faults 1 High Frequency oscillations A C Gain Pot 23 exhibited by motor located on the Comp Card turned too far CW Turn Pot 23 CCW 2 Motor makes large oscillatory BDS2 system backwards movements or runs away in Position Loop Motor moves in wrong direction Refer to section 5 0 3 Motor creeps Will not Adjust Zero Pot 114 maintain zero speed Located on large BDS2 MC2 Board Incorrect grounding scheme Refer to section 3 1 4 While at zero speed motor Check A and C phase jumps out of position or Hall Effect Current exhibits excessive cogging Sensor offset adjustment at low speed per Section 6 12 Checking the Individual Modules Basically the BDS2 is made up of the following modules 1 8DS2 MC2 Control Section C M80561 1 Figure 1 2 BDS2 8D1 or VFS2 BD1 Base Drive Section C M80152 1 C M80386 1 Figure 2 3 HECS Single or DHEI Dual Hall Effect Current Sensing Board s Figure 2 C M79087 1 C M80585 1 4 Power Transistor Paks Figure 3 BDS
16. following procedure is given in order for those wishing to do so to check the resolver phasing Open the PSRI circuit breaker Apply only the 115V AC control power Have a colleague rotate the motor shaft clockwise as viewed form the large shaft end while observing Bar Graph 277 on the BDS2 MC2 Motor Control Card See Fig 1 Rotate the motor shaft until all sections of the Bar Graph go out Using this indication as a starting point begin slowly turning the motor shaft C W As the counter counts up the first bit on the right should come on and remain on during C W rotation of the motor shaft This is the direction bit The second bit on the right represents the BCD number 2 1 is not displayed on the Bar Graph As the motor shaft is rotated C W the sections of the Bar Graph should continue to illuminate from right to left as the counter counts up until all sections are illuminated CAUTION The direction bit L E D at the extreme right hand side of Bar Graph 277 must be illuminated for clockwise rotation only as viewed from the large shaft end Otherwise the motor may run away on power up Rotate the motor shaft until all sections of the Bar Graph are illuminated Using this display as a starting point begin slowly turning the motor shaft counterclockwise as viewed from the large shaft end The first bit on the right should go out and remain out during C C W rotation of the motor shaft This is the direction bit The sec
17. 2 1 208 25 79957 BDS2 1 208 40 A 80641 8052 1 208 60 75 90 80504 8052 1 208 130 A 80644 The PSR1 power supply is made up basically of only two sections 1 The power module and main panel assembly Refer to drawing C 79924 20 LEY 7 3 1 2 ACS REG2 Regen Board C 80737 1 or the older ACS REGI Regen Board C 79668 1 Individual Module Testing Begin the simplified troubleshooting process by starting with the PSR1 power supply unit Under normal operation the Regen circuit should act to prevent main bus pump up due to energy feedback during the regeneration cycle somewhat in the following manner 1 The Red LED on the Regen board should become illuminated at 375 to 390V DC This LED will automatically go out at 355 to 365V DC usually resulting in a blinking action 2 The Regen LED in bar graph 274 on the 8052 should become illuminated at 390 to 420V DC and will remain on indicating a fault mode due to excessive regeneration activity Depress the pushbutton on the Regen Board and this LED will go out If the main bus is allowed to exceed 420V severe damage may occur Remove power Check the 30 40 amp fuse If the fuse is blown check the power transistor pak with a digital volt ohmmeter Refer to drawing C 79924 Remove the leads from the emitter and base terminals of the power transistor pak mounted on the large heatsink on the main panel and check the transi
18. 26 37 C 80453 38 C 80652 39 C 80681 40 C 80716 41 C 80718 42 79924 43 C 79668 1 44 C 80737 1 45 C M80561 1 46 50 C M80152 1 51 52 C M80386 1 53 54 C 80562 1 55 C M79087 1 56 C M80585 1 57 PREFACE This Installation and Service Manual is a general document and is applicable to the entire BDS2 1 series product line However since these motor controllers are interfaced with motors of varying sizes having different operating characteristics such as internal resistance inductance rotor inertia etc the complete model number of these amplifiers will vary more or less with the motors they are made compatible with Thus after an amplifier and a particular motor are connected together to form a complete Rate Loop system the model number applied to the amplifier nameplate is in reality the model number for the system However the PSRI Main Bus power supply will have a nameplate bearing its specific Model Number The Test Limits and Modification Sheet TL is a specific document and is applicable only to individual systems The TL Sheet contains such information as maximum operating speed peak current limits and the component compensation values which make the amplifier motor combination compatible vi MODEL NUMBER SYSTEM BDS2 1 208 25 01 100 4501AXX 8 C F Brushless Drive Sine Wave Controller Number of
19. 3 Minimize lead lengths as much as practical 4 Double check all wiring Carefully inspect all connections 5 00 NOT USE MAIN CONTACTOR FOR CONTROL FUNCTIONS IMPORTANT Motor Tachometer and Resolver phasing are critical for proper operation Grounding Scheme Refer to the appropriate System Wiring Diagram and Fig 3 It is recommended that the motor be grounded at the AMPLIFIER CHASSIS GND stud Tne 8052 1 AMPLIFIER GND stud should then be grounded at Earth or Machine ground 4 Signal Inputs and Modes of Operation The following descriptions are given to help the user decide what inputs and modes of operation to incorporate into the overall system and to identify the appropriate connecting points The External Current Limit may be utilized when external control of motor torque is desired by opening a contact between Pins 8 and 16 of Connector 233 or Points 8 and 11 of TB2 Refer to the T L Sheet for reduced current limit value The Direction Limits may be utilized when it becomes necessary to restrict the movement of a slide etc in a given direction while allowing movement in the opposite direction When a limit switch is contacted and opened between Pins 11 or 12 with respect to 16 of Connector 233 or Points 9 or 10 with respect to 11 of TB2 movement is restricted beyond the limit switch contacted while allowing movement off of the limit switch in the opposite direction Movement in the oppos
20. 630 Contact Crimp SNAP IN 22 18 AWG BDS2 1 208 25 BDS2 BD1 01 Base Driver Board A 78900 004 Fuse 1 2 Amp 250V A 80078 Thermostat A 79957 Power Transistor Module 75 MODEL NUMBER BDS2 BD1 02 A 78900 004 A 80078 A 80641 A 78782 001 BDS2 BD1 03 A 78900 004 A 29616 A 80504 A 79054 001 VFS2 BD1 78899 008 78900 005 80078 80504 VFS2 BD1 A 78899 008 A 78900 005 A 80078 A 80504 BDS2 1 208 40 DESCRIPTION Base Driver Board Fuse 1 2 Amp 250V Thermostat Power Transistor Module 100A Fan 4 115V BDS2 1 208 60 Base Driver Board Fuse 1 2 Amp 250V Thermostat Power Transistor Module 150A Fan 6 115V BDS2 1 208 75 Base Driver Board Fuse 1 1 2 Amp 250V Fuse 3 4 Amp 250V Thermostat Power Transistor Module 1504 BDS2 1 208 90 Base Driver Board 1 1 2 Amp 250V 3 4 Amp 250V Thermostat Power Transistor Module 1504 MODEL NUNBER VFS2 BD1 A 78899 008 A 78900 005 A 29616 A 80644 A 78782 001 BDS2 1 208 130 DESCRIPTION Base Driver Board 1 1 2 Amp 250V 3 4 Amp 250V Thermostat Power Transistor Module 300A Fan 4 115V 29 Launoi 35Vl1S 1OHLNOO 531935 1 25 08 L 222 212 4 zez Aeidsiq L PUQAH oe W y 9H9 uoo 1949100 662 pug H AM ul puq H 3421409 Aejdsiq aveau WA gt9Zd1 m
21. 8 25 volts Monitor TP38 and adjust Pot 26 for 6 1 volts Speed Scale Factor Adjustment With N C or C N C Monitor the INPUT HI with respect to INPUT LO with a D C voltmeter Refer to the appropriate System Wiring Diagram Command maximum traverse speed from the N C C N C Adjust the Speed Scale Factor Pot 22 located on the Comp 3 Card to obtain the input voltage level which the Control normally delivers at maximum speed DO NOT EXCEED THE MOTORS MAXIMUM RATED SPEED If the Following Error is displayed by way of readout simply adjust the Speed Scale Factor Pot for the proper amount of Following Error at any commanded speed Speed Scale Factor Adjustment Manually Operated Monitor the INPUT HI with respect to INPUT LO with a DC voltmeter Refer to the appropriate System Wiring niagram 14 7 Turn Pot 22 located the Comp 3 Card fully Apply command input signal of the desired voltage level 4 to 10 volts which represents maximum traverse speed Adjust the Speed Scale Factor Pot 22 CW for desired maximum speed DO NOT EXCEED THE MOTORS MAXIMUM RATED SPEED Velocity Loop Zero Adjustment For N C or C N C machines If the Following Error is displayed by way of readout simply adjust the Zero Pot 114 located on the Motor Control Card for zero Following Error at zero speed Optional Monitor INPUT HI with respect to INPUT 10 with a DC voltmeter Command zero spe
22. A Phase left board see Figure 2 Monitor TP45 2 located on the Comp 3 Card with respect to common with a DVM Adjust pot 18 located on the Dual DHE1 board for zero volts 0 010V If the single H E C S is used adjust Pot 2 of the C phase right board see Figure 2 17 6 13 PSR1 Circuit Breaker Adjustment ud If nuisance circuit breaker trips are experienced on power up the circuit breaker trip setting may be adjusted upward not to exceed the setting of 670 Using a screw driver push in on the adjustment screw and turn For the best protection try the lower settings first 7 0 TROUBLESHOOTING HINTS In this section it is assumed that a fault mode about the BDS2 has been confirmed or that the BDS2 has at least been identified as number one suspect in exhibiting a fault mode Some recommended equipment for troubleshooting the BDS2 amplifier is as follows 1 Adjustable signal source 0 10VDC small 9 battery with reversing input switches will do 2 Dual channel oscilloscope 3 Digital Volt Ohmmeter Before beginning the troubleshooting process consider the following points I There are three 3 distinct areas within which a fault may occur 1 External Interface a Circuitry external but connecting to the 8052 amplifier This area should already have been eliminated as a problem source 2 Control Section a BDS2 MC2 Contro Board b 8052 801 or VFS2 BD1 Base Drive Board c
23. Current Sample Offset Adjustment 5 1 Circuit Breaker Adjustment TROUBLESHOOTING HINTS 7 1 7 3 The Motor Exhibits Very Low Torque 0r Is Totally Inoperative The Motor Is Erratic or Exhibits An Improper Mode of Operation Checking the Individual Modules 7 3 1 Individual Module Testing SPEED AND CURRENT MONITORING INFORMATION SPARE PARTS LIST 15 15 15 16 16 17 17 18 18 19 20 20 21 25 27 LIST OF ILLUSTRATIONS BDS2 1 Series BDS2 MC2 Control Stage BDS2 BD1 Base Drive Board BDS2 1 Series Power Stage Motor Rear End Bell Brushless Motor Connections LIST OF DRAWINGS PSR1 208 040 and 100 Outline and Dimension BDS2 1 208 25 208 40 Outline and Dimension BDS2 1 System Wiring Diagram BDS2 1 Interconnection Wiring Diagram BDS2 1 45 Interconnection Wiring Diagram BDS2 1 21 Interconnection Wiring Diagram Liquid Cooled BDS2 1 103 System Wiring Diagram BDS2 1 103 Interconnection Wiring Diagram PSRI 208 1008208 040 Schematic ACS REG1 Regen Board Schematic ACS REG2 Regen Board Schematic BDS2 MC2 Motor Control Board Schematic BDS2 BD1 Base Drive Board Schematic VFS2 BD1 Base Drive Board Schematic BDS2 Comp3 Board Schematic HECS Single Hall Effect Board Schematic DHE1 Dual Hall Effect Board Schematic Figure 1 30 Figure 2 31 Figure 3 32 Figure 4 33 Figure 5 34 79671 35 C 80252 36 C 804
24. EPTACLE 6 02 24 195 MATING PLUG MS 3106E 24 105 CLAMP 4 20 S e L amp SOC HO SCREW 5 V E RIGID CONDUIT HUB APPLICATIONS BLOCKWASHER NUT CONNECTOR MTA RESOLVER PLATE ASSEMBLY GASKET TI Sexe LG SHOULDER SCREW RATE GASKET FLAT WASHER 3 SCR THERMOSTAT PAN SCR SPRINGWASHER ERNE TEFLON ASC u 312 0130 WIRE B MIN LENGTH CABLE CLAMP 70920 04 WHITE 6 32 A 76 4 5 82 X 3 5 LG PAN HO SCR PAN SCR 6 LOCKWASHER TERNAL TooTH EACH RES D LOCATION NSULATE LERD CON WITH SHRINK SLEEVING N N N GEAR CLAM P 1 0 q TACH 4 RESOLVER CLAMP CEPTACLE M5 3 102 22 4P 20 5 6 1 6 SOC HO SCREW RECEPTACLE 5 3 026 12 149 MATING PLUS 5 3106 22 14 5 4 LOCKWASHER RECEPTACLE A11400 z2 SYSTEMS 94 40 Na LS PAN SCREW ENNER PLATE ASSEMBLY RESOLVER HODKUP LS SHOULDER SCREW SCHEMATIC FLATWASHER URNED SPRINGWASHER CABLE CLAMP 10920 02 8 32 0130 amp LG PAN Hb SCR gt TOOTH LOCKWASHER INSTALL SHRINK ALEEVING OVER TACH RESOLVER LEADS NOTE THIS IS COMPOSITE ASSEMBLY CRAWING INTENDED TO SHOW_INTERNAL CONFIGURATION EXTERNAL CONFIGURATION SHOWN OR MAY NCT PERTAIN ANY SPECIFIC MODEL
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26. Motor Rear End Bell Figure 4 33 N C RESOLVER CONNECTIONS PIN H RED BUK VEL STATOR Rowe O YELLOW PRIMARY 3 Ri C 4 LUE RED WHT PINK Pi E APPLICATION CONNECTION FOR PLEAD RESOLVER SYSTEM CONNECTION FOR 6 LEAD RESOLVER CONNECTION DIAGRAM NEUTRAL WHITE BLACK PHASE C COMPLEMENTARY BLUE PHASE PLEMEN TARY BOBROWN 1 PHASE R COMPLEMENTARY GREEN U PHASE ORANGE PHASE RED BRUSHLESS TACH CONNECTIONS SINGLE VOLTAGE NEUTRAL WHITE PHASE IN BROWN PHPSE B GREEN PHRASE C ORANGE BROWN GREE ORANGE SINGLE VOLTAGE OPTIONAL MOTOR RECEPTACLE CONNECTION BLACK PIN 2 BROWN LEAD PIN A GREEN LEAD PIN B ORANGE LEAD PIN C BRUSHLESS MOTOR CONNECTIONS Figure 5 34 BDS2 1 RESOLVER CONNECTIONS be men 00 NOISN3AIQ wanpu auosova 234 SS aen erem O gt IE Ni NI 1 0 arue ozay 0172 35 3 nh so
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28. Open the TORQUE HOLD circuit Apply power 3 Enable the 8DS2 1 Place a command voltage at the input so that the motor turns CW at approximately 100 RPM The correct scope trace should be POSITIVE at a smooth D C level If not proceed to step 4 4 With Channel 1 of the oscilloscope monitor 2648 the BDS2 MC2 Motor Control Card With channel 2 monitor B phase of the tach at TP181A See Figure 1 Run the motor slowly CW and check that the signals are 180 degrees out of phase as shown below If the waveforms are not as shown REMOVE POWER and loosen the two screws holding the tach stator in place Rotate the stator and tighten the screws Apply power and recheck waveforms Repeat this procedure until waveforms are as shown below CAUTION DO NOT PUT HANDS IN MOTOR WITH POWER ON 5 With motor rotating CW check that the tach phasing is as shown below If phasing is not as shown tach is connected incorrectly either at amplifier or in the motor Correct tach wiring error Phase A Phase B Phase C Phase D Phase E Phase F 12 6 Recheck TP9 on the Comp 3 Card to verify that the tach signal is now a smooth POSITIVE D C voltage for CW rotation Final Check Out Before Connecting Motor to Load Perform the final check Out in the following manner 1 Connect the adjustable manual signal source to the input of the BDS2 1 and set for 0 volts in 2 Apply power Enable BDS2 1 and cl
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30. board in the following manner Refer to drawing C M80561 1 and Figure 1 Open the circuit breaker on the PSR1 unit Close the Remote Inhibit input circuit and open the Torque Hold input circuit Only the 115V AC power should be applied Connect a jumper between 8 and 9 of the power terminal block on the BDS2 amplifier to defeat the Regen fault circuit due to the absence of the main bus voltage Remove and reapply the 115V AC power to reset any fault circuits If there are any fault s which can not be cleared or if a fault persists in reoccuring check to be sure that all of the prerequisites for the Drive Up mode are met per section 7 1 If the prerequisites for the Drive Up mode are present and no legitimate fault mode can be confirmed while one or more section s of diagnostic bar graph 274 is illuminated then in all probability the defect lays with the input connectors or fault circuits located on the BDS2 MC2 board The control bus at TP13 and TP23 should be 15V DC 0 05V with respect to common The control bus at TP31 should be 5V DC 0 2V with respect to common TP13A Reference all DVM and scope reading to on the BDS2 MC2 board unless stated otherwise With oscilloscope monitor TP52 located in the resolver excitation circuit The waveform should appear as shown in section 6 9 With scope monitor TP157 located in the system clock circuit The waveform should appear as follows
31. e common A TOP if VFS2 BD1 circuit s _ Ld L d 88V shaft slowly by hand Repeat for each of se drive circuits Move Scope gnd If any of the BDS2 BDI or VFS2 BD1 fuses are blown or if any of the base drive circuits remove the power and check the associated with the base drive sec tion that the large capacitors have discharged Remove the connections from the aff With a DVM in the diode test mode transistor pak by placing the RED and BLAC meter on the designated points according t pak chart DVM LEAD 82 C2 C2 Red Red Black Black Black Red Red Red Black Black El Black 1 Red Red Red Black Black Black Red POWER TRANSISTOR TEST CHART BDS2 1 208 25 a lt gt 240 6 0 7 to to to to to to to to to to to to 2 1 2 2 1 2 2 2 BDS2 1 208 130 to to to to to to 23 DVM LEAD Black Black Red Red Red Black Black Black Red Red Red Black Black Black Red Red Red Black on u i H Hl prove to be defective power transistor pak Check to be sure ected power transistor check the power K probes of the the following LOW LOW HIGH LOW LOW HIGH LOW LOW HIGH LOW LOW HIGH LOW LOW HIGH LOW LOW HIGH Check the large BDS2 MC2
32. e mounted in their horizontal up right positions CAUTION Allow sufficient clearance for the large regenerative heat producing resistor mounted at the upper edge of the PSR1 unit 1 It is recommended that the BDS2 1 not be mounted behind the front center sections of the cabinets otherwise the amplifiers swingout unit will be blocked and access to its internal area will be restricted WIRING Refer to the appropriate System Wiring Diagram and Fig 1 2 3 4 and 5 IN ORDER TO ADHERE TO SUITABLE ENGINEERING PRACTICES IT IS RECOMMENDED THAT THE CONTROL VOLTAGE BE APPLIED FIRST IN ORDER TO ACTIVATE THE CONTROL AND FAULT CIRCUITS BEFORE APPLYING THE MAIN BUS VOLTAGE There are two package configurations The first of which the control interface wiring is brought directly to Connectors 180 and 233 of the Large Motor Control Card BDS2 MC2 Standard See Figure 1 C 80252 and C 80426 The second configuration of which the control interface wiring is brought to terminal blocks mounted on the end side of the package 103 series See Figure 2 and C 80716 Reference to the NOTES on the appropriate System Wiring Diagram will aid in correctly wiring the system up The following precautions are recommended 1 Twist all AC leads to minimize electromagnetic emissions and pick up Avoid running signal leads in close proximity to power leads armature leads or other sources of electromagnetic noise
33. ed from the or C N C Adjust the Zero Pot 114 for zero volts on the meter i With the input signal at zero volts simply adjust Pot 114 for zero speed A C Gain Adjustment In many cases Pot 23 located on the Comp 3 Card may be turned fully CCW and disregarded However if necessary the AC Gain Pot can be used to improve tae dynamic response of the servo loop To increase the AC Gain monitor the brushless tach signal at TP9 on the Comp 3 Card Apply a step input command and while accelerating and decelerating the motor at approximately 25 of maximum speed Adjust the AC Gain Pot 23 CW and watch for indications of instability in the tach waveform Turn Pot 23 back CCW until the tendency to go unstable diminishes CAUTION INCREASING THE AC GAIN TOO MUCH MAY CAUSE THE SYSTEM TO GO UNSTABLE Current Foldback Zero Adjustment Inhibit the BDS2 1 Open the PSR1 circuit breaker Place a jumper from TP55 to 1 Monitor 193 with a DC voltmeter Adjust Pot 216 located on the Motor Control Card for zero volts at TP193 Remove jumper Overspeed Adjustment Turn Overspeed Pot 33 located on the Comp 3 Card fully CM Run the motor at maximum speed DO NOT EXCEED THE MAXIMUM SPEED SPECIFIED BY THE TL SHEET Adjust Pot 33 slowly CCW until the system just shuts down Adjust Pot 33 back 1 1 2 turns CW 15 6 9 R D Oscillator Adjustment Inhibit the BDS2 1 Open the PSR1 circuit breaker Monitor TP52 on Motor
34. he Bar Graph 277 Tighten the motor gear clamp Recheck that all L E D s are still on This is the resolver zero point Remove power Replace the motor end bell cover Reconnect the motor stator lead to point 1 of the power terminal block Remove all jumpers Close the TORQUE HOLD circuit HINT There are three points located 120 mechanical degrees apart where the motor torque goes to minimum The point where the reference mark on the motor shaft faces the motor 1 0 port is the only one to which the motor system resolver may be zeroed for proper operation If rotating the motor shaft by hand is difficult apply less input signal If the motor torque 10 5 dead point cannot be felt increase input signal IMPORTANT Input signal must always make TP18 on Comp 3 Card NEGATIVE for proper operation See Figure 1 4 6 Brushless Tach Phasing If the brushless tach is wired according to the appropriate System Wiring Diagram the phase sequence will automatically be correct However the following procedure is given in order for those wishing to do so to check the tachometer phasing The motor system resolver must be properly zeroed before checking tachometer phasing Refer to Section 4 5 To check the tach phasing do the following 1 Remove power Connect the adjustable manual signal source to the input of the BDS2 1 and set for 0 volts in 2 With an oscilloscope monitor TP9 on the Comp 3 Card
35. ite direction will be restricted when the other limit switch is contacted and opened The Remote Inhibit allows a means by which the amplifier may be disabled without removing the main power When a contact is closed between Pins 10 and 16 of Connector 233 or between Points 5 and 11 of TB2 the amplifier will be put into the Drive Up mode Opening the contact will Inhibit the amplifier The Drive Up contact closure internally is provided at Pins 3 and 4 of Connector 233 or Points 3 and 4 of TB2 and when closed is an indication to the outside world software etc that the amplifier is in its Drive Up mode or when open is an indication that it is in the Inhibit mode These contacts are rated at 115V AC at 2 amps The Torque Hold mode of operation can be utilized when the motor is required to dwell against hard stops or operate in a tension control system Opening a contact between Pins 6 and 16 of Connector 233 or Points 7 and 11 of TB2 will convert the amplifier from a constant velocity to constant torque system The Input Reference Signal not to exceed 10 volts is applied to the amplifier at Pin 5 with respect to 7 of Connector 233 or Point 1 with respect to 2 of TB2 4 Signal_and Shield Commons are provided at Pins 16 17 19 20 of Connector 233 or points 11 and 12 of TB2 providing adequate points without overloading pins or terminal points The Velocity Output signal may be monitored at TB2 13 with res
36. ity and less motor maintenance since there is no commutator or brushes 6 Smooth output torque even at very low speeds due to sinusoidal current control There are no torque pulsations at low speeds 7 Minimized motor heating due to the absence of harmonics which are normally associated with stepping waveforms 8 The BDS2 1 sine wave controller allows for a wider speed range because of the ability to electronically change the angle between the rotor flux and the stator flux commonly known as the torque angle 9 The BDS2 1 sine wave controller has the capability to dynamically and adaptively change the torque angle as a function of speed and load thus allowing the system to operate at the most efficient operating point 1 1 Ratings 5 1 RATINGS INPUT VOLTAGE OUTPUT CURRENT OUTPUT VOLTAGE MODEL NO L L RMS CONTINUOUS DC DC PSR1 208 040 208V AC 40 300V PSR1 208 100 208V AC 100A 300V PSR1 230 130 230V AC 130A 325V BDS2 1 RATINGS OUTPUT RMS PHASE CURRENT OUTPUT VOLTAGE MODEL NO CONTINUOUS RMS PHASE PEAK RMS PHASE NO LOAD 8052 1 208 25 25 50 200 BDS2 1 208 40 40 10 200V BDS2 1 208 60 60A 105A 200 BDS2 1 208 75 75 105 200 BDS2 1 208 90 90A 1053 200V BDS2 1 208 130 130A 185 200V INDUSTRIAL DRIVES DIVISION KOLLMORGEN CORPORATION Patent Numbers 4447771 and 4490661 In an improved motor control system for a pulse width modulated synchronous brushless motor means for adapti
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38. machine If it is determined that the direction of rotation of the IDD motor is reversed or runs in the wrong direction remove power and remove jumper JR27 and install jumper JR26 on the Comp 3 card See Figure 1 13 6 6 0 1 FINAL ADJUSTMENTS Refer to Figure 1 With exception to the Speed Scale Factor Pot 22 the AC Gain Pot 23 the Overspeed Pot 33 and the Velocity Loop Zero Pot 114 the adjustments are factory set and sealed and should not require adjustment The following procedures are given only in the event of component or card replacement or in the event the seals are unintentionally broken Reseal all pots after adjustment WARNING DO NOT ADJUST THE CURRENT FEEDBACK GAIN POTS LOCATED ON THE HALL EFFECT CARDS THESE ARE FACTORY SET AND SEALED ADJUSTMENTS ONLY IF A SEAL IS EVER BROKEN RETURN THE HALL EFFECT CARD TO THE FACTORY FOR ALIGNMENT OR ORDER A REPLACEMENT CARD See Figure 2 Power Supply Adjustments With a DC voltmeter monitor the 15 volt test point TP13 with respect to TP13A on the Motor Control Card Adjust Pot 5 for 15 volts 0 1V Monitor the 15 volt test point TP23 Adjust Pot 15 for 15 volts 40 1 volts Regen Level and Overvolts Adjustments Located on PSR1 Monitor TP27 on the ACS REG2 module with a DC voltmeter Adjust Pot 19 for 8 25 volts With D C voltmeter monitor TP4 and adjust Pot 20 for 6 1 volts If ACS REG1 C 79668 1 monitor TP30 and adjust Pot 27 for
39. motor controllers They are fully regenerative four quadrant bi directional velocity loop amplifiers designed to be used with Industrial Drives high performance brushless D C motors The D C brushless motor consists of a six pole rare earth permanent magnet rotor and a three phase Y connected stator winding Being a brushless motor there is no commutator or associated brushes The motor is run as a synchronous motor meaning that the rotor speed is the same as the speed or frequency of the rotating stator magnetic field A brushless tach and a resolver are utilized as feedback devices and are mounted internally as part of the overall motor construction An unregulated 300 325V DC bus derived from full wave rectification of a three phase 208 230 AC line by the PSRI Power Supply unit is used to power the BDS2 1 motor controller A shunt regulator or regen module located within the PSRI unit is used to prevent the bus from being bumped up during periods of regeneration Benefits resulting from the BDS2 1 and brushless motor construction are 1 Lower rotor inertia permits higher acceleration rates 2 The motor is thermally more efficient since all heat is generated in the stator windings which are located in the outside shell of the motor 3 Higher speed operation and high peak horsepower are achieved since there is no commutation limit 4 Smaller physical motor size for a given H P rating 5 Higher reliabil
40. ond bit on the right represents the BCD number 2 1 is not displayed As the motor shaft is rotated CCW the sections of the Bar Graph should continue to go out The illuminated sections should now move from left to right as the counter counts down At the end of one complete revolution all sections should be out The LSB is the second indicator on the right end of the Bar Graph yee lt One mechanical revolution of the motor shaft 360 equals 1024 counts as indicated by the Bar Graph as shown below the 1 count is not displayed Remove the 115V AC control power Direction Bit Must Be Illuminated for CW Rotation of Motor Shaft As Viewed From The Large Shaft End 4 5 Zeroing the System Motor Resolver WARNING DO NOT DISTURB THE SYSTEM MOTOR RESOLVER CAUTION DO NOT MISTAKE THE SYSTEM MOTOR RESOLVER FOR THE APPLICATION POSITION LOOP RESOLVER The SYSTEM motor resolver has to do only with the Industrial Drives BDS2 1 Velocity Loop Motor Controller This resolver has been factory set at its ZERO POINT and should never require adjustment However the following procedure is given in the event of resolver replacement or in the event the resolver is unintentionally moved off of its zero setting See Figure 4 and 5 To set the Industrial Drives SYSTEM motor resolver to its zero point do the following 1 Remove the 115V AC control voltage Open the PSRI circuit breaker 2 Connect
41. ose the TORQUE HOLD circuit Using the adjustable DC signal source and starting with a small input signal apply a command to the input of the amplifier Run the motor first in one direction then the other Have an assistant help observe the operation of the motor The motor should accelerate and decelerate with quick crisp response and run with constant speed for any given input signal level Gradually increase speed while exercising the motor until maximum speed is obtained Adjust the Scale Factor Pot 22 on the Comp 3 Card CW to increase speed if necessary See Figure 1 DO NOT RUN THE MOTOR IN EXCESS OF THE MAXIMUM SPEED SPECIFIED BY THE TL SHEET FOR THE SYSTEM 3 Command zero speed Adjust Scale Factor Pot 22 on the Comp 3 Card fully CCW See Figure 1 Apply input signal equal to the amount that the N C normally delivers for maximum motor speed Adjust Pot 22 on the Comp 3 Card CW for the same maximum speed Command zero speed from the input source CONNECTING THE N C OR C N C Remove the power Remove the DC signal source and connect the Control input signal Connect the load to the motor shaft CAUTION INCORRECT SERVO TO POSITION LOOP PHASING CAN CAUSE LARGE EXCURSION OSCILLATIONS OR RUNAWAYS Appropriate precautions should be taken to stop the machine if necessary Slides etc should be moved a reasonable distance away from hard stops before applying power Apply power enable the BDS2 1 and observe the action of the
42. pect to 2 12 103 Series Only There is a direct relationship between this voltage level and the actual motor speed in R P M Refer to the T L Sheet for Scale Factor in Volts R P M Refer to section 8 0 PRELIMINARY CHECKS Refer to the appropriate System Wiring Diagram Once the BDS2 1 system has been installed and wired in The initial start up should be done with the load and control command disconnected Disable the if necessary to prevent automatic shutdown The following equipment will be required 1 Adjustable Signal Source 0 10V DC at 10ma 2 Multimeter 3 Oscilloscope 4 Channel Checking the Power Input Open the circuit breaker on the PSR1 Power Supply A a power to the primary of the large input 1501 transformer t The 3 phase secondary line to line voltage should be either approximately 208 230V RMS depending on PSRI Model 10 at the line side of the PSRI Circuit Breaker If the voltage is above or below the rated voltage by more than 10 please select another transformer tap Checking the PSRI Output Remove the main power Remove the D C bus leads at 4 and 5 of the Power Terminal Block on the BDS2 1 Monitor the lead formerly connected to terminal 4 with respect to the lead formerly connected to terminal 5 Apply the main power This voltage should be approximately 300 325V DC depending on PSR1 Model Open the circuit breaker CAUTION Wait 3 minutes for large Power S
43. stor unit per the following chart PSRI POWER TRANSISTOR TEST CHART DVM DVM LEAD LEAD APPROX Red to C Black LOW 5V Red to E Black LOW 1V B Black to C Red HIGH open B Black to E Red LOW 1V C Black to E Red LOW 4V E Black to C Red HIGH open Reconnect the two leads if removed at the emitter and base terminals of the power transistor Install a jumper between TP7 and TP31 of the ACS REG2 board C 80737 1 or TP20 and 34 of the older ACS REGI board C 79668 1 to disable the output transistor pak Mounted on the large heatsink on the main panel Open the Remote Inhibit and the Torque Hold input Circuits Apply power 21 With a DC voltmeter monitor 3 with respect to 4 on the power terminal block of the PSRI The main bus voltage should be 300 325 15 Observe the bus current with a DC current probe around the positive output lead at 4 the current should not exceed 40 ma Monitor TP28 on the ACS REG2 TP33 on the older ACS REG1 The voltage should be 13 0 16 5V DC Monitor TP27 on the ACS REG2 It should be 48 25 volts Also monitor TP4 It should be 6 1 volts If ACS REGI board is used monitor TP30 and TP38 The voltage levels should be the same as ACS REG2 board Refer to section 6 2 With an oscilloscope monitor 3 with respect to 4 on the Regen board terminal block Refer to C 79924 1 Depress the test button on the Regen board and a pulse of
44. the adjustable manual signal source to the input of the BDS2 1 and set for 0 volts in 3 Open the REMOTE INHIBIT and TORQUE HOLD circuits 10 11 12 Temporarily place a jumper from TP188 to TP190 on the BDS2 MC2 Motor Control Card See Figure 1 Remove the motor stator lead from point 1 of the BDS2 1 power terminal block and temporarily tape its end up Remove the rear end bell cover from the motor to allow access to the resolver cavity Refer to Figure 4 Locate the black 0 12 in long reference mark stamped on the motor shaft between the tachometer and the motor gear Rotate the motor shaft so that the reference mark is positioned facing the motor 1 0 port Refer to Figure 4 Loosen the motor gear clamp to allow the entire gear train to be turned independent of motor shaft position Apply the 115V AC power and close the PSRI circuit breaker Close the INHIBIT circuit to enable the BDS2 1 Leave the Torque Hold Circuit Open Apply small amount of input signal so that TP18 on the Comp 3 Card is negative 1 0 volt Rotate the motor shaft to locate the nearest zero torque point It should be very near the point where the motor shaft orientation places the reference mark facing the motor I 0 port With the reference mark on the motor shaft facing the motor I 0 port secure the shaft at the center of the low torque point and rotate the motor gear DO NOT MOVE THE SHAFT until all L E D s are illuminated on t
45. upply capacitors to discharge Reconnect the D C bus wires to the Power Terminal Block on the BDS2 1 so that terminal 4 remains positive with respect to 5 3 Checking the Brushless Motor Phasing Refer to Figure 4 and 5 The motor should be connected to the amplifier so that a phase sequence of ACB will result in a CW direction of rotation as viewed from the large shaft end Refer to the appropriate System Wiring Diagram If the motor stator is wired according to the System Wiring Diagram the phase sequence will automatically be correct However the following procedure is given in order for those wishing to do so to check the motor phasing Remove power Connect one end of a lk resistor to terminals 1 2 and 3 of the BDS2 1 power terminal block with the motor stator leads connected Connect the free ends of the lk resistors together to form a simulated three phase neutral With an oscilloscope monitor the motor stator leads with respect to the neutral of the resistors in the following manner CHANNEL 1 to TB 1 CHANNEL 2 to TB 3 CHANNEL 3 to TB 2 Have a colleague rotate the motor shaft clockwise as viewed from the large shaft end The waveforms should appear as shown below Remove the resistors ov CH 120 OV OV Checking the Resolver Phasing If the resolver is wired according to the appropriate System Wiring Diagram the phase sequence will automatically be correct However the
46. vely controlling the torque angle 1 6 the angle between the rotating magnetic field created by the permanent magnets on the rotor is provided The relationship between the two magnetic fields is controlled as a function of load and speed to provide the optimum operating point at all times Controlling the torque angle effectively varies the back EMF constant Kg V RPM and the torque constant K torque ampre of the motor 2 T Standard Features Packaged for ease and quickness of service using built in diagnostic features Accurate digital control of motor dynamics achieved through Industrial Drive Division s SELF SYNCHRONOUS motor control concept Improved dynamic response due to wide band current loop utilizing isolated feedback for increased personnel and equipment safety Smooth operation down to zero speed Self Protection The BDS2 1 amplifiers are fully protected against a variety of fault conditions for a high degree of reliability Fault modes are identified by a diagnostic bar graph indicator 274 as shown below 1 POWER LOSS Control Bus 6 FOLDBACK Peak Current 2 OVERTEMP Heat Sink Thermostat 7 DIRECTION LIMIT 3 OVERSPEED Excessive Speed Shut down 8 OPTION Fault 4 REGEN Excessive Loss Main Bus 9 NOT USED 5 REMOTE INHIBIT 10 NOT USED MOUNTING Refer to the appropriate Outline and Dimension Drawing It is recommended that the 8052 and PSR1 units b

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