BD5/10 Brushless DC Motor Drive - applied …

1 Hardware ManualBD5/10 Brushless DC Motor Drive920-0065F1/29/20182BD5/10 Drive Hardware Manual920-0065F1/29/2018 ContentsSafety Instructions ..3 Introduction ..4 Features ..5 Block Diagram ..6 Getting Started ..7 Drive the Power Supply ..9 External (Line) Fuse Supply Voltage Inrush Limiting ..11 Connecting the ..13 Dip Switches ..13 Inputs and Outputs ..14I/O Connector Pin Diagram ..14 Motor Test ..15 Input/Output Connector Wire Colors ..15 Input Signals ..16 Analog Input (AIN) ..17 Output Signals ..17 Digital Input Circuit ..18 Analog Input Circuit ..18 Wiring an External Speed Potentiometer ..19 Digital Output Circuit ..19 Connection diagrams: ..20 Control wiring for sinking signals with an external power source.: ..20 Control wiring for sourcing signals from an external power source:..21 Control wiring for sinking signals using the drives internal power supply: ..22 Control wiring for sourcing signals using the drives internal power supply.

2 23 Reference Materials: ..24 Motor Mechanical Outline - 42mm ..24 Motor Mechanical Outline - 57mm ..25 Motor Mechanical Outline - 80mm ..2642mm BL030 Speed Torque Curve ..2742mm BL060 Speed Torque Curve ..2742mm BL090 Speed Torque Curve ..2857mm BL060 Speed Torque Curve ..2857mm BL120 Speed Torque Curve ..2957mm BL180 Speed Torque Curve ..2980mm BL100 Speed Torque Curve ..3080mm BL200 Speed Torque Curve ..3080mm BL300 Speed Torque Curve ..31BD5/10 Drive Mechanical Outline ..32 Technical Specifications - Drive ..33 Technical Specifications - Motors ..34 Mating Connectors and Accessories ..35 Connector Diagrams ..35 LED Error Codes ..36 Contacting applied Motion Products ..363BD5/10 Drive Hardware Manual920-0065F1/29/2018 Safety Instructions Only qualified personnel are permitted to transport, assemble, commission, and maintain this equipment. Prop-erly qualified personnel are persons who are familiar with the transport, assembly, installation, commissioning and operation of motors, and who have the appropriate qualifications for their jobs.

3 The qualified personnel must know and observe the following standards and regulations:IEC 364 resp. CENELEC HD 384 or DIN VDE 0100 IEC report 664 or DIN VDE 0110 National regulations for safety and accident prevention or VBG 4To minimize the risk of potential safety problems, you should follow all applicable local and national codes that regulate the installation and operation of your equipment. These codes vary from area to area and it is your responsibility to determine which codes should be followed, and to verify that the equipment, installation, and operation are in compliance with the latest revision of these damage or serious injury to personnel can result from the failure to follow all applicable codes and standards. We do not guarantee the products described in this publication are suitable for your particular ap-plication, nor do we assume any responsibility for your product design, installation, or operation. Read all available documentation before assembly and commissioning.

4 Incorrect handling of products in this manual can result in injury and damage to persons and machinery. Strictly adhere to the technical information on the installation requirements. It is vital to ensure that all system components are connected to earth ground. Electrical safety is impossible without a low-resistance earth connection. The BD5/10 contains electrostatically sensitive components that can be damaged by incorrect handling. Dis-charge yourself before touching the product. Avoid contact with high insulating materials (artificial fabrics, plastic film, etc.). Place the product on a conductive surface. During operation keep all covers attached, otherwise, there are deadly hazards that could possibility cause severe damage to health or the product. In operation, depending on the degree of enclosure protection, the product can have bare components that are live or have hot surfaces. Control and power cables can carry a high voltage even when the Motor is not rotating.

5 Never pull out or plug in the product while the system is live. There is a danger of electric arcing and danger to persons and contacts. After powering down the product, wait at least ten minutes before touching live sections of the equipment or undoing connections ( , contacts, screwed connections). Capacitors can store dangerous voltages for long 4BD5/10 Drive Hardware Manual920-0065F1/29/2018periods of time after power has been switched off. To be safe, measure the contact points with a meter before alert to the potential for personal injury. Follow the recommended precautions and safe operating practices. Safety notices in this manual provide important information. Read and be familiar with these instructions before attempting installation, operation, or maintenance. The purpose of this section is to alert users to possible safety hazards associated with this equipment and the precautions that need to be taken to reduce the risk of personal injury and damage to the equipment.

6 Failure to observe these precautions could result in serious bodily injury, damage to the equipment, or operational you for selecting an applied Motion Products BD Drive . We hope our dedication to performance, qual-ity and economy will make your motion control project BD5/10 is a DC powered Brushless DC Drive , with advanced control technology, excellent performance and ease of you have any questions or comments, please call applied Motion Products Customer Support: (800) 525-1609, or visit us online: Drive Hardware Manual920-0065F1/29/2018 Features Velocity modes controlled via analog input, digital input or on board trimpot 150 - 4500 rpm continuous, 5000rpm peak. Speed tolerance: (valid over temp range 0 to +40 C) Acceleration rate set by on board trimpot. Power supply: 12-48 VDC Current output: BD5-G1-AH peak (5 sec max) BD5-G2-AH cont/7 Arms peak (5 sec max) BD5-G3-AH peak (5 sec max) BD5-H2-AH peak (5 sec max) BD10-H4-AH peak (5 sec max) BD10-H5-AH peak (5 sec max) BD5-I6-AH peak (5 sec max) BD10-I7-AH 10 Arms cont/20 Arms peak (5 sec max) BD10-I8-AH cont/15 Arms peak (5 sec max) Motors Currently Offered: BL030-H03-G, 42MM, 30W, 24V BL060-H03-G, 42MM, 60W, 24V BL090-H03-G, 42MM, 90W, 24V BL060-H03-H, 57MM, 60W, 24V BL120-H03-H, 57MM, 120W, 24V BL180-H04-H, 57MM, 180W, 48V BL100-H03-I, 80MM, 100W, 24V BL200-H04-I, 80MM, 200W, 48V BL300-H04-I, 80MM, 300W, 48V Protection against over voltage; under voltage.

7 Over temperature, short circuit(phase to phase, phase to ground), bad Hall signal Inputs & Outputs one 0-5V analog input eight 5-24V single-ended digital inputs, can be configured for sinking or sourcing two differential digital outputs all digital inputs and outputs are optically isolated Compact size: 100 65 30mm Available with nine performance matched, BLDC motors: 30 to 300 watts continuous output. CE pending and RoHS compliant6BD5/10 Drive Hardware Manual920-0065F1/29/2018 Block DiagramAMPLIFIER12-48 VDCfrom external power supplyStatus LEDsSTOPENABLESTOPMODEDIRSPEEDSELM0M1M2 FAULT OUTSPEED INDSPV oltageSensors1234 OptoisolatorConfiguration7BD5/10 Drive Hardware Manual920-0065F1/29/2018 Getting StartedTo use the Drive model BD5/10 , you should have the following: A DC power supply (12-48V ) A compatible Motor A small flat blade screwdriver for tightening the connectors. A screwdriver suitable for this purpose is included with your Drive Mating I/O cable connector with 12-inch flying leadsThe photograph shows the location of important connection and adjustment points.

8 Please examine it LEDsSpeed Adjustment PotAccel Adjustment PotI/O ConnectorMotor Feedback ConnectorMotor Power ConnectorGrounding ScrewPower Supply ConnectorDIP Switches(Remove cover to access)8BD5/10 Drive Hardware Manual920-0065F1/29/2018 Drive MountingYou can mount your Drive on the narrow side of the chassis using #6 screws. The Drive should be securely fas-tened to a smooth, flat metal surface that will help conduct heat away from the chassis. If this is not possible, then forced airflow from a fan may be required to prevent the Drive from overheating. Never use your Drive in a space where there is no air flow or where the ambient temperature exceeds 40 C. Never put the Drive where it can get wet. Never allow metal or otherwise conductive particles near the are in millimeters9BD5/10 Drive Hardware Manual920-0065F1/29/2018 Connecting the Power SupplyThe BD5/10 accepts a DC power supply voltage from 12 to 48V. Using the connector supplied and AWG16 or 18 wire, connect to the power supply as shown below:Be careful not to reverse the wires.

9 Reverse connection may destroy your Drive .+DC-DCTo Earth GroundGroundingScrewFUSELINE FILTER(OPTIONAL)Locate an optional line filter adjacent to the Drive for full CE complianceExternal (Line) Fuse CriteriaWe recommend the Bussman ABC series of fast-blo, ceramic body fuses. For all DC supply currents up to 9A (this includes peak values) use the ABC-12-R This is a 12A fast-blo ROHS all currents above 9A (this includes peak values) use the ABC-15-R. This is a 15 A fast-blo ROHS internal fuse is not user-replaceable, if tripped, the unit must be returned for Drive Hardware Manual920-0065F1/29/2018 Power Supply Voltage RequirementNormal operating range: 12 to 48 VDCO vervoltage shutdown: 62 alarm: VDC. Undervoltage shutdown: 6 Supply Current RequirementTo determine the size of the power supply you will need for your application, use one of the formulas below to calculate the rating of the power supply in Watts. Remember to use the peak torque value which typically occurs during acceleration.

10 Note that these formulas include a 35% safety factor to account for the efficiency of the Motor and torque in oz-in and speed in rpm:Rating of power supply in Watts = Torque * Speed / 1000 For torque in N-m and speed in rpm:Rating of power supply in Watts = Torque * Speed / 7 Examples:1. The application requires 35 oz-in maximum at a top speed of 1200 rpm. (35 oz-in) * (1200 rpm) / 1000 = 42 Watts2. The application requires maximum at a top speed of 3600 rpm. ( N-m) * (3600 rpm) / 7 = 206 Watts Note: The PS320A48 power supply from applied Motion is rated for 320 Watts and would be a good choice for this Motion Products currently offers the following power supplies:MOTORP O W E R - WAT T SPOWER SUPPLYBL030-H03-G30PS150A24BL060-H03-G60 PS150A24BL090-H03-G90PS320A48BL060-H03-H 60PS150A24BL120-H03-H120PS320A48BL180-H0 4-H180PS320A48BL100-H03-I100PS320A48BL20 0-H04-I200PS320A48BL300-H04-I300N/A11BD5 /10 Drive Hardware Manual920-0065F1/29/2018 Current Inrush Limiting Power input to Drive has no provision for current inrush limiting.