Brushless DC Drive - servosystems.com

1 For Catalog Nos. BMC6A01, BMC6A02,BMC6A04, BMC6A05, BMC2A06, BMC2A09 Brushless DC DriveInstallation and Operating ManualMN1365 TABLE OF CONTENTSS ectionPage1 Introduction .. 4 Safety Notice .. 72 Quick-Start Instructions .. 83 Mounting Instructions ..144 Finger-Safe Cover ..145 Electrical Connections Instructions ..146 Setting Selectable Jumpers ..217 Trimpot Adjustments ..258 Drive Operation ..289 Troubleshooting ..29 Baldor District Offices ..35 Limited Warranty ..36 TablesPage1 Standard Features .. 42 Performance Features .. 43 Protection Features .. 54 Trimpot Adjustments .. 55 Optional Accessories .. 56 Electrical Ratings and Features .. 57 General Performance Specifications .. 68 Terminal Block Wire and Tightening Torque Specification ..159 J1 Settings for AC Input Voltage and motor Voltage Choices ..2110 motor Pole Count ..2311 Troubleshooting Guide ..2912 Fault Recovery and Resetting the Drive ..3013 Drive Operating Condition and Status LED Indicator.

2 31 FiguresPage1 Catalog Nos. BMC6A01, BMC6A02, BMC6A04, BMC6A05 Quick-Start Connection Diagram .. 92 Catalog Nos. BMC2A06, BMC2A09 Quick-Start Connection Diagram ..103 Hall Isolator Board Layout ..114 Catalog Nos. BMC6A01, BMC6A02 Mechanical Specifications and Drive Layout ..115 Catalog Nos. BMC6A04, BMC6A05 Mechanical Specifications ..126 Catalog Nos. BMC2A06, BMC2A09 Mechanical Specifications (Inches/mm) and Drive Layout .. 137 AC Line Input, motor , and Ground Connections ..168 Hall Sensor Connection ..179 Unidirectional Operation Main Speed Potentiometer Connection ..1810 Bidirectional Operation Main Speed Potentiometer Connection ..1811 Unidirectional Operation (Shown with Forward Run Switch) ..1812 Bidirectional Operation (Shown with Run Switch) ..1813 Automatic Start (Jumper Installed) ..1914 manual Start Switch Connection ..1915 Forward-Stop-Reverse Switch (Shown with Main Speed Potentiometer) ..2016 Form C Contact or Relay Forward-Stop-Reverse (Shown with Main Speed Potentiometer).

3 2017 Open Collector Forward-Stop-Reverse Connection (Shown with Main Speed Potentiometer) ..2018 Forward Run Switch Connection (Shown with Main Speed Potentiometer) ..2119 Reverse Run Switch Connection (Shown with Main Speed Potentiometer) ..2120 Catalog Nos. BMC6A01, BMC6A02, BMC6A04 AC Line Input Voltage Selection ..2221 Catalog No. BMC6A05 AC Line Input Voltage Selection ..22iiTABLE OF CONTENTS (Continued)FiguresPage22 Removing J1 for Catalog No. BMC6A05 ..2223 Decel Extend Enable/Disable Selection ..2224 Hall Sensor Phasing Selection ..2325 motor Poles Selection ..2326 Coast-to-Stop (Non-Braking) During Deceleration ..2327 Adjustable Braking During Deceleration (2Q Braking Mode) ..2428 Calibration in the 4Q Braking Mode ..2529 Dynamic Braking During Deceleration (4Q Braking Mode) ..2530 Maximum Speed Trimpot Setting ..2631 Main Speed Potentiometer Range ..2632 Acceleration Trimpot Range ..2733 Deceleration Trimpot Range ..2734 Response Trimpot Range ..2735 Catalog No.

4 BMC6A01 Current Limit Trimpot Range ..2836 Catalog No. BMC6A02 Current Limit Trimpot Range ..2837 Catalog No. BMC6A04 Current Limit Trimpot Range ..2838 Catalog No. BMC6A05 Current Limit Trimpot Range ..2839 Catalog No. BMC2A06 Current Limit Trimpot Range ..2840 Catalog No. BMC2A09 Current Limit Trimpot Range ..2841 Available Torque vs. Speed ..28iii41 INTRODUCTIONT hank you for purchasing the Brushless DC Drive . This Drive is UL Listed for US andcUL for Canada and is RoHS Brushless DC Drive provides the best of DC control by providing extended constanttorque speed range, accurate speed control, fast response, and no brush wear for the BSMseries motors. Signal isolation is standard on all Brushless DC Drives. Adjustable speed control is provided for standard 160 Volt and 320 Volt Brushless DC motorsfrom sub fractional thru 3 hp. The Pulse Width Modulated (PWM) output operates at a carrierfrequency of 16 kHz, providing high motor efficiency, low motor heating, and low linear acceleration and deceleration are also provided for soft-start the Drive for a specific application is accomplished with selectable jumpers and trim-pots.

5 However, for many applications no adjustments are features of the Brushless DC Drives include adjustable RMS Current Limit and I2t MotorOverload Protection*. In addition, precision speed accuracy is possible over the extendedspeed range through the use of the Hall Feedback as an encoder. Electronic Inrush CurrentLimit (EICL ) eliminates harmful AC line inrush current. The Drive is suitable for constanttorque or variable torque applications.*UL approved as an overload protector for product complies with all CE directives pertinent at the time of your local Baldor District Office for Declaration of to OperateTrimpots and jumpers are factory set for most Standard MountingThe Drive has industry standard mounting LEDsPower on (PWR, IPWR), Drive status (ST), and Drive Calibration (CAL).Hall Sensor FeedbackStandard Hall A, B, C, +5V, Common; 60/120 degree jumper SelectionsLine Voltage, 4, 6, 8, 12 Pole, 60/120 Degree Hall Sensor Phasing, Automatic/ManualStart, AdjustmentsMaximum Speed, Current Limit, Response, Acceleration, Deceleration, Input SignalScaling, Input Signal Offset, coverMeets IP-20 1 STANDARD FEATURESF eatureDescriptionHigh TorqueDrive can maintain constant torque throughout the extended speed Control AccuracyBetter than with load and CurrentTwo times rated current, continuous for 3 DoublingAllows 320 Volt motors to be used on drives with 115 Volt AC line IsolationAll signal input connections, speed reference connections, and Hall Sensorconnections are isolated from the AC CommandAccepts industry standard 10 Volt DC bidirectional signal ApplicationsBraking capability and PWM speed 2 PERFORMANCE FEATURES5 FeatureDescriptionMotor Overload (I2t)

6 With RMS Current LimitProvides motor overload protection which prevents motor burnout and eliminatesnuisance Inrush Current Limit (EICL )Eliminates harmful inrush AC line current during CircuitPrevents Drive failure if a short circuit occurs at the motor (phase-to-phase).Hall Sensor Input ProtectionProtects the Hall Isolator Board from damage due to accidental FilterReduces harmful voltage spikes to the and OvervoltageShuts down the Drive if the AC line input voltage is outside the operating input transient failure of power devices caused by voltage spikes in the AC 3 PROTECTION FEATUREST rimpotMaximum Speed (MAX)Sets the maximum motor speedScaling (SCALE)Sets the scaling for the input signalInput Offset (OFFSET)Sets the offset for the input signalAcceleration (ACC)Sets the motor acceleration time (time to reach full speed)Deceleration (DEC/B)Sets the motor deceleration time (time to reach zero speed)Response (COMP)Sets the response time of the Limit (CL)Sets the current limit and limits the maximum current (torque) to the motorBraking (% BRAKE)Sets the desired amount of braking (2Q Braking Mode only).

7 TABLE 4 TRIMPOT ADJUSTMENTSA ccessoryDescriptionDynamic Brake Module(Catalog No. ID5 RGA-1)Provides up to 200 Watts of continuous braking for all 5 OPTIONAL ACCESSORIESTABLE 6 ELECTRICAL RATINGS AND Line InputFuse orCircuitBreaker1 Rating(Amps) Drive OutputFeatures by Model2 Net AC(50/60 Hz)Phase( )MaximumCurrent(Amps AC)OutputVoltageRange(Volts AC)MaximumContinuousLoad Current(RMS mps/Phase)MaximumHorsepower(HP (kW))MotorFilterAC (.18) (.37) (.75) 2( ) , ( ) ( ) Fuse Type: Littelfuse 312/314, Buss ABC, or equivalent. = Standard Feature, N = Not Available, QC = Quick-Connect Terminals for AC line and motor connections,TB = Terminal Block for AC line and motor connections. No. BMC2A09 contains a built-in cooling Setting115 Volt AC Line Input Voltage Operating Range (Volts AC)*115 ( 10%) 208/230 Volt AC Line Input Voltage Operating Range (Volts AC)*208 (-10%) / 230 (+10%) Maximum Load (% Current Overload for 1 Minute)150 Switching Frequency (kHz)16 Signal Following Input Voltage Range (Volts DC) 250 5 Speed Range (RPM with 4-Pole motor )0 70000 4000 Maximum Speed Trimpot (MAX) Range (RPM)1000 70004000 Acceleration Trimpot (ACC) and Deceleration Trimpot (DEC) Range (Seconds) Scaling Trimpot (SCALE) 250 5 Current Limit Trimpot (CL) Range (% Drive Rating)75 230200 Offset Trimpot (OFFSET) Range (% Signal Input) 200 Response Trimpot (COMP) Range (Slow to Fast) (milliseconds (Hz))1000 200 (1 5)700 ( )Speed Range (Ratio)150.

8 1 Speed Regulation (% Base Speed)Better than Overload Protector Trip Time for Stalled motor (Seconds at 200% Load Current)3 Operating Temperature Range ( C / F)0 45 / 32 113 TABLE 7 GENERAL PERFORMANCE SPECIFICATIONS*Do not operate the Drive outside the specified AC line input voltage operating NOTICEA Warning statement indicates a potentially hazardous situation which, if not avoided, could resultin injury or Caution statement indicates a potentially hazardous situation which, if not avoided, could resultin damage to Note indicates additional information that is not critical to the installation or ! This equipment may contain voltages as high as 1000 volts! Electricalshock can cause serious or fatal injury. Only qualified personnel should attempt thestart-up procedure or troubleshoot this ! Electrical shock can cause serious or fatal injury. Be sure that all power isdisconnected from Drive before the finger-safe cover is removed. Removal of thefinger safe cover is required to make installation connections.

9 Electrical shock can causeserious or fatal injury if the finger-safe cover is removed and power is still ! Electrical shock can cause serious or fatal injury. Verify there is no volt-age phase-to-phase or phase-to-neutral at the AC Line Conductors before touchingthe AC Input wires. Do not touch live wires, all power must be disconnected before ! It is the responsibility of the equipment manufacturer and individualinstaller to supply this Safety Warning to the ultimate end user of this product.(SW/FSC 5/2005) Be sure to follow all instructions carefully. Fire and/or electrocution can resultdue to improper use of this ! Do not use this Drive in an explosive environment. An explosion cancause serious or fatal injury. This Drive is not explosion !Disconnect motor leads (U, V and W) from control before performing a LeakageResistance test on the motor . Failure to disconnect motor from the control may result inextensive damage to the control. The control is tested at the factory for high voltage / leak-age resistance as part of Underwriters Laboratories !

10 Suitable for use on a circuit capable of delivering not more than 5,000 RMS symmetricalshort circuit amperes listed here at rated !Proper shielding, grounding, and filtering of this product can reduce the emission of radiofrequency interference (RFI) which may adversely affect sensitive electronic equipment. CAUTION!Do not use the 115V position for 230 Volt AC line input voltage. Damage will occur to thedrive. The 115V position provides 2 times the AC input voltage to the QUICK-START INSTRUCTIONSThis procedure will help get your system up and running quickly and allows motor and controloperation to be verified. WARNING! Electrical shock can cause serious or fatal injury. Be sure that allpower is disconnected from Drive before the finger-safe cover is of the finger safe cover is required to make installation connections. Electricalshock can cause serious or fatal injury if the finger-safe cover is removed and power isstill ! Electrical shock can cause serious or fatal injury.