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The following are features of the MC3 board that is incorporated into the BDS5T and the VSA.
NOTICE:
Some changes may be required to existing wiring or probram in order to make the BDS5T
compatible to the BDS5 or the VSA, or the VSA compatible to the VFS5.
HARDWARE:
On-board analog input
The analog input is on the connector T1 of the BDS5T and connector C10 on the VSA, Pin 5 is Diff.
Hi and Pin 6 is Diff. Low.
Tach output
Scaled for 1750 RPM/volts
Communications
To convert from RS232 to RS485 install a jumper between pins 9 and 10 on connector J1
Inputs
Built-in filters
SOFTWARE:
Program Execution
Twice as fast as BDS5
PL, PLIM, TRIP, and PDF
State is remembered through power-down
A2D Switch
When using the on-board analog input set A2D to 1. When using the encoder input for master / slave
application set A2D to 0. The gear ration when using the on-board analog input is GEARI / GEARO =
700 / 16384 for 10 volts = 10000 RPM.
CAM function
Cam now has 1024 points, NORM ) ECAM starts the CAM function.
PDF switch
Set to 1 for brushless motors. For induction motor control if PDF=1, the auto tune feature is available.
If PDF=0, the control scheme is identical to the VFS5 and the auto tune feature is not available.
Supports 10-bit resolver resolution for higher speed applications.
User variables
2,000 user variables (x1 – x2000)
Program memory is 27K
"P"
May be omitted when printing one variable.
UPGRADE NOTICE for BDS5T / VSA
Diff Hi
Diff Lo
Front View of Connector C10 on VSA, T1 on BDS5T

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Summary of Contents for Kollmorgen BDS5

  • Page 1 The following are features of the MC3 board that is incorporated into the BDS5T and the VSA. NOTICE: Some changes may be required to existing wiring or probram in order to make the BDS5T compatible to the BDS5 or the VSA, or the VSA compatible to the VFS5. HARDWARE: •...
  • Page 3 BDS5 NSTALLATION AND ETUP ANUAL Old Number M93101 - I SSUE New Number MB5000H...
  • Page 5 BDS5 ECHNICAL ANUAL ONFIGURATION ECHNICAL ANUAL ONFIGURATION M93101 ) NSTALLATION AND ETUP ANUAL PAGE NO. DESCRIPTION ISSUE NO.* -- ....... Title Page........................0 -- ....... Technical Manual Configuration ................. 0 -- ....... Configuration Table..................... 0 -- ....... Customer Response...................... 0 -- .......
  • Page 6 BDS5 ONFIGURATION ABLE ONFIGURATION ABLE M93101 ) NSTALLATION AND ETUP ANUAL RECORD OF REVISIONS ISSUE NO. (Revision) DATE CHANGED PAGES/BRIEF DESCRIPTION OF CHANGE CHANGE NO. 15 Mar 95 Replaces issue dated 15 Feb 95 Original Release 10 Nov 95 Add Appendix E and include On-line Reference Guide Disk...
  • Page 7 HANK YOU Thank you and congratulations for choosing Industrial Drives' 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.
  • Page 9 U.L. is a trademark of Underwriters Laboratories. N.E.C. is a trademark of the National Electric Code. GOLDLINE, BDS4, BDS5, PSR4/5, Motion Link, PC-Scope, and Macro Moves are trademarks of the Kollmorgen Corporation. Dangerous voltages, currents, temperatures, and energy levels exist in this product and in the associated servo motor(s).
  • Page 11 The results of these and other efforts has encouraged industry, Industrial Drives and its parent, Kollmorgen some of the most significant innovations in the servo Corporation, continue to rank first in servo industry.
  • Page 12 It is recommended that you read this entire manual word is not recognized. before you attempt to install the BDS5 so you can promptly find any information you need. This will • also familiarize you with system components, and...
  • Page 13 The User's Manual is intended to instruct Clockwise the user on the normal operating procedures and Direction Limit practices to be used with the BDS5. Programming is Goldline Cable explained as well as other software considerations. Goldline Cable Set...
  • Page 14: Table Of Contents

    LOSS .............. 3-2 3.2.2 If You Get ERROR 14, POWER BUS ..3-2 2.6.2.6 Wiring the AC Line........2-6 3.2.3 If Your BDS5 System is Unstable....3-2 2.6.2.7 Wiring the Regen Resistor ......2-6 3.2.4 Jogging the Motor ........3-3 2.6.3 Wiring the PSR4/5 Front Panel...
  • Page 15 BDS5 ABLE OF ONTENTS 3.6 Tuning The BDS5 Yourself ......3-7 APPENDIX A. WARRANTY INFORMATION 3.6.1 Tuning the Velocity Loop ......3-7 3.6.2 Tuning the Position Loop ......3-7 3.7 RECORD and PLAY ........3-8 APPENDIX B. DRAWINGS 3.8 Problems............3-9 3.8.1 Overloading the Motor .........
  • Page 16 1.1 BDS5 Model Number Scheme......1-4 2.1 Safety-Alert Symbols ........2-1 1.2 Compensation Model Number Scheme... 1-5 2.2 Master BDS5 and Slave BDS5 ....... 2-8 1.3 PSR4/5 Model Number Scheme ..... 1-6 2.3 Encoder Phasing For Clockwise Rotation..2-8 1.4 External Regen Resistor Model 2.4 BDS5 (C1) ............
  • Page 17 ABLES TABLE PAGE TABLE PAGE 1.1 BDS5 Model Number Scheme......1-4 2.6 PSR4/5 C2 Wiring ........2-17 1.2 PSR4/5 Model Number Scheme ..... 1-6 2.7 Target of PRD vs. R/D Resolution....2-21 1.3 External Regen Resistor Model 2.8 Target of PRD vs. R/D Resolution After Number Scheme..........
  • Page 19 A-63100 Outline B-606-X-A1,A3,B1,B3(-S)........B-18 A-63097 Outline B-802,4-X-A1,A3,B1,B3(-S)........B-19 A-63096 Outline B-806-X-A1,A3,B1,B3(-S)........B-20 A-93569 Outline & Dimension BDS5-3 & 6 Amp ........ B-21 A-93571 Outline & Dimension BDS5-10 Amp ........B-22 A-93570 Outline & Dimension BDS5-20 Amp ........B-23 A-93880 Outline & Dimension BDS5-30/40 Amp ........ B-24 A-96010 Outline &...
  • Page 21: Chapter 1. System Description

    These concepts will allow you to apply them to your • LOW COST own unique applications. The BDS5 is very affordable--even though it is full of 1.2 PRODUCT DESCRIPTION advanced features. Use all or only a portion of these features to accomplish your application.
  • Page 22 The ratio can be from 32767:1 to 1:32767 and can be negative The BDS5 can tune itself. You do not have to be a to allow the slave to move in the opposite direction.
  • Page 23: Part Number Description

    • I/O Panel, or any other serial communications device, the operator can be prompted for specific process data. The BDS5 has up to 32 I/O sections that you connect • MONITOR MODE via ribbon cable to standard OPTO-22 compatible I/O boards or to INDUSTRIAL DRIVES I/O-32.
  • Page 24: Bds5 Model Number

    Voltage and Cur r ent Ratings Us er Pr ogr am O ptions Firm ware Vers ion Motor and W inding R/D Res olution Figure 1.1. BDS5 Model Number Scheme Table 1.1. BDS5 Model Number Scheme LEGEND DEFINITION UL Designator UL Listed (standard)
  • Page 25: Compensation Module Model Number

    A partial model number is printed on a gold and black tag on the front of the compensation module (the black plastic box secured to the front of your BDS5 by two YOU MUST HAVE THE screws). See Figure 1.2 for the descriptions of the PROPER COMPENSATION model number (that is, what ABB and HHHH mean).
  • Page 26: Psr4/5 Model Number

    1 - S BDS5 HAPTER YSTEM ESCRIPTION 1.4.3 PSR4/5 Model Number P S R 4 / 5A - 2 2 0 - 0 0 0 3 A B C UL Des ignator O ptions Voltage Rating Cur r ent Rating Figure 1.3.
  • Page 27: Er-External Resistor Kit Model Number

    You can obtain the crimping and extraction tools from 1.4.5 Molex Assembly Tools your nearest Molex distributor or by contacting Molex at (708) 969-4550. GOLDLINE series electronics (BDS4's, BDS5's, and PSR4/5's) use Molex MINI-FIT JR. series connectors. Hand Crimping Tool Molex Order# 11-01-0122 The necessary connectors and pins are included in your BDS5 and PSR4/5 connector kits.
  • Page 28: Specifications And Ratings

    1 - S BDS5 HAPTER YSTEM ESCRIPTION 1.5 SPECIFICATIONS AND RATINGS Table 1.4. Specifications BDS5-1XX-(90-160 VAC L-L OUTPUT TO MOTOR) DESCRIPTION BDS5-103 BDS5-106 BDS5-110 BDS5-120 Main DC Bus Minimum 130 VDC 130 VDC 130 VDC 130 VDC Maximum 225 VDC...
  • Page 29 BDS5 1 - S HAPTER YSTEM ESCRIPTION Table 1.4. Specifications (Cont.) BDS5-2XX-(160-253 VAC L-L OUTPUT TO MOTOR) DESCRIPTION BDS5-203 BDS5-206 BDS5-210 BDS5-220 Main DC Bus Minimum 225 VDC 225 VDC 225 VDC 130 VDC Maximum 360 VDC 360 VDC 360 VDC 225 VDC ±15-20 VDC...
  • Page 30 1 - S BDS5 HAPTER YSTEM ESCRIPTION Table 1.4. Specifications (Cont.) PSR4/5-1XX-(90 - 160 VAC L-L INPUT) DESCRIPTION PSR4/5-112- PSR4/5-120- Main AC Line Input Voltage 90-160 VAC 90-160 VAC Phase Frequency 47-63 Hz 47-63 Hz Current Cont. (RMS) 3-Phase 12.0 AMPS 20.0 AMPS...
  • Page 31 BDS5 1 - S HAPTER YSTEM ESCRIPTION Table 1.4. Specifications (Cont.) PSR4/5-2XX-(160 - 253 VAC L-L INPUT) DESCRIPTION PSR4/5-212- PSR4/5-220- Main AC Line Input Voltage 160 - 253 VAC 160 - 253 VAC Phase Frequency 47-63 Hz 47-63 Hz Current Cont. (RMS) 3 Phase 12.0 AMPS...
  • Page 32: Theory Of Operation

    • two signals, HOME and CYCLE, can be input to the MICROPROCESSOR SYSTEM BDS5 on two connectors, C2 and C7. Connector C2 provides these three signals with optical isolation. The BDS5 is a digital positioner and servo drive Connector C7 expects non-isolated TTL signals on a combined into one unit.
  • Page 33: Simplified Schematic Diagram And System Diagram

    BDS5. The current loop compensation changes when you change the motor model. You must install the correct compensation module when changing motor As an option, the BDS5 can accept a ±10 volt analog input. This input is converted to digital format by the models.
  • Page 34 DIFF CMD HI TO PULSE C2-PIN 1 CONVERTER DIFF CMD LO OPTIONAL C1-PIN 5 SN75175 CH A IN A IN A BDS5 SYSTEM OVERVIEW ENCODER C1-PIN 10 DIGITAL C1-PIN 4 CH B SN75175 IN B IN B C1-PIN 9 1-14...
  • Page 35 BDS5 1 - S HAPTER YSTEM ESCRIPTION 75155 "ACTIVE" HARDWARE "SYS OK" WATCHDOG 75156 "CPU" "FAULT" 75156 "RELAY" RD TD C2-PIN 17 "RELAY" C2-PIN 16 RELAY ( N. O. ) C2-PIN 10 01 HI 24 VOLT OPTICAL C2-PIN 20 01 LO...
  • Page 36 MODEL No MODEL No STATUS MANUAL SERIAL No SERIAL No INDUSTRIAL INDUSTRIAL TERMINAL DRIVES DRIVES BDS5 BUS+ BUS+ BUS- PC COMPATIBLE BUS- 115 VAC, 1 PHASE 230 VAC, 3 PHASE 115 VAC, 1 PHASE GOLDLINE MOTOR TYPICAL BDS5 SYSTEM INTERCONNECT 1-16...
  • Page 37: Chapter 2. Installation

    Follow the Complete the entire checkout procedure before recommended precautions and safe operating practices attempting to put your BDS5 system into operation. included with the alert symbols. "Warning" refers to personal safety. They alert you 2.2 SAFETY INFORMATION...
  • Page 38: Unpacking And Inspection

    Do not dispose of shipping materials until the packing list has The BDS5 and PSR4/5 should be mounted in a cabinet been checked. Parts that are contained within the or other suitable enclosure to protect them from shipment, but not physically attached to the physical and environmental damage.
  • Page 39: Mounting The External Regen Resistor

    A-93103 before wiring your BDS5 system, including regen resistors, check its model number. Also, the all of the notes on the last sheet. Refer to BDS5 model number indicates the standard resistor value. Connectors Diagram A-96372M, provided at the end These resistors should be enclosed to reduce shock of this chapter, for connector locations.
  • Page 40: Wiring The Ground

    Power Terminal Block located on motor must be grounded. Each BDS5 and PSR4/5 has the front of the BDS5 amplifier. Connect Pin D of the two ground screws on the front of its chassis. motor connector through the same motor cable to the BDS5 chassis ground screw located directly beneath the Power Terminal Block.
  • Page 41: Motor Protection

    The thermostat contacts are closed during normal latch the thermostat. operation and open when the motor overheats. The BDS5 does not provide a direct input for the motor thermostat. You should connect the thermostat B series (GOLDLINE) motors contacts to a BDS5 general purpose input, and...
  • Page 42: Wiring The Dc Bus

    C1 and C2 are supplied with the PSR4/5. 20, the DC Bus can be connected to any combination of 3 BDS4's or BDS5's (for example, 2 BDS5's and 1 2.6.3.1 Wiring the Control Power to BDS4). The PSR4/5-50 and -75 can be connected to any combination of 6 BDS4's or BDS5's, although no The Control Power for the PSR4/5 is 115 VAC.
  • Page 43: Wiring The Bds5 Front Panel Connectors

    PSR4/5 then connect the output from the master to INA and (PER Connector Connector INB. If your BDS5 is the master axis, connect OUTA, VOLTAGE AXIS) C4 PIN C2 PIN OUTB, and OUTZ to the inputs on the slave axies.
  • Page 44 CONNECTOR C7 (PIN 9) REFERENCE TO NOTE 13 LAST SHEET STATES, NOTE 13 - IF THE BDS5 USES THE OPTIONAL ANALOG INPUT CARD (BDS5 - OPT1), THE OPTIONAL ENCODER INPUTS IN CONNECTOR C1 ARE NOT USED. Figure 2.2. Master BDS5 and Slave BDS5 (Part of Drawing A-93103) The BDS5 uses the same phasing for the encoder inputs and outputs;...
  • Page 45: Encoder Equivalent Input

    Encoder Equivalent Output can cause the BDS5 to run another controller is closing a position loop, reversing away or oscillate. BE CAREFUL TO CONNECT the encoder inputs can cause the BDS5 to run away or THE ENCODER EQUIVALENT OUTPUT SO oscillate. BE CAREFUL TO CONNECT THE...
  • Page 46: Wiring C2, Customer I/O

    Connect the shield to Pin 13 or 3 on autobauding. The relay is controlled by the watchdog Connector C2 on the BDS5, or to the frame at the timer. If the contacts open once the BDS5 is running, source of the signal, or at both ends.
  • Page 47: Wiring C3, Resolver

    If you use both CYCLE inputs, HOME, CYCLE, and REMOTE then the BDS5 will sense that CYCLE is on if the CAUTION ENABLE can damage the CYCLE signal from either Connector C2 or C7 is on.
  • Page 48: Wiring C5, Serial Communications

    RS-232-to-RS- Connector C5, the Serial Communications Connector, 485 converter. For example, Anaheim Automation is on the front of the BDS5. It is a 9-pin, D-type, sub- (Anaheim, CA) produces Model DC 2170 for this miniature plug connector (DE-9P). The purpose.
  • Page 49 Connect the pins on the DE-9S connector that came jumpers across Pins 3-4 and with your BDS5 as follows: 7-8 on J1 on the front of the BDS5 at the end of the Table 2.4. Terminal Wiring communication cable. If the device you are using to...
  • Page 50: Wiring C6, Fan Power (20 Amp Units Only)

    PC to the BDS5 serial port. when using standard OPTO-22 compatible I/O boards. Both the PC and the BDS5 must share the same power This supply must provide 5 volts DC to power the I/O supply common. If they do not, the voltage difference modules on the BDS5 side of the isolation.
  • Page 51: Wiring C8, Optional I/O

    Connector C7, you can hardwire MOTION, NOTE by installing a jumper directly on C7 between Pins 15 • and 16. The BDS5 is shipped from the factory with HOME Pin 9 this jumper installed. HOME is the input for the home limit switch. It is •...
  • Page 52: J1 Configuration Jumper

    I/O modules. NOTE 2.6.5.1 Required Data Format The BDS5 and your terminal must use the same format for serial data. RS-232-C and RS-485 describe • O1-O6 Odd numbered Pins from 37 to 47 hardware only. There are other specifications left to up to the user: full- or half-duplex, the number of bits O1-O6 are general purpose outputs.
  • Page 53: Checking The Control Power

    Chapter 5 for descriptions of the --> fuses. The green SYS OK LED on the front of the BDS5 Turn off control power. Re-install PSR4/5 Connector should turn on and remain on at all times after power- up (and autobauding).
  • Page 54: If You Can't Communicate

    P LIMIT If your cable is functioning properly... and the BDS5 will print 1 or 0. 1 means that the input is on, indicating that the contacts are closed. 0 means the serial cable may still be the problem. You can...
  • Page 55: Checking Discrete Inputs

    __I8 that you enter will be shown in italics and surrounded by a __I9 __I10 __I11 __I12 double line box. The response NOTE from the BDS5 will be in plain __I13 __I14 __I15 __I16 upper case letters. __CYCLE __GATE __HOME...
  • Page 56: Cycle Ready

    PEXT should have changed by the number of pulses you injected. If the results are not what you expected, Check STATUS later in this chapter when the BDS5 is make sure that you have set the pulse format switch active. The STATUS output will turn on when you properly.
  • Page 57: Checking The Resolver

    Not Used No Connect Sine High The standard R/D resolution is 12 bits. The resolution of your BDS5 is listed as part of the model number, Shield No Connect which is shown on the front of the drive and described Cosine High at the beginning of this chapter.
  • Page 58: Checking The Ac Line Voltages

    If the reference signal is correct and the feedback Turn on Control Power to PSR4/5 Connector C1 and circuitry is not working, your BDS5 may be turn on the AC Line to the PSR4/5 Power Terminal malfunctioning. Contact the factory.
  • Page 59: Checking The Motor

    You MUST connect remain in the zero position. Type: Pin A of the motor connector to M a of the BDS5 power connector, Pin B of the motor connector to M b , P PRD and Pin C of the motor connector to M c .
  • Page 60 2 - I BDS5 HAPTER NSTALLATION If the motor rotated to the wrong position, then you must stop and correct this problem. Either the resolver is improperly wired, the motor is improperly wired, the motor is not functioning properly, or the resolver is not functioning properly.
  • Page 61 BDS5 2 - I HAPTER NSTALLATION MODEL No. REV No. C2 LOGI C POWER (t o BDS5 C4) 1 +18 VDC 5 +18 VDC ACTIVE 2 -18 VDC 6 -18 VDC SYS OK 3 COMMON 7 COMMON 4 +10 VDC...
  • Page 62 2 - I BDS5 HAPTER NSTALLATION 2-26...
  • Page 63: Chapter 3. Operation

    (opening the contacts) of servo systems functions and features. Work with only LIMIT or REMOTE. one axis section at a time. Confirm all other BDS5 amplifiers are inhibited, meaning the enable circuits This section discusses how to enable the BDS5.
  • Page 64: If You Get Error 17, Feedback Loss

    First, disable the position enable the BDS5 before bus voltage is present. loop. Type: OK2EN is a switch that is ON when your BDS5 can be enabled without generating a fault. You can delay enabling the BDS5 until bus voltage is present by...
  • Page 65: Jogging The Motor

    PROP on and PL off WARNING every time you power-up the Disable the BDS5 and enable the software position drive. limits. Type: Now enable the drive by typing: PLIM ON 3.2.5 Low Speed Adjustment...
  • Page 66: System Compensation

    Tuning is the damped. process whereby the position and velocity loop gains are set, attempting to optimize the performance of a system (a BDS5 and a motor connected to a load) to a three-part criterion: Table 3.1. Tuning Criterion Noise Susceptibility...
  • Page 67: Overdamping

    0 to 4 times the rotor inertia. Many applications have approximately matching inertia. If your system does, you may not have to adjust the tuning of your BDS5. The following section describes how you can re-tune your system.
  • Page 68: If Your System Is Completely Unstable

    ILIM to a low value (say 5 or 10%) and gradually raise it. If the tuning is acceptable (that The BDS5 will shake the motor and set the tuning so is, it does not ring or overshoot excessively, and it...
  • Page 69: Tuning The Bds5 Yourself

    You need to make several decisions: Is the unit The tune command does not always provide an underdamped? Is the system response too fast? Is acceptable tuning. If not, you can tune the BDS5 the system ringing? Is there a resonance present? yourself.
  • Page 70: Record And Play

    3000 30 Hz ;1000 RPM 4000 40 Hz Records the velocity response of the BDS5 to a jog 5000 50 Hz command. After data is recorded, you can use the PLAY If you want to eliminate some or all of the following command to print each point on the screen.
  • Page 71: Problems

    The motor current is near or at saturation controller is that the total reflected inertia should not during a large part of the move. Use the BDS5 RECORD function to record ICMD. change substantially during operation. Load inertia...
  • Page 72: Resonance

    For example, if LPFHZ is 200 and LPF is corrections: on, then a 200 Hz low-pass filter is run in the BDS5. The filter can be modeled as two cascaded, low-pass, •...
  • Page 73 BDS5 CHAPTER 4 - MAINTENANCE...
  • Page 74 CHAPTER 4 - MAINTENANCE BDS5...
  • Page 75: Chapter 4. Maintenance

    4.2 PREVENTATIVE MAINTENANCE NOTE Solid state controls of the BDS5 may be affected by Preventative maintenance can prevent situations that transient voltages. These voltages are in excess of the will damage your equipment. Four types of specified voltage for any given circuit.
  • Page 76: Electrical Noise

    Periodic maintenance should be The low levels of energy in the BDS5 control circuits performed at scheduled intervals to insure proper may cause them to be vulnerable to electrical noise.
  • Page 77: Grounding Integrity

    BDS5 4 - M HAPTER AINTENANCE 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...
  • Page 78 4 - M BDS5 HAPTER AINTENANCE...
  • Page 79: Introduction

    5 - T HAPTER ROUBLESHOOTING HAPTER ROUBLESHOOTING Connector Kit for 3, 6, and 10 Amp BDS5's 5.1 INTRODUCTION (BDS5-x03, BDS5-x06 and BDS5-x10): BDS5C-100 The information in this chapter will enable you to order spare parts and isolate and resolve common system hardware problems.
  • Page 80: Ordering Information

    6 Amp Fuse: A-80552-008 FAULT This LED indicates that a fault has occurred. A fault is an error that is serious enough to disable the BDS5. 5.2.3 Ordering Information You can turn the FAULT LED on or off from your program.
  • Page 81: Error Log

    You must remove power and replace The BDS5's response to an error depends on the the fuse. The spare parts list at the end of this chapter error's severity. There are four levels of severity, provides ordering information for this fuse.
  • Page 82: Dep

    ERR 50 BDS5 INHIBITED PROP 2 You may display messages for errors from 1 through 999. If you type in an error number that the BDS5 will be displayed. does not recognize, it will respond with: ERROR NOT FOUND.
  • Page 83: Enable And Fault Logic

    You can print REMOTE with the P command. It up in Appendix C. The only way to reset these faults must be 1 to activate the BDS5. Note that some is to power-down the BDS5. These faults are serious faults "hide" the value of the REMOTE input from and you should consult the factory if they occur.
  • Page 84: Motor Brake

    BDS5 HAPTER ROUBLESHOOTING you can use STATUS to indicate that the BDS5 is One way to use the relay is to interconnect it with the ready for the REMOTE input to turn on. That is, if main power contactor. In this case, a hardware REMOTE turns on, the BDS5 will be ACTIVE.
  • Page 85 NFORMATION PPENDIX ARRANTY NFORMATION 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.
  • Page 86 A - W BDS5 PPENDIX ARRANTY NFORMATION...
  • Page 87 Outline B-606-X-A1,A3,B1,B3(-S) A-63100 B-19 Outline B-802,4-X-A1,A3,B1,B3(-S) A-63097 B-20 Outline B-806-X-A1,A3,B1,B3(-S) A-63096 B-21 Outline & Dimension BDS5-3 & 6 Amp A-93569 B-22 Outline & Dimension BDS5-10 Amp A-93571 B-23 Outline & Dimension BDS5-20 Amp A-93570 B-24 Outline & Dimension BDS5-30/40 Amp...
  • Page 88 B - D BDS5 PPENDIX RAWINGS THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 89 C2-PIN 17 RELAY C2-PIN 16 " REMOTE " INPUT " STATUS " " RELAY " SOFTWARE C2-PIN 9 OPTICAL SWITCH C2-PIN 6 ISOLATION STATUS OUTPUT (OPTIONAL) C8-PIN 35 " STATMODE " SOFTWARE SWITCH BDS5-ENABLE/FAULT LOGIC DIAGRAM A-84732 Sheet 1 of 1...
  • Page 90 RECOMMENDED THAT MOTOR WIRING BE A SHIELDED CABLE. USE PROPER SIZE WIRE. USE COPPER WIRE AND 60°C OR 75°C TABLE FROM NEC FOR WIRE SIZE. CAD DWG. COPY CODE ISS. ECN NO. DATE APP'D. Kollmorgen Industrial Drives BDS5 WIRING DIAGRAM ISS. ECN NO. DATE APP'D. 83906 V. ALLIE 3-12-91 G.H.E. RADFORD, VIRGINIA...
  • Page 91 OCCASIONALLY THE ENCODER THROUGH CONNECTOR C4 IF THE BDS5's MUST BE TIED TO BDS5 COMMON OUTPUTS MUST BE TERMINATED SHARE ONE PSR4/5. AT THE BDS5 WITH A 120 ohm, 1/2 WATT RESISTOR TO REDUCE RINGING. IN B (OPTIONAL) IN B (OPTIONAL)
  • Page 92 RIBBON LOCATION PROPER SHIELD CABLE MAY TERMINATION. BE USED. ONLY INSTALL JUMPERS ON THE CONN. LAST BDS5 AXIS IN THE STRING PIN 1 NORMALLY DETAIL J1 NOT CONNECTED DEP01 SERIAL (RS-485 ONLY) TO C5 COPY CODE ISS. ECN NO. DATE APP'D.
  • Page 93 THE ANALOG INPUT, SEE APPENDIX F OF THE BDS5 MANUAL FOR INSTRUCTIONS .01UF .01UF 16.2k ON HOW TO CONFIGURE THE BDS5 AS A I MONITOR IS A COMMON-REFERENCED COMMON VELOCITY DRIVE. SIGNAL SCALED FOR FULL CURRENT = 5 VOLTS. THIS SIGNAL HAS A 3.01k ohm I MONITOR RESISTOR IN LINE.
  • Page 94 PIN 25 MOTION GATE CYCLE READY THE COMMON OF THIS PIN 25 SUPPLY IS CONNECTED EVEN SIGNAL RETURN/ TO THE BDS5 COMMON PIN 1 +5 VOLTS DC PINS COMMON THROUGH THE RIBBON ENCODER AND CABLE BY THE I/O POWER EVEN NUMBERED PINS.
  • Page 95 DWG. NO. SHEET 6 OF 7 ISSUE NOTES: 93103 1. VFS5 USES BDS5-EXT1-I/O WITH FILTERED INPUTS AND POWER METER DRIVER. 2. INPUT #16 (PIN 1) IS POWER METER INPUT. PIN 49 LOGIC SUPPLY LOAD ISOLATED OUTPUT IS METER DRIVE OUT...
  • Page 96 TO NATIONAL ELECTRICAL CODE (NEC) OR UL STANDARD 486B FOR RECOMMENDED TORQUES IN THE BDS5 3 AMP THRU 20 AMP AND THE PSR4/5 12 AMP AND 20 AMP, THE SCREWS IN THE POWER TERMINAL BLOCKS ARE CAPTIVE. DO NOT ATTEMPT THERMAL OVERLOAD PROTECTION DOES NOT PROVIDE INTERNAL TO AMPLIFIER TO REMOVE THEM TO USE RING TERMINALS.
  • Page 97 CAD DWG. COPY CODE ISS. ECN NO. DATE APP'D. ISS. ECN NO. DATE APP'D. MOUNTING HOLE PATTERN Kollmorgen Industrial Drives 1-20-93 84949 TDG BDS4A, BDS5A, PSR4/5A RADFORD, VIRGINIA DWG. NO. SHT 1 OF 2 ISSUE DWN. BY: DATE CHK. BY: DATE APP'D.
  • Page 98 COPY CODE ISS. ECN NO. DATE APP'D. ISS. ECN NO. DATE APP'D. MOUNTING HOLE PATTERN Kollmorgen Industrial Drives BDS4A, BDS5A, PSR4/5A RADFORD, VIRGINIA DWG. NO. ISSUE SHT 2 OF 2 DWN. BY: DATE CHK. BY: APP'D. BY: DATE D ATE...
  • Page 99 ISS. ECN NO. DATE APP'D. ISS. ECN NO. DATE APP'D. OUTLINE INDUSTRIAL DRIVES 84634 8-4-92 RADFORD, VIRGINIA B-102-X-12,14 A KOLLMORGEN DIVISION DWG. NO. ISSUE DWN. BY: DATE CHK. BY: APP'D. BY: DATE D ATE SCALE 62370 HALF S.P. 12-90 J.S.
  • Page 100 ISS. ECN NO. DATE APP'D. ISS. ECN NO. DATE APP'D. OUTLINE INDUSTRIAL DRIVES 84634 8-4-92 RADFORD, VIRGINIA B-104,6,-X-12-14 A KOLLMORGEN DIVISION DWG. NO. ISSUE DWN. BY: DATE CHK. BY: APP'D. BY: DATE D ATE SCALE 62371 HALF S.P. 12-90 J.S.
  • Page 101 B-202 236.2 [9.30] 123.9 [4.88] MODEL "A" MAX "B" COPY CODE ISS. ECN NO. DATE APP'D. ISS. ECN NO. DATE APP'D. Kollmorgen Industrial Drives OUTLINE 76523 J.S. 12-89 S.P. B-20X-X-21,31,23,33(-S) RADFORD, VIRGINIA 76615 J.S. 05-90 S.P. 84634 08-04-92 DWG. NO.
  • Page 102 KEYWAY DETAIL MODEL "A" MAX "B" COPY CODE ISS. ECN NO. DATE APP'D. ISS. ECN NO. DATE APP'D. OUTLINE Kollmorgen Industrial Drives 84835 12-14-92 J.B. B-40X-X-A1,A3,B1,B3,(-S) RADFORD, VIRGINIA 84977 J.B. 2-08-93 DWG. NO. ISSUE DWN. BY: DATE CHK. BY: DATE APP'D.
  • Page 103 248.0 [9.76] MODEL "A" MAX "B" COPY CODE ISS. ECN NO. DATE APP'D. ISS. ECN NO. DATE APP'D. OUTLINE Kollmorgen Industrial Drives 84835 GLK 12-14-92 J.B. B-602,4-X-A1,A3,B1,B3(-S) 84977 J.B. 2-08-93 RADFORD, VIRGINIA DWG. NO. ISSUE DWN. BY: DATE CHK. BY: DATE APP'D.
  • Page 104 [1.055] MODEL "A" MAX "B" COPY CODE ISS. ECN NO. DATE APP'D. ISS. ECN NO. DATE APP'D. OUTLINE Kollmorgen Industrial Drives 84835 GLK 12-14-92 J.B. B-606-X-A1,A3,B1,B3(-S) RADFORD, VIRGINIA 84977 J.B. 2-08-93 DWG. NO. ISSUE DWN. BY: DATE CHK. BY: DATE APP'D.
  • Page 105 6 - ELECTRICAL HOOK-UP PER HD-804. MODEL "A" MAX "B" COPY CODE ISS. ECN NO. DATE APP'D. ISS. ECN NO. DATE APP'D. OUTLINE Kollmorgen Industrial Drives 84768 9-24-92 S.P. B-802,4-X-A1,A3,B1,B3 (-S) RADFORD, VIRGINIA 84835 EWR 12-8-92 J.B. 84977 J.B. 2-08-93 DWG. NO. ISSUE DWN. BY: DATE CHK.
  • Page 106 6 - ELECTRICAL HOOK-UP PER HD-804. MODEL "A" MAX "B" COPY CODE ISS. ECN NO. DATE APP'D. ISS. ECN NO. DATE APP'D. OUTLINE Kollmorgen Industrial Drives 84768 S.P. 9-24-92 B-806-X-A1,A3,B1,B3 (-S) RADFORD, VIRGINIA 84835 EWR 12-8-92 J.B. 84977 J.B. 2-08-93 DWG. NO. ISSUE DWN.
  • Page 107 COPY CODE ISS. ECN NO. DATE APP'D. INDUSTRIAL DRIVES OUTLINE & DIMENSION ISS. ECN NO. DATE APP'D. RADFORD, VIRGINIA BDS5-3 & 6 AMP A KOLLMORGEN DIVISION PLOT SCALE DWG. NO. DWN. BY: DATE CHK. BY: DATE APP'D. BY: DATE ISSUE 93569...
  • Page 108 COPY CODE ISS. ECN NO. DATE APP'D. INDUSTRIAL DRIVES OUTLINE & DIMENSION ISS. ECN NO. DATE APP'D. RADFORD, VIRGINIA BDS5-10AMP A KOLLMORGEN DIVISION PLOT SCALE DWN. BY: DATE DATE DWG. NO. ISSUE CHK. BY: APP'D. BY: DATE 93571 8-03-92 8-03-92...
  • Page 109 COPY CODE ISS. ECN NO. DATE APP'D. INDUSTRIAL DRIVES OUTLINE & DIMENSION ISS. ECN NO. DATE APP'D. RADFORD, VIRGINIA BDS5-20AMP A KOLLMORGEN DIVISION PLOT SCALE DWN. BY: DATE DATE DWG. NO. ISSUE CHK. BY: APP'D. BY: DATE 93570 8-03-92 8-03-92...
  • Page 110 COPY CODE COMPONENTS ISS. ECN NO. DATE APP'D. ISS. ECN NO. DATE APP'D. OUTLINE AND DIMENSION Kollmorgen Industrial Drives BDS5A-30/40 AMP RADFORD, VIRGINIA DWG. NO. ISSUE DWN. BY: DATE CHK. BY: APP' D . BY: DATE D ATE SCALE 93880...
  • Page 111 CAD DWG COPY CODE COMPONENTS ISS. ECN NO. DATE APP'D. ISS. ECN NO. DATE APP'D. OUTLINE AND DIMENSION Kollmorgen Industrial Drives BDS5A-55AMP RADFORD, VIRGINIA DWG. NO. ISSUE DWN. BY: DATE CHK. BY: APP' D . BY: DATE D ATE SCALE 96010...
  • Page 112 CAD DWG COPY CODE COMPONENTS ISS. ECN NO. DATE APP'D. ISS. ECN NO. DATE APP'D. OUTLINE & DIMENSION Kollmorgen Industrial Drives XXXXX XX-XX-XX PSR-4/5A-12 & 20 AMP RADFORD, VIRGINIA DWG. NO. ISSUE DWN. BY: DATE CHK. BY: DATE APP'D. BY:...
  • Page 113 (3.15) CAD DWG COPY CODE ISS. ECN NO. DATE APP'D. ISS. ECN NO. DATE APP'D. Kollmorgen Industrial Drives OUTLINE & DIMENSION 84111 EWR 08-05-91 PSR4/5A-50 & 75 AMP RADFORD, VIRGINIA LLS 8 5645 02-22-94 85945 AWL 07-06-94 DWG. NO. ISSUE DWN.
  • Page 114 APP'D. PSR4/5 SIMPLIFIED INDUSTRIAL DRIVES 3)- THESE VALUES FOR EXTERNAL REGEN ONLY. ISS. ECN NO. DATE APP'D. RADFORD, VIRGINIA SCHEMATIC A KOLLMORGEN DIVISION PLOT SCALE DWN. BY: DATE CHK. BY: DATE APP' D . BY: DATE DWG. NO. ISSUE 84723...
  • Page 115 USE EDITOR TO INSTALL USE PROGRAM USER PROGRAM ( SHOW AT RIGHT ) X1 500 SET: AMAX=100000 ACC=AMAX D 1000 DEC=AMAX PL=ODD D 1000 TQ=OFF GOTO 81 LPF=OFF J X1 ILIN=100 KV=100 NOTE KVI=0 INCREASE KV FOR STABILITY. INCREASE KVI FOR IMPROVED RESPONSE.
  • Page 117 PPENDIX RROR ODES C.1 INTRODUCTION The BDS5's response to an error depends on the error's severity. There are four levels of severity, listed below in increasing order: Table C.1. Error Severity Levels and Actions Errors which cause warnings. Errors which cause a program break and stop motion, in addition to Level 1 Actions.
  • Page 118 ERROR 17 "FEEDBACK LOSS" SEVERITY 3 The BDS5 has detected that one or more wires to the resolver have been broken, or the resolver connector has been removed. This error breaks program execution. ERROR 18 "BAD TL"...
  • Page 119 ODES The BDS5 has two boards: a small MC board and a larger IBD board. Both boards have the current and voltage rating encoded and they must match. If this error occurs because you exchanged the MC card, then you should replace the original card.
  • Page 120 If your application requires this, consider using the rotary mode as described in Chapter 11. ERROR 27 "R/D JUMPERS" SEVERITY 3 Either the jumpers on your BDS5 MC2 card are incorrectly set or the wrong TL has been loaded. Contact the factory. C.3 MOTION ERRORS C.3.1 Position Calculation Errors ERROR 30 "TOO MANY MOVES"...
  • Page 121 ERROR 50 "DRIVE INHIBITED" SEVERITY 2 You attempted to execute an instruction that required the BDS5 to be enabled while it was inhibited. This error will break program execution if the instruction is issued from the user program. ERROR 51 "DRIVE ENABLED"...
  • Page 122 ERROR 58 "NOT w/JOGGING" SEVERITY 2 You attempted to execute an instruction that is not allowed when the BDS5 is jogging. This error breaks execution if the instruction was issued from the program. ERROR 59 "NOT w/ROTARY"...
  • Page 123 The user's error (ERROR$) must be the last label in the program buffer. You cannot have labels after ERROR$, nor can you use the GOTO or GOSUB commands when the BDS5 is executing the error handler. The error handler is intended to provide a graceful exit during error conditions and cannot be used to restart the program.
  • Page 124 ERROR 80 "INVALID INSTRUCTION" SEVERITY 2 You attempted to execute an instruction or change a variable that the BDS5 does not recognize. This error breaks program execution if the instruction is issued from the user program. ERROR 81 "NOT PROGRAMMABLE"...
  • Page 125 "USER PROGRAM FULL" SEVERITY 2 You attempted to load a program larger than the BDS5 can hold. This occurs with the >BDS instruction and from the Motion Link communications software "Program Transmit (^T)." This error breaks program execution. ERROR 87 "EMBEDDED QUOTE"...
  • Page 126 C - E BDS5 PPENDIX RROR ODES The BDS5 encountered an expression in which the number of closing parentheses was not equal to the number of opening parentheses. This error breaks program execution. ERROR 96 "SCALING OVERFLOW" SEVERITY 2 During a conversion to or from user units, the result was greater than 2 31 or less than -2 31 . This error breaks program execution if the instruction is issued from the user program.
  • Page 127 GOSUBs. This error breaks program execution. C.4.8 Power-Up Marker (Not An Error) ERROR 199 "DRIVE POWERED UP" This is not a true error. ERROR 199 is used to mark the error history buffer when the BDS5 powers-up. C.4.9 Internal Errors ERROR 200 "FOLDBACK OUT"...
  • Page 128 ODES ERROR 204 "PROGRAM OVERRUN" SEVERITY 3 This is an internal error. Contact the factory. This error breaks program execution and disables the BDS5. ERROR 205 "MBUF OVRRUN" SEVERITY 3 This is an internal error. Contact the factory. This error breaks program execution and disables the BDS5.
  • Page 129 Kollmorgen is committed to quality customer service. Our goal is to provide the customer with information and resources as soon as they are needed. In order to serve in the most effective way, Kollmorgen offers a one-stop service center to answer all our customer’s product needs. This one number provides order status and delivery...
  • Page 130 INTRODUCTION HOW TO USE THIS MANUAL A BDS5 REFERENCE GUIDE on-line Technical 1. Insert the BDS5 REFERENCE GUIDE disk into Manual (diskette) is included as part of this product Drive A (or your designated 3.5" disk drive support documentation package. This diskette letter).
  • Page 131 E - O BDS5 PPENDIX LINE EFERENCE UIDE...
  • Page 132 BDS5 LOSSARY LOSSARY A device which creates mechanical motion by converting various forms of energy to mechanical Absolute Position energy. Position referenced to a fixed zero position. Adaptive Control Absolute Positioning A technique to allow the control to automatically Refers to a motion control system employing position...
  • Page 133 BDS5 LOSSARY information. Bit (Binary Digit) CAM Profile A unit of information equal to 1 binary decision or having only a value 0 or 1. A technique used to perform nonlinear motion electronically similar to that achieved with mechanical cams.
  • Page 134 BDS5 LOSSARY Commutation A control action which combines the characteristics of lead and lag compensations. A term which refers to the action of steering currents or voltage to the proper motor phases so as to produce optimum motor torque. In brush type...
  • Page 135 BDS5 LOSSARY A term used to describe the linking of several The maximum torque that can be applied to an un- RS232C devices in sequence such that a single data energized stepping motor without causing continuous stream flows through one device and on to the next.
  • Page 136 BDS5 LOSSARY A motor drive in which the output is directly Efficiency proportional to either a voltage or current input. The ratio of power output to power input. Normally both inputs and outputs are analog signals. This is a relatively inefficient drive type.
  • Page 137 BDS5 LOSSARY Encoder Marker Flutter A ounce-per-revolution signal provided by some Flutter is an error of the basic cycle of an encoder per incremental encoders to specify a reference point one revolution. within that revolution. Also known as Zero Reference signal or index pulse.
  • Page 138 BDS5 LOSSARY A feedback device which is used in a brushless servo Hysteresis system to provide information for the amplifier to The difference in response of a system to an electronically commutate the motor. The device uses increasing or a decreasing input signal.
  • Page 139 BDS5 LOSSARY Inrush Current For a speed control system it is the maximum deviation between actual and set speed expressed as a The current surge generated when a piece of percentage of set speed. equipment such as a servoamplifier is connected to an AC line.
  • Page 140 BDS5 LOSSARY The time for an unloaded motor to reach 63.2% of its final velocity after the application of a DC armature voltage. Motor, DC A device that converts electrical direct current into mechanical energy. It requires a commutating device, Microstepping either brushes or electronic.
  • Page 141 BDS5 LOSSARY The difference between 180 degrees and the phase angle of a system at the frequency where the open Open Collector loop gain is unity. A term used to describe a signal output that is performed with a transistor. An open collector output...
  • Page 142 BDS5 LOSSARY Power The acceleration and deceleration of a motor. May also refer to the change in frequency of the applied The rate at which work is done. In motion control, step pulse train. Power = Torque x Speed. Rated Torque...
  • Page 143 BDS5 LOSSARY Rise Time low level control signal into high voltage and current levels top produce torque in the motor. The time required for a signal to rise from 10% of its final value to 90% of its final value.
  • Page 144 BDS5 LOSSARY A brushless, electromagnetic feedback transducer which produces an analog velocity feedback signal and commutation signals for a brushless servo motor. The tachsyn is functionally equivalent to hall sensors Steps-Per-Second. A measure of velocity used with and a tachometer.
  • Page 145 BDS5 LOSSARY Velocity Transistor-Transistor Logic. The change in position as a function of time. Velocity has both a magnitude and a direction. Variable Frequency Drive Voltage Constant (or Back EMF Constant) An electronic device used to control the speed of a standard AC induction motor.
  • Page 146 BDS5 Model Number Scheme......F1-4 Firmware Faults, Area 1........5-5 BDS5 Model Number Scheme......T1-4 Motor Brake............ 5-6 BDS5 Spare Parts List ......... 5-1 Output Relay ........... 5-6 Ready Latch, Area 4........5-5 - C - Relay and STATUS Control, Area 6....5-6 Enclosures............
  • Page 147 If You Get ERROR 17, FEEDBACK Mounting the External Regen Resistor....2-3 LOSS............... 3-2 Mounting the PSR4/5 ........... 2-3 If Your BDS5 System is Unstable......3-2 If Your System Is Completely Unstable....3-6 - N - Initial Check-Out..........2-18 Checking Analog Input (Optional) ....
  • Page 148 BDS5 NDEX Ventilation ............4-3 If Your BDS5 System is Unstable....3-2 Preventative Maintenance ........4-1 Jogging the Motor ........... 3-3 Electrical Noise..........4-2 Low Speed Adjustment ........3-3 Radio Frequency Energy......... 4-2 Surge Current ............4-2 Surge Current ..........4-2 System Compensation ..........
  • Page 149 Wiring C7, Standard I/O ........2-14 Wiring C8, Optional I/O........2-15 Wiring PSR4/5 Connector C2 ......2-6 Wiring the AC Line..........2-6 Wiring the BDS5 Front Panel Connectors ............2-7 Encoder Equivalent Input......2-9 Encoder Equivalent Output ......2-9 J1 Configuration Jumper ......2-16 Pulse Input (OPT2 Card).......
  • Page 150 BDS5 INSTALLATION AND SETUP MANUAL M93101 - Issue 4 PRINT KEY ---- The following filenames have been assigned : DESCRIPTION..................... FILENAME Cover / Title Page ...................AFM1 .DOC Technical Manual Configuration / Configuration Table .........AFM2 .DOC Customer Response..................AFM3 .DOC Copyright Page....................AFM4 .DOC Foreword......................AFM5 .DOC...

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