,

j
,
r

BL Brushless Servo Drives

User Guide

For IInglnsenng For engineering

assistance In Europe: assistance In til. U.S.:
Parker Hannilin pic Parker HannID" Corporation
Dlglplan Division DIQlplan Division
21 Ba1ena Close 5500 Business Par1r. Drtve. Suite 0
Poole. Dorset Rohnert Par1f., CA 94928
England. BH17 7DX USA
Telephone: 01202-699000 Telephone: (SOO) 358-9070
Fax, 01202·695750 FIDe (707)584-8015

Part No: 1600.135.08 8th March 1995

 IMPORTANT INFORMATION FOR USERS

Installation and Operation of Dlglplan Equipment

11 is important that Digiplan molion control equipment IS installed and operated in such a way that air applicable
safety requirements ara met. It is your resp:)nSlbllity as a user to ensure that you idenlHy the relevant safety
standards and comply with them; failure to do so may resuH in damage to equipment and personal injury. In
particular, you should study the contents ollhis user guide carefully before installing or operating the
equipment.

Under no circumstances will the suppliers of the equipment be liable for any incidental, consequential or special
damages of any kind whatsoever, including but not limited 10 Iosl profits arising from or in any way connected
with the use of the equipment or this user guide.

SAFETY WARNING
High-periormance mOlion oonlrol equipment is capable of producing rapid movement and very high forces.
Unexpected motion may occur especially dUring the development 01 controller programs. KEEP WELL CLEAR
of any machinery driven by stepper or servo motors. Never lauch It while it IS In operation.

This product is sold as a motion control component to be installed in a complete system using good engineenng
practice. Care must be taken to ensure that the product IS installed and used in a safe manner according to
local safely laws and regulations. In particular, the product must be enclosed such that no part is accessible
while power may be applied.

The information in this user guide, including any apparatus, meUlOds, techniques, and concepts described
herein, are the proprietary property 01 Parker Digiplan or its licensors, and may not be copied, disclosed, or
used lor any purpose not expressly authorised by the owner thereof.

Since Diglp1an constantly strives to improve all of its products, we reserve the right to modify equipment and
user guides without pnor notice. No part of thiS user guide may be reproduced in any lorm without the prior
consent 01 Oigiplan.

@ Digiplan Division of Parker Hannlfln pic, 1995

- All Rights Reserved -
User Guide Change Summary

The following is a summary of the primary changes to this user guide

since the last version was released. This user guide. version
1600.135.08. supersedes version 1600.135.07.

When a user guide is updated. the new or changed texl is

differentiated with a change bar in the outside margin (this paragraph
is an example). If an entire chapter is changed. the change bar is
located on the outside margin of the chapter title.
 CONTENTS

CONTENTS
CONTENTS ............................................................................................................... i
List 01 Figures .......................................................................................................... iii
List 01 Tables ........................................................................................................... iii
Installation Prcx:ess Overview ......................................................................... v
Chapter 1. INTRODUCTION ................................................................................... 1
Chapter Objectives ......................................................................................... 1
Product Description ........................................................................................ 1
Product Featur"s ............................................................................................ 2
Theory of Operation ........................................................................................ 2
Controls and Indicators ................................................................................... 3
Chapter 2. GETTING STARTED ............................................................................. 5
Chapter Objectives ......................................................................................... 5
What You Should Have ................................................................................. 5
Pre·installation Test ........................................................................................ 6
RS232C Controller .......................................................................................... 9
Testing the BL System without a Positioner ................................................... 10
Testing the BL System with a Positioner ........................................................ 11
Chapter 3. INSTALUITION ..................................................................................... 13
Chapter Objectives ......................................................................................... 13
Environment .................................................................................................... 13
Mounting the Drive ......................................................................................... 13
Mains Transformer ......................................................................................... 15
Voltage Adjustment ........................................................................................ 17
DC Power Input ............. ,. ................................................................................ 18
Power Dump Ratings ...................................................................................... 18
Drive Signal Connections ........................... _................................................... 20
Using an Exlernal +24V Supply ...................................................................... 23
Using an External Positioner .......................................................................... 23
Rewiring the Motor Connections .................................................................... 24
Direction of Rotation ....................................................................................... 24
Tach Feedback .............................................. "................................................ 24
Setling Up the Drive ........................................................................................ 24
Initial Precaution ......................................... _................................................... 24
Setling the Driv" Jumper Links ....................................................................... 25
Tuning the Drive ............................................................................................. 29
Tuning the DriVE! without a Positioner .............................................................. 29
Chapter 4. HARDWAIRE REFERENCE .................................................................. 3t
Chapter Objectives ......................................................................................... 31
BL Drive Specification ..................................................................................... 31
InpuVOutput Sp'3cification ............................................................................... 32
Brushless Motor/Drive Packages ................................................................... 33
Transformer Dimensions ................................................................................ 35
Fuse Ratings .................................................................................................. 37
Chapter 5. MAINTENANCE & TROUBLESHOOTING ........................................... 39
Chapter Objectives ......................................................................................... 39
General ........................................................................................................... 39
Repairs ........................................................................................................... 39
Drive Removal ............................................................................................... 39
Drive Fault LED .............................................................................................. 39
i BL SERVO DRIVES USER GUIDE

Overtempera-tu r<l LED ................................................. " ... " ... " ...... "." "" "". ". 40
Powe r On LE D "." """ .. " " ...... "" ........................... " ............................. " """". 40
Incorrect Ope rat;'Jn ..... "" .. " .. " .. " .............. "" .......... " ... ". " .. "" .. " ... " " .. ". "" .... 40
Returning the Sy.stem ........ " .. "" """ "" """ .......... ",,""""" ............................. 4 t
Inserting in-line connectors ... __ ... _.................................................................... 43
Proprietary CablE' Types ........ " ....................................................................... 44
Index .... "" .... " ...... " ... " ... " ................ "" ....... " ...................... " .. '" " .................. " ......... 45
 CONTENTS III

list of FiglJres
Figura 1-1. Basic BL Drives with Positioner .................... _........................................ 1
Figure 1-2. BL Drive System Schematic ................................................................... 3
Figure 1-3. Jumper Unk Setting Schematic .............................................................4
Figure 2-1. Pre-installation Test Configuration (240V AC Mains Supply) ................ 6
Figure 2-2. Pre-installation Test Configuration (120V AC Mains Supply) ................ 7
Figure 2-3. Pre-installation Test Configuration (Positioner-equipped Systems) ....... 8
Figure 2-4. Controller to Positioner RS232C Connections ....................................... 9
Figure 3-1. Mounting the Drive ...................................................: ............................. 14
Figure 3-2. 240VAC Connections ............................................................................. 16
Figure 3-3. 120VAC Connections .......................... ,. ................................................. 16
Figure 3-4. Total inertia plotted against motor speed ............................................... 18
Figure 3-5. Connectol·s and Indicators ..................................................................... 20
Figure 3-6. Jumper Unk Setting Schematic ............................................................. 25
Figure 3-7. ReseVDis.• ble Input Circuit Options ....................................................... 27
Figure 4-1. Motor Type ML-l 620 Dimensions .......................................................... 33
Figure 4-2. Motor Type ML-2340 Dimensions .......................................................... 34
Figure 4-3. Motor Type ML-3450 & ML-3475 Dimensions ....................................... 34
Figure 4-4. Transformer Dimensions for T092, T0170 and TOI 71 - mm(ins) ........... 35
Figure 4-5. MotorlDrive Packages Torque Curves ................................................... 36

list of Tables
Table I -1. BL Drive Type Variants .......................................................................... 2
Table 2-1. BL Dnve Ship Kit ..................................................................................... 5
Table 3-1. Optional Mains Transformers .................................................................. 15
Table 3·2. Transformm Connections ........................................................................ 17
Table 3-4. Motor Connector ..................................................................................... 21
Table 3-5. Motor Feedback Connector ..................................................................... 22
Table 3-6. AC Input Connector ................................................................................. 22
Table 3-7. 24V Supply Connector ............................................................................ 23
Table 3-8. Current Limit Link Settings ...................................................................... 28
Table 3-9. Recommended Peak Current .................................................................. 28
Table 4-1. BL Servo Drives Specification ................................................................. 31
Table 4-2. User 1/0 Specification ............................................................................ 32
Table 4-3. Bnushless Motor Data ........................................................................... 33
Table 4-4. BL Fuse Ratings ...................................................................................... 37
iv BL SERVO DRIVES USER GUIDE

How To Use This manual is designed to help you install, develop, and maintain
This Manual your system. Each chapter begins with a list of specific objectives
that should be met after you have read the chapter. This section is
intended to help you find and use the information in this manual,

Assumptions This user guide assumes that you have a fundamental

understanding of the following:

• Basic electronics concepts (voltage, switches, current.

resistors, etc.)
• Basic motion control concepts (torque, velocity, distance, etc.)

With this basic level of understanding. you will be able to effectively

use this manual to install. develop, and maintain your system.

COntents of This The following information is included in this user guide:

Manual

Chapter t: This chapter provides a description of the product and a brief

Introduction account of its specific features.

Chapter 2: Getting This chapter contains a detailed list of items you should have
Started rE~ceived with your BL system shipment. It will help you become
fa.miliar With the system and ensure that each component functions
properly. In this chapter, you will perform a preliminary configuration
or the system,
en,pter 3: This chapter provides instructions to enable you to properly mount
Installstlon the system and make all electrical and non-electrical connections.
Upon completion of this chapler, your system should be completely
configured, installed, and ready to perform basic operations.

Chspter4. Information on the motorldrive packages available from Digiplan is

BL Motor/Drive provided in this chapler.
Packages

Chapter 5. Tl,is chapter contains drive speCifications (dimensions and

Hardware performance) and information on mains transformers available from
Reference
D'giplan suitable for use with the dove. It may be used as a quick-
reference tool far proper switch settings and 1/0 connections.

Chapter 6: TI,is chapter describes the recommended system maintenance and

Maintenance snd troubleshooting procedures. It also provides methods for isolating
Trouble.-shootlng and resolving hardware and software problems.
 CONTENTS v
Installation To ensure trouble-free operation, you should pay special attention to
Process the following:
Overview
• The environment in which the system will operate
• The system layout and mounting
• The wiring and grounding practices used

These recommendations are intended to help you to easily and

safely integrate the system into your equipment. Industrial
environments otten contain conditions that may adversely affect solid
state equipment. Electrical noise or atmospheric contamination may
also aHect the system.

Installation Before you attempt 10 install this product, you should complete the
Recommendations following steps:

Step 1 Review this entire manual. Become familiar with the manual's
contents so that you can quickly find the information you need.

Step 2 Develop a basic understanding of all system components, their

functions, and interrelationships.

Step 3 Complete the basic system configuration and wiring instructions

provided in Chapter 2, Getling Started. Note that this is a
preliminary configuration, not a permanent installation, usually
performed in a bench·top environment.

Step 4 Perform as many basic moves and functions as you can with the
preliminary configuration. You can perform this task only if you have
reviewed the entire manual. You should try to simulate the task(s)
that you expect to perform when you permanently install your
system. However, do not attach a load at this time. This will give
you a realistic preview of what to expect from the complete
configuration.

Step 5 After you have tested all of the system'S functions and used or
become familiar with all of the system's features, carefully read
Chapter 3, Installation.

Step 6 After you have read Chapter 3 and clearly understand what must be
done to properly install the system, you should begin the installation
process. Proceed In a linear manner; do not deviate from the
sequence or installation methods provided.

Step 7 Belore you begin to customize your system, check all of the system
functions and features to ensure that you have completed the
installation process correctly.
VI BL SERVO DRIVES USER GUIDE

The successful completion of these steps will prevent subsequent

perlormance problems and allow you to isolate and resolve any
potential system difficulties belore they affect your system's
operation,

Developing Your Befor. you attempt to develop and implement your application, you
Application should consider the following:

• Recognize and clarify the requirements of your application.

Clearly define what you expect the system to do.
• Follow the guidelines and instructions outlined in this user guide.
Do not skip any steps or procedures. Proper installation and
implementation can be ensured only if all procedures are
completed in the proper sequence.
------------------------CHAPTER 1. INTRODUCTION 1

Chapter 1. INTRODUCTION

Chapter The information in this chapter will enable you to understand the
Objectives product's basic functions and features.

Product The BL Series drives are high performance. low-loss pulse width
Description modulated DC servo drives suitable for use with Digiplan brushless
(ML range) servo motors. The drives can be supplied with an
integral positioner which accepts motion control commands over an
RS232C link. They are designed for rack or panel mounting and
power-plate technology makes them capable of delivering a
continuous output power of 1OOW to 2kW. Adjustable current
limiting allows them 10 be matched to a wide range of motors.

The drives are fully protected against damage caused by

overheating and by short·circuits across motor connections or to
earth. Additional protection circuitry monitors the vottage rails within
the drives and disables the power switches if these fall outside the
specification.

AOAPTOR I'CB
F'OSmONEA PCB

REAR LEOS ~s:~:;:""':;:;::;'r

P.IVE PCB II'"
LED'

AOJUST'MENTS
"
HEAT511\[1( ~1~'("",,;'iiill
CONNECTOAS

BLX30 .lX75 BLX150

Figure 1-1. Basic 91. Drives with Positioner

The buill-in power supply operates from a single AC input voltage

and uses a switching regulator to generate low vo~age supplies.
including power for the optional positioner. The supply has a built·in
power dump circuit which protects its circuits by absorbing the power
generated by the motor during deceleration.
2 BL SERVO DRIVES USER GUIDE

Product
Features
Protection Clrcuhs Adjustable Current Limit
Overcurrent
Overtamparature (Motor or dnve)
Overvo~age
Output short circuil

Function Inclicators Current Limit

Drive Fauij
Overtemperatura
l.ogic Supply On

Adjustments Tachometer gain

Balance
Time constant
Damping

Outputs and Inputs HesetiDisable

Differential velocity/torque demand input
Fault output
Incremental encoder oulpulS

Other Features Power dump

Euro rack system

Variant I"tennatlo" D~ositioner Fitted. not fitted

[MounlinQ RacK. L bracKet or packaged

l'able 1-1. BL Drive Type Variants

Theory of The drive contains all the necessary circuitry to control a brushlass
Operation DC servo motor. It must be used in conjunction with a mains
i~;olating transformer as this produces a suitable AC supply voltage
from the AC mains supply.
 CHAPTER 1. INTRODUCTION 3

The input to the drive is an analogue signal source. for example an

analogue servo controller Dr simply a potentiometer. When the
optional positioner is fitted, commands entered at an RS232C
terminal or from a computer resu~ in signals from the positioner to
the drive which produce the commanded motion control function.
The drive generates motor currents required to achieve the motion
from the servo motor and an encoder provides feedback to complele
the basic system shown in Figure 1·2.
.
BL UNIT

POWER
N;
MAINS
.. I TRANSFORMER SUPf=!LY

ANALOGUE
j
SERVO MOTOR CURRENT
CONTROLLER DRIVE
Cfi
POTENTIOMETER
'-- .. 1
SERVO
MOTOR P
RS232C POSITIONER
TERMINAL'COMPUTER IOPTIONAL) l- t
ENCODER(S)

Figure 1-2. BL Drive System Schematic

Controls and
Indicators
LED's

Current Limit LED Illumination of this LED indicales that the axis is in currenllimit (does
(Yellow) nol disable Ihe axis). This occurs if Ihe rale of change of velocity
demanded cannol be met by the drive or the torque request is
greater than the set peak CLirrent.

Oveffempersrum Illumination of this LED indicates overtemperature in the drive or the

LED (Red) motor connected to it The LED may also be illuminated if an
excessive voltage drop occurs in the motor feedback cable.

Dr/ve Fault LED This LED, when illumlnaled. indicates Ihal there has been an
(Red) incremental encoder signal loss, overcurrent or overvoltage. It will
also illuminale if Ihe 24V DC is present bul the AC inpul is absent.
4 BL SERVO DRIVES USER GUIDE

Logic Supply On This LED indicates that the power to the logic circuits of the drive is
(G"",n) present and correct.

Potentiometers

Balance ThiS 20 tum potentiometer is used to adjust the balance of the

amplifier to give zero motor current when there is no velocity input
demand.

Tach Gain The level of the velocity feedback is adjusted by this 20 turn
potentiometer.

TIme COnstant The Time Constant single turn potentiometer and associated
o)mponents detemnine the bandwidth of the amplifier.

Damping This single tum potentiometer adjusts the response characteristic of

the amplifier so that the aXIs achieves the demanded velocity without
overshoot.

Jumper Links BL drive options are selected by means of nine jumper links as
sllown in Figure t -3. A full description of the jumper link functions
will be found under "Setting Up the Drive". See Table 3-8 for Current
Lmit link settings and Figure 3-7 for Pull Up/Pull Down on disable
ir.put.

[. ___ . :R,; e: m;,; :.o.!~: :eA. tR: :o:.: : .:I:o:~. :b~ o:~: :~e:.:r: . ~: :r~ Ca: : : Jhl.:O,: cl k. lh: :a:;za:c': .:. :I: .in: :k: s: .
____...J

puu UP/PULL DOWN

~
ONDISABLE INPUTA •
ups .. Pull DOWl'1
Pu~

o A RepresentS a
B link in position A

A " Velocity leedl:lac:;k

ENCODER RESOLUTlON
from eneoder A = Torque
B = Nor normally used (sea
s9Ctlon on Tuning Iha I)ri....e)
C .. Torque Amp
A = Up to (1.51" standard)
B = AboV9 (1 5 • 'Slalldard) :'::1" V"oo~
"..., 2 3 J 4 5 6 7 8 9
I I I
~~~~~:
1%1 I ] Ii'0il I Whl f?,%iJ
A B G A 8 A 8 ABC

MODE ./
/ L - I- . - - - - '
A .. VelOCIty Amp /
B .. TorqtJe AmpC .. NOI
normally used (see
section on Tuning the Drivti)
A .. Velocity
AmpB = Torque
Am,
\ CURRENT UMIT
NOTE: Jumper links ara shown In the laCioty sat posillons

Fi!lure 1-3_ Jumper Link Setting Schematic

- - - - - - - - - - - - -CHAPTER 1. INTRODUCTION 5
 CHAPTER 2. GETIING STARTED 5

Chapter 2. GETTING STARTED

Chapter The information in this chapter will help you to do the following:
Objectives
• Verify that each component of your system has been delivered
correctly.
• Become familiar with system components and their
Interrelationships.
• Establish the basic system configuration.
• Ensure that the drive functions correctly.

What You Upon receipt. you should inspect your BL system delivery for
Should Have obvious damage to its container. Report any damage as soon as
possible. The items listed in Table 2·1 should be present and in
good condition. To verify that you have the proper drive model,
check the model number listed on the drive serial plate.

Ship Kh Table Part Deseri tion Part Number

BL Drive L bracket mount: BL30L, BL75L,
BLI50L
Packaged: BL30B, BL75B,
BLI 50B
Front connectors: BL30F, BL75F,
BL 150F
Rear connectors: BL30R, BL75R,
BLISOR
Positioner (i1 ordered-r- BLX30,BLX7S, BLX1S0
Optional Transformers:
Model T092 20S0.036.04
Model TOl70 2050.120.03
Model TOl71 2050.121.03
BL User Guide 1600.13S.XX
Positioner Option User
Guide (if positioner is fitted) tSOO.137.XX

Table 2-1. BL Drive Ship Kit

Systems may be shipped configured with drives and motors prewired

or supplied as separate units.
6 BL SERVO DRIVES USER GUIDE

Pre- This section provides procedures to help you to connect up your BL

installation drive system for a pre-instaliation test. A temporary bench·top
c:onfiguration is used for the pre·installation test. Detailed permanent
Test il~staliation instructions are provided in Chapter 3, Instaliation.

The drive, motor and transformer must be separately connected to

the machine protective earth connection. Terminals are provided for
this purpose as shown in the 1ollowing connection diagrams.

Figure 2-t illustrates the pre-instaliation test configuration for

.ystems without a positioner operating from a 240V mains supply.

LOGIC SUP'"l... YON

CUflRENT U",IT
QP.tVE FAULT
OIl'EATE"'PERAfl.FlE

""""'"
TACH GAIN

§ Ti"'E CONSTANT

::
"
.- USER 110
SAFETY "':
@EARTH
"
TRANSfORMER SECONDARY VOLTAGE'
6WAC MAX FOR BL10
107VAC MAX FOR BL75, BlISO
""
~m ..
FEEO~AC~
"":
: 25WfJ.Y"o-

"
.0 TYPE PLUG
TRANSFORMER .:
" .
::
eM
L "'>e'
N
a"
6'
'1511

I.IOT~ 81
240\1
SINGLE UOT~821IJ~
UOTCND
PHASE MOTOR AI
MAINS WOTM A2

MOTOR ENCODER

Figure 2-1. Pre-installation Test Configur.tion (240V AC Mains Supply)

 CHAPTER 2. GETIING STARTED 7

Figure 2·2 shows the pre·installation test configuration for systems

without a positioner operating from 120V AC mains supplies.

LOCIt: SLPPl YON

CURRENT UMIT
DPJV'E ""lA,.T
OVERTEIdPERAnJRE

' 'AN<'
TAO-IGAIN

nue COHST ANT

! o_~

'"
••
••
••
•• COER'"
SAm·v ••
••
Q:)EA"TH
TRANSFORMER SECONDA.AY IIOLTAGE'
~
61VAC MAX !=OR BL.30 qJ
107\iAC .vAX F;OA BL75, Bl150
l.i
••
..,n,,, ••
•• r-
••
•• 2SWA...,"[)"
FEEDBACX ••
•• TYPE. PLUG l-
sc;~ TRAI~SFORMER
••
••
••
lina ~
L
Iu~ , , , •
,
• • , :)
0' 6" ... C IN

m
N

120V
SINGL.E
0000
olJ oo'c:f
,. O~
'~-:)6 IIIiY
61Var
.oN
u MOTOR!!I
'" 'N
G"
+24VDC
Oil (24VDC)

~
Io'OTQR 92
PHASE IIOfGND
MAINS UOTOR .. ,
IotOToo A;.
I
=
MOTOR
..
T ENCOO e"

Figure 2-2. Pre-installation Test Configuration (l20V AC Mains Supply)

8 BL SERVO DRIVES USER GUIDE
----------------------
Figure 2-3 illustrates the pre-installation test configuration for
s)'stems supplied with a positioner.

LOGIC SLPI"LY ON
C::UAAENT UUlT
OF\lVEF"~T
OVERTEI.F'EP.ATUP:E
RS232C
"'-"<CE

"
•"
0'
0'
"
0>
ISO\. eND
=G~

"".
"".
He",

SAFETY

AlII OUT I
No! OUT Z
TRANSFORMER SECONDARY VOLTAGE_ CON[)
6WAC MAX FO~ BL30
107VAe MAX FOR BL.7S. BL1SO

TRANSFORMER

TO SAFETY
EARll<
o" @
o
Il&V
'"

2,",'
SINGLE
PHASE
MAINS

Figure 2-3_ Pre-installation Test Configuration (Positloner-equipped Systems)

 CHAPTER 2. GETTING STARTED 9

RS232C If a positioner is fitted, the RS232C connections from the controller to

Controller the positioner are as shown in Figure 2·4. Note that the Tx and Rx
lines are cross-connacted so that the transmit output is connected to
the receive input in each case.

POSITIONER

CONTROllE R
ITerminal or computer) FAULT 0

Pin 13 ~
n~
Pi 00
@ ".
0.
g.
~ @
.••'.
.0

,"'
'-'
GN D

:.'.
RX
TX
RX E
• TXE
14 ~
@
Pin 1
Viewed from the sold er side.
The connector require d may
be male or female.
~

Figure 2-4. Controller to Positioner RS232C Connections

A cable suitable for this connection is available from Digiplan. Its

part number is 7967.100. The connections RXE and TXE are not
used for the test.
----------.-------------------------
1. Connect the
Motor WARNING· Electric shock hazard
Ensure that AC power is disconnected before attempting to
, connect or disconnect the motor. Lethal voltages are present
on the motor connectors.

Motor and feedback connectors are pre·wired. Plug the 5-way screw
terminal connector into the Motor socket and the 25·way D
connector into the Motor Feedback socket. During final installation it
may be necessary to extend the leads or re·wire the connectors·
information on lead colours etc. will be found in Chapter 3
"Installation" .
10 BL SERVO DRIVES USER GUIDE

2. Connect the TI,e motor and logic supplies are derived from a single-phase
Transfonner isolating transformer, which should be rated for the total loading.
TI,is clearly depends on the duty cycle, but would be typically 2.5A
@ 61 V forthe BL30. 6A @ 1OlV for the BL75 and 11 A@ 107V for
the BL 150..

Normally, the BL system is shipped with one of the Digiplan

transformers: T0170, T0171 or T092.

primary Fuses Primary in-line fuses protect the transformer and secondary
conductors in the event of a secondary shan circuit fau~ condition.
Suitable fuse values can be calculated using the formulae given in
Chapter 3.

~
efore connecting the AC suppty teads, measure the secondary
v,)ttage(s) from the tsotatlng transformer_ These should not
exceed 61V AC forthe Bl30 or 107V AC forthe Bl75 or BL150
at: the nominal AC input voltage_

Connection Figures 2-1 and 2-2 illustrate connections for the standard Digiplan
Examples transformers. Note separate wires should be used for the drive and
transformer screen connections to safety earth.
Transformer covers must be replaced before power is applied to any
pre-installation test configuration circuit arrangement.

Testing the 1. Set the drive potentiometers as follows:

BL System
TfME CONSTANT FullyCCW
without a DAMPING Fully CCW
Positioner TACH GAIN FullyCW

2. For the pre-installation test set the drive up as a velocity amp by

putting the jumper links in the fotlowing position:

1 A
2 A
3 A
4 A
5 8
6 A
7,8 and 9 A (to give minimum motor current)

For more information on jumper link settings see Figure 1-3 and
Table 3-8.
 CHAPTER 2. GETTING STARTED 11

3. Refer to Figure t -3 and Table 3-8 and set the drive jumper links
- accordingly_ Informalion on setling the jumper links will be
found in the same section.

4. Maka sura that tha motor is held securely and that the shaH is
free to rotate.

5. Turn the Time Constant and Damping controls fully CCW and
the Tach Gain conlrol fully CWo

6. Tum on the 24V supply (if used) and the main AC supply.

7. Rotate the Balance control unlil the molar shaft remains

stalionary. ROlating Ihe Balance control CW should cause the
motor to rotate CW and therefore, rotating CCW should cause
the motor to rotate CCW.

Testing the t. Set the drive potentiometers as follows:

BLSystem
TIME CONSTANT FullyCW
with a DAMPING Fully CCW
Positioner TACH GAIN Fully CW

2. For the pre-installation test set the drive up as a torque amp by

putting the jumper links in the following position:

1 C
2 A
3 A
4 B
5 A
6 B
7.8 and 9 A (to give minimum motor current)
12 BL SERVO DRIVES USER GUIDE

For more information on jumper link settings see Figure 1-3 and
Table 3-8.

:1. Make sure that the motor is held securely and the shaft is fre~
to rotale.

4. Turn on the 24V supply (if used) and the main AC supply.

S. Check that the cOI,troller is communicating with the positioner

by typing I R<CR> (assuming the device address is I). Note
that all commands should be followed either by a space or
carriage return <CR>. The positioner should respond with *R if
it is ready to accepl commands. If there is no response. or a
different character is relumed. refer to the Troubleshooting
seCiion before going any further.

Type OFF to ensure Ihe drive is disabled.

f). Put a wire jumper link or normally closed push-button switch,

between emergency stop and isolated 24V.

~'. Type the following:

CPG5 CVG2 CFGO CTGO COFFO

H. Type the lollowing:

MC VI A500 ON G

H. Motor should rolate slowly. This confirms that the drive is

working.

, O. Type S OFF
 CHAPTER 3. INSTALLATION 13

Chapter 3. INSTALLATION

Chapter The information in this chapter will enable you to do the following:
Objectives
• Mount all system oomponents
• Connect all system inplrts and outputs
• Ensure that the syslem is inslalled properly
• Perform basic system tests

You must complete all steps In Chapter 2, "Getting Started"

before proceeding with the steps In this chapter.

This chapter also covers mains transformer information.

Environment The drive system should be installed in an area where there is

adequate ventilation above and below the racks. In some
applications involving high duty cycles. ventilation fans andlor
additional dump resistors may be required.

BL Power The Bl Series of drives have the following power dissipations:

Dlsslpaliona
Bl30 20W
Bl75 30W
BL150 45W

Additional power dissipations oould result from the power dump

circuits. Since all drives have a 40W continuous rated power dump,
these figures should be increased by 40W each, to give the worst
case conditions.

Mounting the The drives are available with finings for various methods of
Drive mounting. Figure 3-1 shows the mounting methods and the
dimensions of the units.
14 BL SERVO DRIVES USER GUIDE
-----------------------
DImension B
" 11.""1
4, 1.61in

t:., '
7
"")

..,. 279,4
P l.el") 261,8 . "'.-
(liD")

~
(10.3 11
(10,""1
,~,

''''

,
r
l] "-
TO REr.tOVE COVER [TO At TEA
JUMPER UNK SETTINGS)
REMOVE THE 4 ARROwED SCREWS
BLJOL·l0HP,50.5/1991.,) 8L..XJOL - 21 HI', 106.3 (4.'9 in) BLJOB· 10HP. SO 5 p.9g,n) BlXl08 - 21HP, 106 J (4 19 rIl)
Bl75L· ,4HP, 70.8 (2.791") BLX75L - 21 foil', 10B.3 (4.19 in) BL.758· ,4HP, 70,8 (2 79,n) BlX7SB - 211-1P, 106.3 (4 , .. <r1)
BL 1SOL - 21"'P, 106.3 (4.19 in) 8LXl SOL • 2111-<1', 141 9 (5.5>1 in) Bl' 508 21 !-iI', HI6 J (4,19 in) eo: 1SOB· 21HP, 141.9 (S.S; in)
'L' BR,ACKET PACKAGEO

",.
(S 19")

261,8
(HI."")

''''

Bl3OF· 10HP, SO.S (1.99 in) BLX30F· 21 HP. 10&.3 (4 19 in) ElLJOR • 10HP. 50 5 (T ~ in) BL.XJOA . 21 HP. 106.3 (4.19 In)
6L75F. 14HP, 70.8 (Z.79 in) BLX15F. 21HP, 106.3 (4.19 In) 6L75R· 14HP. 70.6 (2 79 In) BL.X75R . 21 HP, 106.3 (4.19 in)
BL 150F· 21 HI', 106 J (4.19 in) BLX150F - 2lIHP, 141 9 (5,59 in) 9L 150R 21HP. 1063 (4.19 in) Bl...X 150R . 26HP. 141.9 (5.59 ,n)

RACK MOUNTING, RACK MOUNT1NG

CONNECT1)RS AT FRONT CONNECTORS ArREAR

Figure 3-1. Mounting the Drive

 CHAPTER 3. INSTALLATION 15

Mains This section describes the range of mains transformers suitable for
use with Bl drives available from Digiplan. It is advisable to test that
Transformer either 61 VAC (for an 85V DC motor supply) or 107VAC (for a t50V
DC motor supply) is obtained on the secondary 01 the translarmer
used belore connecting it to the equipment. The equipment will be
damaged il the voltage is too high. A qualilied electrician should
carry out this work.

NOTE: It is our convention to quote transformer secondary VOltages

in the open circuit condition.

To use the system on a different mains supply. you will need to

change the translormer connections. The informalion given in this
section will show you how to do this.

Table 3-t shows details of the transformers available. These are all
for single phase operation.

Type DC Supply VA Raling Suilable Drive

Model T092 8Sv 700 Bl30
Model T0170 'SOv 1300 Bl7S. BL150
Model TO'7' , 50v 2500 Bl75. Bl150

Table 3-1. Optional Mains Transformers

Figures 3-2 and 3-3 show the translormer connections when used
with 240VAC mains supplies and t20VAC mains supplies
respectively.

Transtonner Where several drives are to be operated from the same isolating
Connections transformer, it is desirable that a separate secondary winding is
provided for each drive. If thiS is not possible, ensure that the wiring
impedances to each drive are closely matched by connecting each
unit individually back to the transformer using equal lengths of wire.
Don't 'daisy chain' drives by looping the AC input from one to the
next.

Wire Size Transformer secondary wiring should use copper conductors with a
cross sectional area of at least 1mm 2 (18awg tri-rated cable).
16 BL SERVO DRIVES USER GUIDE

it:N. TRANSFORMER
'" )
"~
L ~-
i'oP. ~

~" ACIN
~
N
0 0 0 0,2 0 ACIN
240V
SINGLE
PHASE
MAINS
0-
000'0
0&' ""
J S. 8 ......
1·24VDC
GND

OV 124VDC)
MOTORBI
MOTORB>
MOT GND
MOTOR A1
MOTORA2

Figure 3-2. 240VAC Connections

SAFETY
@EAFITH

:IC>t.. TRANSFORMER
'" )
"oo
.~,
, , ,
N
L

Geido
XX)
•
0'1
0,...
n ACIN

I o() 0' c/
ACIN

m
11.4

I20V 1, ).0..06 S>s.... ()... U GND

.24VDC
SINGLE elY",
PHASE "" OV(2 4VDC)
MAINS

MOTO R B,
MOTO R 82
MOT GND
MOTOR A1
MOTO RA2

Figure 3-3. 120VAC Connections

 CHAPTER 3. INSTALLATION 17

Prtmary Fuse Primary fuses need to be rated to protect the transformer and
RatIngs secondary wiring from short circuit fau~s whilst withstanding the
primary in-rush current at power up. The fuse rating can be
calculated as follows:

. (A) Transformer VA x 1.2

Fuse rating = 5 "
upply vo"s

Fuses need to be of the anti-surge high breaking capacity type,

which have a limited range of values, consequently you may need to
select the next highest standard value rather than the calculated
value.

For example, a 300VA transformer used with a supply of NOV will

require a 1.5A fuse, consequently the next highest standard value of
2A will need to be selected.

Voltage Table 3-2 gives details of the terminal connections for the range of
mains input Voltages. Input vollages in the range 360 to 480V are
Adjustment
for connection across two phases of a three phase supply.

Input Primary Jumper Links

voltage connections
Line 1 Line 2
100 1 9 1-2-3-4, 9-10·11-12
1 10 5 13 5-6·7-8, 13·14-15-16
120 1 13 1-2'3-4, 13-14-15·16
200 1 10 9-2, 11-4, 1-3. 10-12
208 5 10 13-2, 5-7, 15-4, 10-12
220 5 14 13·6, 15·8, 5·7, 14-16
230 1 14 1·3, 13·6, 15·8, 14-16
240 I 14 1-3, 13·2, 15·4, 14-16
360 5 12 9-6,10-7,11-8
380 5 16 9-6, 10-7, 11-8
400 1 12 9·2. 10·3, 11-4
420 1 16 9·2, 10-3, 11-4
440 5 16 13·6, 14-7, 15-8
460 5 16 13-6, 14-3, 15-4
480 1 16 13·2, 14·3. 15-4

Tabfe 3-2. Transformer Connections

The transformer safety cover must be replaced following adjustment

Of the terminal connections.
18 BL SERVO DRIVES USER GUIDE

DC Power BL drives may be powered from DC supplies connected through the

Input AC IN connectors. The maximum DC vo~age for BUBLX30 is 85V
DC, while the BUBLX75 and BUBLX150 is 150V DC.

Power Dump The regenerative power dump incorporated in the BL drtve has a
Ratings maximum continuous power rating of 40W. The power actually
dissipated in any specific application is not simple to calculate - it
depends on a large number of factors including maximum speed,
load inertia, deceleration rate, duty cycle, motorldrive losses & time
elapsed since acceleration. The worst situation occurs when a high·
inertia load is decelerated repeatedly from high speed using the
maximum decelerating tOrQue.

The following graph show the relationship between total inertia and
maximum speed if the rating of the power dump is not to be
exceeded. It is assumed that the load is decelerated from its
maximum speed to rest at full torque, and that the operation is
"'peated at the maximum duty cycle allowable for the motor. If the
maximum speed is below the crttical speed "'c then the maximum
inertia is not limited by the power dump, but of course the motor duty
cycle must not be exceeded. There is no danger of over-rating the
power dump when using either the ML 1620 or ML2340 motor.

60.0

->~ 50.0
~
"0

"
~
CI) 40.0

30.0
10 20 30 40 50
Inertia Kg/cm 2

Figure 3-4. Totallnerti. plotted against motor speed

 CHAPTER 3. INSTALLATION 19

The power dump circuit incorporates a fuse which will blow if the
dump turns on for an excessive period. This may occur under fauH
conditions or when a very large inertia is decelerated hard from
maximum speed. The largest load inertia which can be decelerated
from maximum speed in current limit without blowing the dump fuse
is given below:

ML3450 motor with BL150 drive - 40 kg-cm 2

ML3475 motor with BL150 drive - 70 kg-cm 2

It should be stressed that these figures and graphs are provided for
guidance only and are based on conservative estimates. Operation
outside the quoted limits will not necessarily over-dissipate the
power dump depending on other factors as mentioned previously.
20 BL SERVO DRIVES USER GUIDE

Drive Signal
Connections

LOOICSU PPLY ON
CURRE NT LIMIT
DRIVE FA ULT
OVERTEM PERATURE
BALANCE
TACH GAl N

§ TIMECONSTANT
'=
DAMPI NO
c!
Pin 15
~ ~ Pin8
.0
c·
o·
@o USE A 110
•
I~.
-
Pin 9
@ Pin 1

Pin 2 ~
~ Pin 13
.@
.@
••
.-
o·
."
."
MOT OR
FEE OBACK

Pin 14
I~' '."ill
@

AC IN
AC IN
ON D

+24VDC
OV (24VD C)

MOTOR 81
MOTOR 82
MOTON D
MOTOR A1
MOTOR A2

Figure 3-5. Conneclors and Indicators

 CHAPTER 3. INSTALLATION 21

User 1I0 Connector Pin Signal Name Function Signal

Pin Functions Type
1 V2t Analogue velocity L
incul
2 Vlt Analogue velocity L
inpul
3 -15v Reference voltage 0
4 GND Ground Q
5 RST ReseVDisable P
6 +15V Reference voltage 0
7 DIG TACH Analogue velocity
oulput
8 Not used
9 FT Fau~ N
10 AOp· A output from M
incremenlal encoder
11 AOP A output M
12 BOp· B outpul from M
incrementa! encoder
13 BOP
- B output M
14 ZOP •• Z output from M
incremental encoder
15 ZOP Z out ut M
t Positive input on pin 2 (VI) wrt pin 1 (V2) causes CW motion
• AOP leads BOP for CW motor rotation
•• ZOP is a once·per-rev high.going pulse. covering ~ of a channel
AOP cycle and occuring when AOP and BOP are both high - see
below;

JUL
0LJI
0L
Table 3-3. User 110 Connector Pin Functions

Motor Connector Pin Signal Name Signal Type Lead Colour·

Functions
Motor Bt I Brown
Motor B2 I Grey
MOTGND J - Green
Motor At I White
Motor A2 I Yellow
-
Table 3-4. Molar Connector Pin Functions
22 BL SERVO DRIVES USER GUIDE
---------------------
Motor Feedback Pin Function Signal Laad Colour
COnnector Pin
FunctIOns
Number Type
I Screen R Drain Wire
2 OV E Bk }
3 5V D Rd Twisted Pair
4 Not connected
5 Not connected
6 MOT F Ad
7 MOT F Gn } Twisted Pair
8 z- C Rd
9 z+ e w } Twisted Pair
10 B- e Bk
} Twisted Pair
II B+ e Or
12 ",. e Bk }
Twisted Pair
13 A+ e Brn
14to 17 Not connected
18 A3 e Bk
} Twisted Pair
19 A3 e W
20 A2 e Bk
}Twisled Pair
21 A2 e Gn
22 AI e Bk
} Twisted Pair
23 AI e BI
24 Ail C Bk
25 AO C Y } Tw'sted Pair
Table 3-5. Motor Feedback Connector Pin Functions

AC In Connector Sianal Name Function Signal Tvpe

ACIN AC supply voijage Irom G
mains transformer
ACIN AC supply vOltage Irom G
mains transformer
GND Ground for mains H
transformer screen

Table 3-6. AC Input Connector Pin Functions

 CHAPTER 3. INSTALLATION 23

24V DC Connector Signal Name !Function Si nalType \

+24V DC +24V DC supply to dove A
OV (24V DC) OV of 24V DC supply to B
dove

Table 3-7. 24V Supply Connector Pin Functions

Key 10 Signal Types A +24v supply 10 dove

B OV of 24V supply to drive
C Differential encoder input
o Encoder supply vottage
E Encoder supply OV
F Motor Qvertemperature input
G AC input from mains transformer
H Ground for mains transformer screen
I Motor supply
J Motor Ground
L Analogue velocity demand signal
M Differential output from incremental encoder
N Open collector output
o Reference vo~age out (1 OmA max.)
P Active low control mput
Q Logic supply ground

Using an The BL drive has an on-board switch-mode power supply which also
External +24V supplies the positioner. if Iitted. This supply normally nuns from the
AC input. If it is requirec that the logic supply to the positioner be
Supply maintained even when the AC input is removed (to keep the
positioner communicating) a 24V DC supply can be connected to
this 2 pin socket. This will maintain all the logic supplies when the
AC input is removed. When the AC Input is restored, the current
from the 24V DC supply, normally about 750mA, falls to zero.

Using an The incremental encoder incorporated in the motor may be used to

External provide position information to an ex1ernal positioner. Terminals 10-
15 on the User I/O connector provide the tnue and complementary
Positioner signals from all three encoder channels (see Table 3-3). These
outputs are generated by 26LS31 line dovers.
24 BL SERVO DRIVES USER GUIDE

Rewiring the If it is necessary to disconnect the feedback cable for any reason (to
Motor feed it through a conduit, for example) it is recommended that it is
disconnected at the motor end. To do this, loosen both gland nuts,
Connections take off the terminal cover by removing the 4 retaining bolts, make a
(:areful note of where each pair of wires Is connected and then-
loosen all the screw terminals to remove the cable.

The main motor cable has 5 leads and is terminated in a 5-way

!;crew terminal connector. This connector is easily removed and
refitted where necessary. The lead colours are shown in Table 3-4;
make a note of where each colour wire is connected before
proceeding and take particular care that the leads are reconnected
c:orrectly.

Direction of The motor shaft will rotate clockwise (viewing the motor from the
Rotation !;haft end) when the VI signal is positive with respect to V2. When
used as a torque amplifier, clockwise torque wi! be produced when
\/1 is positive with respect to V2_

Tach Pin 7 of the User I/O connector is available to monitor the motor
Feedback velocity. Motors with an incremental encoder line count of 1000 will
generate signals of 3V/l 000 rpm ±20%. whilst motors with an
incremental line count of 500 will generate 1.SV/l 000 rpm ±20%.

Setting Up the
Drive
ApplicatIon Types There are two basic types of applications (described below) for the
ElL servo drive. Each type of application requires a different type of
tuning.

Velocity FollowIng For this application, it is required that the axis follows programmed
velocities as accurately as possible. A high amplifier gain is needed
so that the small Signals resulting from small velocity errors will
produce large correcting torques.

Torque AmplifIer In this type of application, the torque produced is required to be

proportional to the input vohage. Low amplifier gain is needed in this
case. The torque produced directly relates to the motor current. For
example, a gain of 1M/olt would produce 1A of motor current for
each vo~ atth. input (±1 OV at the input would produce ±1 OA of
motor current).

Initial Before starting to tune the drive ensure that the motor mechanism is
Precaution clear of obstructions. Position the mechanical system at the mid-
position of its total travel. Do not allow the molar to remain unstable
for more than a second or two.
 CHAPTER 3. INSTALLATION 25

Setting the Depending on how you want to use the drive, you may need to
Drive Jumper change some of the factory· set link positions. Figure 3-6 shows the
positions and functions of all the jumper links. See Table 3-8 for
links Current Um~ link settings and Figure 3-7 for the Pull UplPull Down
on Disable Input.

WARNING - Electric shock hazard

Remove power before chanalna Jumper links.

PUll UP/PULL DOWN ON

DISABLE INPUT
,A,. Pull up
,B .. Pull Down

A • Velocity feedb<lck
ENCODER RESOLUTION
from encoder A = Torque A"1J
B - Not normally used (se,!
section on Tuning the Drive)
A '" Up to (1.5 x standard)
B ,.. Above (1.5 x standard)
B• TOCily Amp
)
C '"' Torque Amp

2 4 5 6 7 8 9
""""'twa"....:.1"1'I twa 1 WfLJ
ABC A B
MODE
A B
~~~~~:
A IIr Velocity Amp / 1

8 '" Torque Amp

C '" Not Mnnally used (see
section on Tuning the Drive)
A = Velocity Amp
B :r Torque Amp
\ CURRENT LIMIT

~
OTE: A KEY
Jumper links are shown Represents link in
IT
in the factory set pOSitions B position A

Figure 3-6_ Jumper Link Setting Schematic

26 BL SERVO DRIVES USER GUIDE

JumparLlnk LINK 1 A Digital Tach Velocily Feedback (VA)

InfonnatJon B Scaled Torque Demand via Tach Gain pot (TA)
C Link Pari< for the Fixed Torque Amp Gain (TA) or
Velocity Feedback Irom Tachomeler (VA)

LINK 2 A Disable input Pull Up

B Disable input Pull Down

LINK 3 A Digital Tach Gain Siandard resolution encoder

B Digital Tach High Res encoder

LINK 4 A Standard velodty demand setting (VA)

B Fixed Gain Torque amp (TA)
Low velocity demand setting (VA)
(Recommended for BUBLX:JO)
C Link Pari< for Scaled Torque Demand (TA)

LINK 5 & 6
TOROUEAMP :L1NK 5 A & LINK 6 B

VELOCITY AMP :AS BELOW

LINK 5 LINK 6 GAIN

None None .66
A B 6.5
A A 51
B B 500
B A 5000
LINK 7. 8. 9 CURRENT LIMIT - see Table 3-8

VelOCity or Torque The BL drive would normally be used as a velocity amplifier, in which
Amplifier case the jumper links are sel as follows:

Link 1 - A Link 5 _ B
Link 4 - A Link 6 = A

To use the drive as a torque amplifier (so that input voltage now
detenmines torque rather than velocity), set the jumper links as
follows:
Link 1 _ C Link 5= A
Link 4 = B Link 6 = B

'When the drive is used as a torque amplifier, turn the Time Constant
conlrol fully CW and the Damping control fully CCW.
 CHAPTER 3. INSTALLATION 27

.15 .t5
LK21nPOSB
(Pull down)
4K7 N.C.

Rst
Rs!

LK21nPOSA 4K7
(Pull up)

ov

Figure 3-7. Reset/Disable Input Circuit Options

Polartty of the Jumper link 2 determines whether the internal resistor on the disable
'Disable' Input input is pulled up or down. In position A, the resistor is pulled up to
+15V and the drive can be disabled by connecting the disable input
to OV using a switch or open-collector transistor. In pOSition 8 the
input resistor is returned to OV requiring a normally-closed switch up
I

to + 15V to keep the drive energised. The options are illustrated in

Figure 3-7. The preferred 'fall safe' connection is with the link in
position B, since the drive de-energises if the connection is broken.

Encoder Resolution With all standard motors, jumper link 3 should be left in position A. If
the motor has been fitted with a non-standard encoder (available to
special order only), and its resolution is greater than 1500 lines,
transfer the jumper link to position B.

Standard encoder msolutions are 500 lines tor size 16 and 23

motors. and t 000 lines for size 34 motors. After quadrature
decoding these procluce working resolutions of 2000 and 4000
counts/rev respectively.

Currem Limit Jumper links 7. 8 and 9 are used to set the peak current which the
Setting drive will deliver. Table 3-8 shows the Jumper link senings for
various peak current levels.

The jumper settIngs limit the peak current of the drive. This is
achieved by the drive amplifier clamping current 10 the level
selected. effectively reducing the dynamic range of Ihe signal. For
example an input of ±10V will generate an output current ot ±Ipeak
(±30A for the BL 150). When the jumpers are set to limit the current
to 1OA the input VOltage will be restricted 10 a range of ±3.3V to
achieve ±t OA, any voltage beyond 3.3V will still only produce 10A.
28 BL SERVO DRIVES USER GUIDE

BL30 BL75 BL150 7 a 9

A
7.5A ISA 30A
B
A
3.75A 7.5A 15A
B
A
2.5A SA lOA
B
A
2A 3.75A 7.SA
B
A
I.SA 3A 6A
B
A
1.2SA 2.SA SA
B

~
A KEY
A Represents link In
lA 2A 4A
B B positIOn A

Table 3-S. Current Limit Link settings

11 is normal to set the peak current at approximately 3 times the

continuous current rating of the motar. The table below shows the
recommended peak current setting for each motor size:

Motor Peak CUirrent

1620 3.75A
2340 7.5A
3450 15A
3475 30A

Table 3-9. Recommended Peak Current

You can use peak current settings higher than the values shown
above provided you tal<9 great care not to exceed the appropriate
duty cycle, otherwise you may burn out the motor. Information on
duty cycle calculation will be found in Digiplan's Analogue Servo
Application Guide, or you can obtain engineering assistance from
Digiplan or your local distributor. Also, if you make the motor go
unstable during tuning, disable the drive immediately to prevent
damage to the motor.
 CHAPTER 3. INSTALLATION 29

Tuning the The appropriate tuning procedure shoutd be carried out on each
Drive axis. The procedures in this section assume that you have
completed the connection and test procedures provided in Chapters
2 and 3. The motor should be coupled to the load at this stage.

Tuning the
Drive without
a Positioner
Tuning for use as a Use the following procedure to tune the drive.
VOloclty AmpUllar

Step 1 Set jumper links.

Step 2 Make sure the power to the drive is off and that the motor is held
securely and the shaft is free to rotate.

Step 3 Adjust the front pan,,1 controls as tollows:

TACH GAIN FullyCW

DAMPING Fully CCW
TIME CONSTANT Fully CCW

Step 4 Apply zero velocity demand to the input by connecting both signal
inputs (VEL t and VEL2) together.

Step 5 Switch on the powerto the drive. Should the motor rotate, adjust the
Balance potentiometer in the opPosite direction to the motor rotation
until stationary.

If any fault LEOs illuminate. refer to Chapter 5, "Maintenance &

Troubleshooting".

Step 6 Set the velocity amplifier sensitivity by applying a signal of 20% of

maximum input (2V for ±t OV operation) and adjusting the Tach Gain
20-turn potentiometer to give 20% of maximum speed.

Step 7 Reduce the input signal to zero to stop the motor.

Step 8 Rotate the Time Constant control clockwise untillhe motor shaft
starts to oscillate (characterized by a high-pitched ringing sound).
Optimum drive performance is achieved at the point when the motor
first starts to ring. Do not allow the motor to oscillate for more than a
second or two.

Step 9 Increase the input signal to l'Un the motor at high speed (not full
speed) and check for smooth behaviour. If there is excessive noise
or vibration, try tuming the Time Constant control anti-clockwise.
30 BL SERVO DRIVES USER GUIDE

Step 10 Penodically apply and remove short 20% velocity input signal pulses
at approximately I-second intervals. If the control system will not
permit this method of control, remove the signal connections and usa
a separate DC power source (i.e., a battery or a DC power supply) to
provide the signal.

Note the response of tl,e system. Tha velocity may be monitored by

attaching an oscilloscope probe to LKI with the earth clip on pin 4 of
tha usar UO connector (15 way D type). The objective is to optimlsa
the moto~s responsiveness to the input signal. Adjust tha Damping
control to give the shortest sen ling time without overshoot and
without sluggishness. Turning the control CCW makes the motor
Inore responsive (stiff), and turning the control CW makes tha motor
more sluggish.

If the final speed chan~~es considerably. you may want to change the
velocity input signal to compensate. If the motor begins to oscillate
(or oscillate louder than the setting derived from step 10) adjust the
Time Constant control.

Step 11 Remova the input Signal and ground VEL 1 and VEL2 to aach othar,
and, if necessary. readjust the Balance control until the shaft
remains stationary.

Tuning for use as a Use the following procedure to tune the drive.
TorqUQ Amplifier

Step 1 Set jumper links.

Step 2 Make sure the power to the drive is oH and that the motor is held
securely and the shaft is free to rotate.

Step 3 Adjust the front panel controls as follows:

DAMPING Fully CCW

TIME CONSTANT FullyCW

In some torque amp applications it is necessary to set an accurate

torque amp gain (i.e. AmpsNoll or NmNolt). ThIS can be achieved
by setting LKt in position Band LK4 in position C. In this mode, the
otherwise redundant TACH GAIN pot is used as a gain control.

Tuning the Please refer to the Positioner User Guide for-this information.
Drive with a
Positioner
 CHAPTER 4. HARDWARE REFERENCE 31

Chapter 4. HAR[)WARE REFERENCE

Chapter This chapter is designed to function as a quick reference tool for

Objectives system specifications.

BL Drive BL30 BL75 BLl50

Specification
Continuous Current 3.75A 7.SA tSA
Peak current 7.SA 1SA 30A
DC bus Vo~aQe 85V 150V l50V
AC Inpul Voltage: Nom. 61V 107V 107V
Max. 67V l18V l18V
Min. 24V 48V 48V
Wei hts" 0.8K 1.7K 2.BK
Motor Options ML·1620. ML·2340, ML-3450,
ML-2340 ML·34S0, ML·347S
ML-1620
Power input AC direct from mains transformer
Control in ut +10V analOClU9 tor ue or velocltv)
Reference outputs +lSVat 10mA
Velocity feedback Built-in incremental encoder
Commutation method 4 bit absolute encoder
Torque amplifier >2S00Hz
bandwidth
SwitchinQ frequency 20Khz
Velocity amp ,ain 0.66/6.6/51/500/4800 set by links
Torque am ain 0.7S/O.075AV I.S/0.1SAVI 3/0.3AV
Gain linearity +4%
Typ. inpul amp drift IOl'V/'C
Power dump current 9A@ 100V I l6A@100V I l6A@100V
Max. cant. dump power 40W
Min recommended load O.5mH
inductance
Jumper link settings Input range. current limit. torquelvel.
mode
Potentiometer settings Time constant. damping, balance, tach
cain
Diagnostic LED's (Front) Power on, current limit,
overtemperature, drivelmotor fauH
Diagnostic LED's (Rear) Power on, com osite fault
.
Dimensions See Figure 3·1 Cha ter 3)
II the dnve IS supplied with the poSitioner optIOn, add O.SKg 10 Ihls weight.

Table 4-1. BL Servo Drives SpeCification

32 BL SERVO DRIVES USER GUIDE

Input/Output
Specification
Signal Input/Output Characteristics
Command Inputs Differential input between V2 (pin 1) &
Vo~age Sense VI (pin 2)
Range ±10V
+15V & -15V Outputs Maximum current source = 10mA
Reference Not short circuit protected
Vo~aqes
.
Reset Input Vih > 10V
Vii >O.BV
Vin(max)=30V DC
Fau~ Output Open collector, active low
Vmax=+30V DC
Imax=BOmA
Vsat=O.2V @ BOmA
Incremental Outputs 26LS31 line driver outputs
Encoder

Table 4-2. User 1/0 Specification

 CHAPTER 4. HARDWARE REFERENCE 33

Brushless The BL Series drives may be matched with motors in the Digiplan
Motor/Drive brush less range and supplied as ready-wired motor/drive packages.
Details of the range of four motors (Types ML-1620,
Packages ML-2340, ML·3450 and ML·347S) are given in Table 4-3.

Type Weights Rotor tnertla Incremenlel

(Including cable) Kg-cm 2 Encoder line Count
ML-1620 0. 8SKS 0.056 500
ML-2340 2.1Kg 0.28 500
ML-3450 5.1Kg 1.6 1000
ML-347S 6.4Kg 2.4 1000

Table 4-3. Brushless Motor Dale

The dimensions of n,e motors are shown in Figures 4-1 to 4-4 .

....I.
~
~7.0
11..85)
DI. ~,00<5 (0.2':160

;-:A(~~'~
1m'
(07'U7 .0 .Q.00'2I

~,-
[t~
..L ~.O
(2..e)
- -----
L --.-
w (1.301
~o
"'3)( C.S ISO.
~ S to_~ .. DEE?
I2J HOlES
I25A<Q.
I_O~
- ,.
0,(l2,
(0 (6)

~ ..
(2.'2) ( 1.18)

Figure 4-1. Motor Type ML·1620 Dimensions

34 BL SERVO DRIVES USER GUIDE

..
~ ~
oon
~
~
N'

~
~ v.o
~C
KEY OI"'~NSiCW'lS
250X~.OX'.O • ,...
L
KEY DIIoI"h'S101I£S
0.7& J: C.125 X C. 12:5
ro ....
~T '" """ ~ •
•
g
I.IETR.::: SHAFT OIOTAIL . ML-ZloIQ,I,
•
e.tP£RIAl SHAFT ~"'L· IoIl-2:MOB

Figure 4·2. Motor Typ" ML·2340 Dimensions

I~II-I
o NUTS IoIAY ~E ROTA !"ED

-I, - -
lr~)
.
--------- -

1-
_ ..1!J 0.25

.
r'OlhOO'l

." •
ULl4SO- T?':l' II 171

'" " I ~~""

""
KEY DIIolENSIONS
lo..S X S.O I ~
Ii:
~~L~ K8' OlhlE"N9ON9
o.7~){OT25lCO.'2'5
ro_
'""""
;~W
o 1.29'

'"
IM!>ERIAL SH.AFT DETAIL· lolL :;.<5OB,IoIL·)l75S

Figure 4·3. Motor Type ML·:1450 & ML·3475 Dimensions

 CHAPTER 4. HARDWARE REFERENCE 35

Transformer
Dimensions
B

.
A
~ •
... .
'

',QII12
,
1 . 2OV.
. . ... •
l.>!l
~

I& • • • ~,.~
Ii. \. '6 UI
IZlY

\,()';
av*
lA"
'TV

~
c D

I"" .. • • OY " ...

BASE vIEW

Figure 4-4. Transformer Dimensions for T092, T0170 and T0171 - mm(lns)
36 BL SERVO DRIVES USER GUIDE

Molor/Drive The torque curves far the possible motor/drive combinations are
Package shown in Figure 4-4.
Performance Data
YL-1G20 MOTOR WITH BL:JO
•
.oo• "I:A~ l"!I. DUT'fCvc!LE

, '\.
11_. 0. 0 '\.
.... ,, CQIo(TINUOO8 r-...

ML·2340 MOTOR WfTH SUO

, ,,

,
,
SPEED - ....---
.~

UI.-Z340 MOTOR WIllt BL 7S

'\.

>
!], .... DUTY cv C-', PEAl< (ti'llo DUN C CLE)
'n, • '" OM ,

l1U 0 • I I TINUOUSi • \
•
.'".,
M> ,

• \
• nNuowS
~. ,, " ,• \
, ,, , , 20 40
I
110 80 100 120 1.&(1_
C "
IlOO
~ ~
1;>00 18C()
~
uoo
~ ~
" "
lOOO lSOO c200 oUICO.,.., o ,2tIJ 2000 :1600 qQJ IKI'Xl nco 1IA(lJ_

SPEED 5PEED

---
-~
'"
, ML-3450 MOTOR

"[All (i?II"o DUTY CYCLE)

wrrn BL75
" P .... ~
WL-3450 MOTOR WITH BL no

I'l' DUTY evcu)

• •
, \ \
'" 0"' •
, ... • I\,
•
\ , "TIN

, ,o , , \
,0 20 30 40 50 $(l 10 10 '-'" 01020)0","50107080_
o IlOO ':lCO 18m 2<100 lQOO lIioo QW <800 """ o uo 1:;>00 ,1IOCl ~ DlO :MOO QOIJ 01800 _

SPEED SPEED

,
•
ML-3475 MOTOR WITH BL75

-
.-.,.. ,
:':."':.
•
,
UL-3415 MOTOR WITH BL 150
,

,,' •
.-
,
0
CONTINUOU
1\
\
,~

"H •
...... ,••
W
'\

'\

, ,•,
•
,0
too
:ro
, 200l

SPEED
lC
1IlOO
..0
~ 0(1:1
50
\
:!CIOJ
till
-
li8OO_
• ,,
, 10:lll
100 1:100

SPEED
30.&0
,Il00 2000
1\
50
XIO!I
10_
JIOO_

Figure 4-5. MotorlDrlve Packages Torque Curves

 CHAPTER 4. HARDWARE REFERENCE 37

Fuse Ratings BL drives incorporate four fuses - two AC input fuses. a DC bus fuse
and a power dump fuse. Types and ratings are shown in Table 4·4.

Rating
Fuse No. Clrcut! Type BL30 BL75 BL150
FSt AC input 32mmTLHBC 8A 15 or 30 or
16A 32A
FS2 AC input 32mmTLHBC 8A 15 or 30 or
16A 32A
FS3 DC bus 32mmQA SA lOA 20A
HBC
FStO Power dump 20mmTLLBC 2A 2A 2A

11. • Time lag

QA • Quick acting
HBC • High breaking capacity
LBC • Low breaking capacity

Table 4-4. BL FuSE! Ratings

38 BL SERVO DRIVES USER GUIDE
 CHAPTER 5. MAINTENANCE & TROUBLESHOOTING 39

Chapter 5. MAINTENANCE & TROUBLESHOOTING

Chapter The information in this chapter will enable you to isolate and resolve
Objectives hardware problems.

General In order to minimise field failures, all drives are soak tested at
elevated temperatures. In spite of this the occasional failure may
still occur and the following notes are intended as a brief guide to
enable the cause of the faun to be located.

Repairs Whenever possible units should be returned to the manufacturers

for repair, since automatic test equipment not available in the field is
used when testing these drives. All repairs are soak tested before
being returned to the customer.

Drive Removal Before disconnecting a drive prior to removal, ensure that all
supplies are switchecl oN and wait for the Power On LED to go out.

Drive Fault The majority of faults that can occur in the drive will resuh in
LED illumination of the Drive Fault LED. The causes of this are as
follows:

1. HT Overvoltaga Failure of the dump circuit to cope with regeneration. Check the
dump fuse, FS4. Check if the fault occurs during a period of
deceleration, if so, then consult Digiplan WIth a view to increasing
the dump capabilily. If when the motor is stationary the DC supply
normally has a value of more than 165V then there is a danger Of
the overvoltage protection operating under average regeneration
conditions. Lowering the normal opera1ing value of the supply may
well cure this apparent fau~.
2. Overcurrent The drive fault LED will also be illuminated in the event of a short
circuit occurring between the motor terminals or if either terminal is
shorted to earth.

If no external reason can be found, switch off the supply, then

remove the associated motor connections. Switch on the supply. If
the fault LED is now illuminated then the drive is at fault and should
be returned for repair. It may be necessary to request motion in
either direction to obtain the fault.
40 BL SERVO DRIVES USER GUIDE

3. Lose of The LED will be illuminated if the signal from the incremental
Incremental encoder is not present. The motor WOUld run away out of control if
Encoder Signal
this was not detected.

If previous tests have not enabled the fauH to be isolated, then

substitution of the drive should enable the fau~ to be narrowed
down to one drive which can then be returned for repair.

Overtempera- This LED indicates an overtemperature fauH. tt may be the resuH of

ture LED a drive fauH. which can of course be proven by substitution. 11 this
does not identify the fauH then checks should be made to ensure
that the ambient temp,nature does not exceed 40°C, when all units
in the vicinity of the dnve have reached their normal operating
temperature. A cooling fan may be necessary if high duty cycles are
required.
If the LED comes on at power·up and cannot be reset, this indicates
an excessive voltage drop in the feedback cable to the motor and
may be due to over·lon9 cables of inadequate size. Please refer to
Appendix 1 for information on extending the motor cables.
The LED may also indicate motor overtemperature.

Power On LED This LED mdicates that the logic supplies are present. tt will remain
illuminated for a short time after the drive has been switched off, due
to the stored charge In the capacitors.

Incorrect
Operation
Noise from Motor or ThiS is usually caused by the Damping or Time Constant controls
Unstable Motor requiring adjustment. Ae-adjustment of either of these two controls
Operation should cure this. If none of these checks has isolated the problem
then substitution of the drive should be used to prove whether or not
the drive module is at fault.

Motor Creep This is usually caused by an incorrect setting of the Balance control,
so first check this setting by confirming that there is zero velocity
command on Vt and V2 inputs. Then adjust the Balance control
until the motor shaft is stationary.

Ensure that all signals are supplied in twisted pairs or screened

cables.

If none of these steps resolves the problem then, once again, try
substitution of the drive module to prove if the drive is at fault.
 CHAPTER 5. MAINTENANCE & TROUBLESHOOTING 41

Returning the Contact the Parl<er Automation Technology Centre or the machinery
System manufacturer who supplied the product. Equipment for repair
should NOT be returned directly to Digiplan without prior
authorisation. Repairs will be carried out by Digiplan but will be
processed via your supplier.

Digiplan may at their discretion authorise direct shipment to and

from Poole or Rohnen Pari<. but only by prior arrangement with your
supplier. Existing UK and USA customers who purchase equipment
directly from Digiplan should contact Poole or Rohnert Pari< for
further information (conlact numbers are at the front of this User
Guide).
42 BL SERVO DRIVES USER GUIDE

Appendix 1.

Fitting Longer When you order an ML motor. you can specify cable lengths up to
Cables 75 feet (22.5 metres). Whenever possible. it's better to order the
motor with sufficient cable in the first place rather than try to extend it
aftarwards. If you need cables longer than 75 feet. you can make
your own up to a maximum of 300 feet (90 metres) provided you
follow the guidelines below.

Motor cables can be lengthened by simply replacing the cable with

a longer one using the standard cable as a pattern. It needs to have
5 cores with an overall screen. Use t mm 2 (or 16 AWG) cores with
a 2340 motor. and 15 mm 2 (or 14 AWG) with a 3450 or 3475.

The 1620 motor is pm-wired with 4-cor8 cable, so it is only

necessary to use 4-core screened cable when extending the lead.

Recommended
Cable Sizes
Motor Frame Motor Cable
Size
.,1001t , ~O-300ft
16 O.5mm 2 0.75mm2
20 AWG 16 AWG
4-core 4-care
23 O.75mm 2 lmm2
16 AWG 16 AWG
5-cor8 5-core
34 1mm2 , .5mm 2
16 AWG 16 AWG
S-core 5-core

Table A-2_ Motor Cable Sizes

 APPENDIX 2 43

Feedback Cables The feedback cable may be extended up to a maximum of 50 feet

(15 metres) using the same type of cable as that supplied with the
motor. Each conductor in this cable is 0.2mm2 (24 AWG). This type
of cable is unsuitable for longer lengths owing 10 the vo~age drop in
the 5-vo~ supply to the encoder.

Encoder cables can be up 10 300 feet long before any noise

problem is encountered, bUl it's important 10 consider lhe vo~age
drop in the 5V supply leads to the encoder. If the vo~age at the
encoder is tao law, it can cause curious problems such as
continuous illumination of the Qvertemperature LED. The encoder
must have a minimuill supply voltage of 4.5 volts and it draws a
current of about 300mA. Thus the total resistance of the 5V and OV
wires must be less than about 1.7 ohms. When you calculate this
resistance, remembetr to multiply the resistance per metre (or per
foot) by twice the cable length.

Probably the easiest way to lengthen the encoder cable is to cut the
existing cable close to the motor and again close to the drive, and to
insert a new length of the same type of cable using in-line
connectors or terminal boxes. Suitable cable types are
Cablemaster OS1024P and Belden 9510. Try 10 keep the two wires
in any pair close to each other as they pass through the terminal
box. Remember to connect the screen of the new section to the
screens of the lwo short lengths of original cable.

Having done this, now locate the red and black pair (which carry 5V
and OV) and run two larger wires in parallel with this pair between
the two terminal bOXE~S. Each of these wires must have a resistance
of less than 0.85 ohm. For example, use 1 mm 2 (or 16 AWG) cable
for leads up to 150 feet (45m) long, and 2.5 mm' (or 14 AWG) cable
for leads up to 300 feet (90m) long.

Insening In- It's sometimes necessary to be able to disconnect Ihe motor easily,
line and a convenient solution is, to fit in-line connectors. Generally the
closer lhe connector is to the motor the beHer. Here are the part
connectors numbers for suitable MIL Spec connectors from Amphenol:

19-way Encoder Connectors 62GB-t lF14-19PN 62GB-16Ft 4-19SN

5-way Motor Connectors 62GB-II F14-05PN 62GB-16FI4·05SN
a-way Motor Connectors 62G13-11 F16-08PN 62GB-16FI6-09SN

The connector shown above for the encoder cable has 19 pins: the
19th pin is used for the drain wire, i.e. the connection to the cable
screen. If the connectors are within 500mm (18-) of the motor, you
can use a 5-way connector in the motor cable and leave the screen
unconnected. In other cases, use the a-way (which is a larger shell
size) and use pin 6 to link the screens on either side of the
connector. Don'l connecllhe screen or drain wire 10 Ov.
44 BL SERVO DRIVES USER GUIDE

Take great care to mal,e sure that both connector halves are wired
correctly. otherwise th" encoder or drive may be damaged. If the
encoder cable has 10 pairs. the red and blue pair should be
connected in parallel with the red and black pair (i.e. red parallel
with red. blue parallel with black).

Proprietary
Cable Types
Mota, NO.of mm2 ODmm Lapp Belden Alpha
Size cores
16 4 0.5 7.0 0034
604
16 4 0.5 6.0 5464C
16 4 0.75 6.0 9418
23 5 0.75 8.2 0034
705
23 6 0.75 7.8 5386C
23/34 5 1.0 9.0 0034
805
23/34 6 1.0 8.9 5366C
34 5 1.5 13.2 5450/5

Table A-3. Moto, Cable Types

No. of mm 2 ODmm Lapp Cable- Belden Alpha National

cores ma,ste,
9x2 0.2 9.2 OS9P24 9509
9x2 0.75 15.0 2249C
10 x 2 0.2 9.4 OS10P24 95tO
10 x 2 0.25 10.1 0035805
10 x 2 0.5 11.8 NOP-
1020FSJ
12 x 2 0.75 16.8 2249/12C
12 x 2 0.75 14.0 NOP-
1218FSJ

Table A-4. Feedback Cable Types

 INDEX 45

Index

150V DC motor supply 15 Jumper link settings 25

24V Supply Connector 23 Jumper Links 4
85V DC motor supply 15
LED's 3
AC Input Connector 22 Logic supplies 40
Assumptions iv Logic Supply O. (Green) 4
Atmospheric contamination v Long cables 42
Long cables fau~ 40
Balance control 40
Balance pot. 4 Mains isolating transformer 2
Basic electronics jv Mains Transformer 15
Basic motion control jv Mains transformer options 15
ML-1620 Dimensions 33
Contents of This Manual iv ML-2340 Dimensions 34
Cooling fan 40 ML-3450 & ML-3475 Dimensions 34
Current Limit LED (Yellow) 3 Motor Cable Sizes 42
Motor cables (extending) 42
Damping pot. 4 Motor Connector 21
DC power input 18 Motor Creep 40
Developing Your Application vi Motor current selection 28
Oigiplan transformers 10 Motor data 33
Drive Fault LED (Red) 3 Motor Feedback Connector 22
Drive operation 2 Motor velocity monitor 24
Drive Removal 39 Mounting methods t 3
Drive Signal Connections 20
Dump fuse 39 Noise from Motor 40

Electrical noise v Overcurrent 39

Encoder Resolution 27 Overtempera-ture LED 40
Environment 13 Ovenemperature 40
External 24V supply 23 Ovenemperature LED (Red) 3
External positioner 23 Overvoltage protection 39

Factory configuration 5 Positioner 1, 9

Feedback cable lengths 43 Potentiometers 4
Fuse descriptions 37 Power dump circuit 1
Fuse rating calculation 17 Power dump rating 18
Fuse Ratings 37 Power On LED 40
Power supply 1
HT Overvoltage 39 Pre-installation test 6
Pre-installation test configuration 6
1/0 specification 32 Pnmary fuses to
In-line connectors 43 Protection Circuits 2
Installation
Transformer connections 10 Regeneration 39
Installation Process Overview v Repairs 39
Installation Recommendations v Returning the System 41
Isolating transformer 10 Rotation direction 24
RS232C terminal 3
46 BL SERVO DRIVES USER GUIDE

Ship kit 5
Switching regulator 1
System specifications 31

Tach Gain pot. 4

Terminal connections 17
Time Constant pot. 4
Torque amplifier 24
Torque Curves 36
Torque jumper settings 26
Transformer dimensions 35
Tuning without positioner 29

Unstable Motor Operation 40

User Guide version i
User 110 Connector 21

Velocity amplifier 29
Velocity following 24
Velocity jumper settings 26

Wire size 15