Kollmorgen BDS5, Installation And Setup Manual

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CHAPTER 1. SYSTEM DESCRIPTION
1.1 Introduction..................................................... 1-1
1.2 Product Description ........................................ 1-1
1.3 Features........................................................... 1-1
1.4 Part Number Description ................................ 1-3
1.4.1 BDS5 Model Number .................................. 1-4
1.4.2 Compensation Module Model Number........ 1-5
1.4.3 PSR4/5 Model Number................................ 1-6
1.4.4 ER-External Resistor Kit Model Number .... 1-7
1.4.5 Molex Assembly Tools ................................ 1-7
1.5 Specifications and Ratings .............................. 1-8
1.6 Theory of Operation...................................... 1-12
1.7 Simplified Schematic Diagram
and System Diagram ..................................... 1-13
CHAPTER 2. INSTALLATION
2.1 Introduction..................................................... 2-1
2.2 Safety Information .......................................... 2-1
2.3 Unpacking And Inspection.............................. 2-2
2.4 Installation Requirements................................ 2-2
2.4.1 Environmental Considerations ..................... 2-2
2.4.2 Enclosures.................................................... 2-2
2.5 Mounting......................................................... 2-2
2.5.1 Mounting the BDS5 ..................................... 2-2
2.5.2 Mounting the PSR4/5................................... 2-3
2.5.3 Mounting the External Regen Resistor ........ 2-3
2.6 Wiring ............................................................. 2-3
2.6.1 Wiring the Ground ....................................... 2-4
2.6.2 Wiring the Power Connections .................... 2-4
2.6.2.1 Wiring the Motor ...................................... 2-4
2.6.2.2 Motor Protection ....................................... 2-5
2.6.2.3 Motor Thermostat ..................................... 2-5
2.6.2.4 Motor Brake.............................................. 2-5
2.6.2.5 Wiring the DC Bus.................................... 2-6
2.6.2.6 Wiring the AC Line................................... 2-6
2.6.2.7 Wiring the Regen Resistor ........................ 2-6
2.6.3 Wiring the PSR4/5 Front Panel
Connectors ...................................................... 2-6
2.6.3.1 Wiring the Control Power to C1 ............... 2-6
2.6.3.2 Wiring to the PSR4/5 Fault
Output on C1................................................... 2-6
2.6.3.3 Wiring PSR4/5 Connector C2................... 2-6
2.6.4 Wiring the BDS5 Front Panel
Connectors ...................................................... 2-7
2.6.4.1 Wiring C1, Encoder Equivalent ................ 2-7
2.6.4.2 Encoder Equivalent Input.......................... 2-9
2.6.4.3 Pulse Input (OPT2 Card) .......................... 2-9
2.6.4.4 Encoder Equivalent Output ....................... 2-9
2.6.4.5 Wiring C2, Customer I/O........................ 2-10
2.6.4.6 Wiring C3, Resolver ............................... 2-11
2.6.4.7 Wiring C4, Logic Power Supply ............. 2-11
2.6.4.8 Wiring C5, Serial Communications ........ 2-12
2.6.4.9 Wiring C6, Fan Power (20 Amp
Units Only) ................................................... 2-14
2.6.4.10 Wiring C7, Standard I/O ....................... 2-14
2.6.4.11 Wiring C8, Optional I/O ....................... 2-15
2.6.4.12 J1 Configuration Jumper ....................... 2-16
2.6.5 Establishing Communications .................... 2-16
2.6.5.1 Required Data Format............................. 2-16
2.6.5.2 First Transmission................................... 2-16
2.6.5.3 Checking the Control Power ................... 2-17
2.6.5.4 If You Can't Communicate...................... 2-18
2.7 Initial Check-Out........................................... 2-18
2.7.1 Checking Discrete Inputs ........................... 2-19
2.7.2 Checking General Purpose Outputs ........... 2-19
2.7.3 Cycle Ready ............................................... 2-20
2.7.4 Checking STATUS .................................... 2-20
2.7.5 Checking Encoder Output .......................... 2-20
2.7.6 Checking Encoder Input............................. 2-20
2.7.7 Checking Pulse Input (Optional)................ 2-20
2.7.8 Checking Analog Input (Optional)............. 2-20
2.7.9 Checking the Resolver ............................... 2-21
2.7.10 Checking the Resolver Cable ................... 2-21
2.7.11 Checking the AC Line Voltages............... 2-22
2.7.12 Checking the DC Bus Voltage ................. 2-22
2.7.13 Checking the Motor ................................. 2-23
CHAPTER 3. OPERATION
3.1 Introduction..................................................... 3-1
3.2 Start-Up and Checkout.................................... 3-1
3.2.1 If You Get ERROR 17, FEEDBACK
LOSS .............................................................. 3-2
3.2.2 If You Get ERROR 14, POWER BUS ........ 3-2
3.2.3 If Your BDS5 System is Unstable................ 3-2
3.2.4 Jogging the Motor ........................................ 3-3
3.2.5 Low Speed Adjustment ................................ 3-3
3.3 System Compensation ..................................... 3-4
3.3.1 Critical Damping.......................................... 3-4
3.3.2 Underdamping.............................................. 3-4
3.3.3 Overdamping................................................ 3-5
3.3.4 Ringing......................................................... 3-5
3.4 Tuning............................................................. 3-5
3.4.1 If Your System Is Completely Unstable....... 3-6
3.4.2 Reducing ILIM............................................. 3-6
3.5 Tune Command............................................... 3-6