BSC Series 2000/ 3000

Servo Control

Installation & Operating Manual

7/92
 CONTENTS

1.0 Specifications ............................... 1

5.0 Dimensions ................................... 16
1.1 Usage Definitions ....................... 1
1.2 Identification .............................. 1
1.3 Features ..................................... 1
6.0 System Set Up Procedure ............ 18
1.4 Declaration of Conformity .......... 2
6.1 Presets ....................................... 18
1.5 EMC Conformity and CE Marking 2
6.1.1 Potentiometer Preset .................. 18
1.5.1 EMC Installation Instructions ..... 2
6.1.2 DIP-Switches Settings ................ 18
1.5.2 Specifications add components .. 3
6.2 System Set Up Step by Step ....... 19
1.5.2.1 Mains Filters .............................. 3
6.3 System Tuning ........................... 20
1.5.2.2 Connection Cables ..................... 4
1.5.2.3 Screen Connections .................... 4
1.5.2.4 Connectors ................................ 4 7.0 Status Monitor ............................. 22
1.5.2.5 PG-Cable Glands ....................... 5
1.6 Technical Data ........................... 5
8.0 Testsignals .................................... 23
1.6.1 Power Section ............................ 5
1.6.2 24VDC Input ............................. 6
1.6.3 Velocity Controller .................... 6 9.0 Identity Modul ............................. 23
1.6.4 Mechanical Section .................... 6 9.1 Component Functions ................ 23
1.6.5 Environmental Section ............... 7 9.2 Component Layout .................... 24

2.0 Installation Recommendations .... 7

10.0 I/O Hardware Description ........... 24
2.1 Mechanical Installation ............... 7
10.1 Input Signals .............................. 25
2.2 Electrical Installation .................. 8
10.2 Output Signals ........................... 26
10.3 Encoder Output ......................... 27
3.0 Interconnection Diagram ............. 9 10.3.1 Encoder Signals ......................... 27
10.4 Resolver ..................................... 28

4.0 BSC Wiring .............................. 10

4.1 Power Wiring ............................. 10
4.1.1 Power Supply ............................. 10
4.1.2 24VDC Connection .................... 10
4.1.3 Motor Wiring ............................. 10
4.2 Control- and Signal Wiring ......... 11
4.2.1 Control Inputs ............................ 11
4.2.2 Control Outputs ......................... 12
4.2.3 Command Input ......................... 13
4.2.4 Encoder Output ......................... 13
4.2.5 Resolver ..................................... 13
4.3 Minimum Wiring Diagram .......... 14
 1
1.0 Specification
1.1 Usage Definitions
The amplifiers of the series BSC2000/3000 are electrical equipment for industrial power installations. They are designed for
machine applications, which need variable speed controlled three-phase A.C. motors.
This product is only for use in industrial applications as described in norms EN 60204 and VDE 0160. This means use
BSC2000/3000 in stationary groundbased applications only. It is not meant for use in home appliances, medical technics,
cars, ships or airplanes.
Before the BSC is put into operation, please contact your Electric-Supply-Company for special operating conditions.

1.2 Identification
BSC x x xx - xx

{ 24 - External 24VDC-Input
MR - Multiresolvercard

15

{ 25
35
45
Nominal Current (Amps)

{ 20 :
30 :
Series 2000
Series 3000

BALDOR-SERVO-CONTROL
1.3 Features

A BSC is an analog 1 axis amplifier with integrated power stage.

It provides the following features:

POWER SECTION:
• 3 respectively 4 output current versions (15/25/35/45A) • Output power up to 30kVA
available. • Brushless-servomotors (2 to 8 poles) can be connected.
• Ratio peak : nominal current = 2:1. (Feedback: 2-pole resolver)
Both values independently adjustable. • Power wiring via terminal screws (max. wiring diameter
• All BSC amplifiers are short circuit proof and require 10mm²/AWG7)
no minimum load.

CONTROL I/O Section:

• 5 opto isolated control inputs for dedicated amplifier • Wiring of control inputs and outputs via plug type
functions screw connection (max. wiring diameter 1,5mm²/
• Diagnostic display on front panel AWG15) or SUB-D connector

GENERAL: • Isolation classification according to DIN 0110 with

• Protection class IP20 (acc. to DIN40 050 / IEC144) overvoltage category II
• Cooling: self-ventilation • Contamination level 2
 2
1.4 Declaration of Conformity
Herewith we declare, that our products are components only and not ready for immediate or instant use within the meaning
of "Safety law of appliance", "EMC Law" or "Machine directive".

The final mode of operation is defined only by the insertion into the user´s construction.

It is the responsibility of the user to verify that his construction is in accordance with existing regulations.

It is prohibited by law to put the machine into operation before verifying that the machine is in accordance with EC directive
89/392 and 921/368.

The supplier declares product conformity with the following standards:

DIN VDE 0160 / 05.88 Electronic equipment for use in electrical power installations

DIN VDE 0100 Erection of power installations with nominal voltages up to 1000V

DIN IEC 326 Part 1 / 10.90 Design and use of printed boards

DIN VDE 0110 Part 1-2 / 01.89 Dimensioning of clearance and creepage distances
DIN VDE 0110 Part 20 / 08.90

EN 60529 / 10.91 Degrees of protection provided by enclosures

1.5 EMC - Conformity and CE - Marking

The application of EMC conformal component and partly systems relieves the observance of EMC Guidelines and the
guaranty of conformity for the manufacturer of machines. Therefore all standard components and partly systems will be
tested according to the requirements of EMC regulation. Those tests will be executed by a competent and indepen-dent
institution. The conformity of the products will be confirmed by a declaration of conformity from the European Community.
The installation instructions refer to elimination of radio interference as well as to immunity from noise for BALDOR Drive
Systems.
Thereby the user is informed about the EMC critical parts. The examples don´t show the complete possibilities of cabinet
components or constructions.

Guidelines for EMC Conformity

⇒ Machine Guideline (89/392/EWG) - Machine Safety Law
Application since 01.01.95
⇒ EMV Guideline (89/336/EWG) - EMC Law
Applicade 01.01.96 on
⇒ Low Voltage Guideline (73/23/EWG) - Machine Safety Law
Applicade 01.01.97 on

1.5.1 EMC Installation Instructions

To ensure electromagnetical compatibility (EMC) at hostile environment inside the cabinet following instructions are to be
observed for construction. Only the implementation of following provisions enables the reduction of interference down to
required values.

For the Drives Technology following key points are to be considered:

- Grounding

- Screening

- Filtering
 3
Furthermore the relevant chapters of the Installation manual for the controllers have to be observed.
For installation of the drives system the starting point is the installation into a cabinet.

For construction of a cabinet the following installation instructions have to be considered:

A) All metal conducting parts of a cabinet are to be connected arealy and conductable.Eventually
the connections should be placed with an earthing strap at a central grounding point .1)

B) Signal lines and Power Cables are to be connected separately. (Avoid interaction space)

C) The screen connection of the signal lines and the power cables has to be ensued on a screen linequaranteeing
enough space. This screen line also has to be conductable and connected to
the remaining housing parts.

D) The cable to the regeneration resistor has to be screened. The screen connection should be on
both sides.

E) The mounting of the mains filter has to be situated at the input of the cabinet or behind the transformer. The
filter is to connect on ground (cabinet housing, mounting plate etc.).

F) Wiring has to be conducted bundled and close to the cabinet housing or at the mounting line.
The unused leads of a cable have to be connected on one side with ground. 1)

G) In case of worse potential balance between the screen connections a compensating leak with at least
10mm2 (AWG) has to be provided parallely in addition to reduction of the screen current.

1) Grounding in general describes all metal parts which can be connected to a protective conductor, e.g. housing of
switch cabinet, motor housing, fundament grounder.

1.5.2 Specifications and Additional Components

1.5.2.1 Mains Filter
Following results are desired through the application of mains filters:
The electronic system should be protected from high frequency interferences which could enter via the mains cable
(immunity from noise) and vice versa the mains cable may not transmit interferences from the electro-nic systems to
the adjoining components (elimination of radio interference).

In the main line a mains input filter has to be provided between transformer and controller
(In case of direct connecton this has to be in front of the controller).

To choose the fitting mains filter types following points have to be considered:
1. The need of power of the connected controller. Thereby the capacity and the ability of peak phase current has to be
considered.
2. The required or prevailing mains impedance.

This table shows the corresponding mains filter types for 3 phase input:

Rated Voltage Rated Current Leakage Power Weight BALDOR

Type (at 40°C) Current Losses -
[V] [A] [mA] [W] [kg] ID-No
FN 351 - 8 - 29 3x 440 8 16 8.0 1.8 24667
FN 351 - 16 3x 440 16 16 9.0 1.8 24668
FN 351 - 25 3x 440 25 170 9.0 3.0 24669
FN 351 - 36 3x 440 36 170 10.5 3.0 24670
FN 351 - 50 - 29 3x 440 50 190 12.5 3.1 24671
FN 351 - 80 - 29 3x 440 80 210 26.0 9.5 24672
FN 351 - 110 - 29 3x 440 110 210 28.0 9.5 24673
 4
1.5.2.2 Connection Cables
All cables have to be screened.

BALDOR
Motorcable and Signalcable
ID - No.
Motorcable 4 x 1.0 mm2 21599
Motorcable 4 x 2.5 mm2 21364
Motorcable 4 x 6.0 mm2 21597
Resolvercable 3 x [2 x 0.14 mm2] 19413
Regen Resistorcable 3 x 2.5 mm2 11302

1.5.2.3 Screen Connection

Siemens Clamp Siemens -No.

5mm Rail Wiring Diameter
1.5 - 16 mm2 8US19 21 -2AA00
1.5 - 35 mm2 -2AB00
16 - 70 mm2 -2AD00
16 - 120 mm2 -2AC00
10mm Rail Wiring Diameter
for T- and double T-profile 95 - 300 mm2 8US19 41 -2AA00

1.5.2.4 Connectors
Connection Designation BALDOR - ID -No.
for Motorcable
Plug CONN SET FEM 2 x 4 pole 24654A
Socket CONN SET MALE 2 x 4 pole 24656A

for Resolvercable
Plug CONN SET FEM 12/6 pole 24655A
Socket CONN SET MALE 12/6 pole 24657A

for BSC with EMC-Regulation

connector X2 with housing

Connector 25043A
Housing 25049A
 5
1.5.2.5 PG - Cable Glands
PG Cable Gland Cable Dimensions Designation BALDOR
ID - No.
4 - 8 mm SCREWING 24658
PG 9 Resolvercable
BALDOR ID-No.19413
6 - 12 mm SCREWING 24659
PG 13.5 Motorcable
BALDOR ID-No. 21599
13 - 18 mm SCREWING 24660
PG 21 Motorcable
BALDOR ID-No. 21364

1.6 Technical Data

All values at Tamb = 40 °C, if not otherwise specified.

1.6.1 Power Section

General Unit BSC BSC BSC BSC BSC BSC BSC

2015 2025 2035 2045 3015 3025 3035
Nominal DC-Bus-Voltage
VDC 320 -
Uin (BPS) = 230V
Nominal DC-Bus-Voltage
VDC - 560
Uin (BPS) = 400V
Nominal DC-Bus-Voltage
VDC - 650
Uin (BPS) = 460V
DC-Bus-Voltage
VDC 0 ... 350 0 ... 740
absolute min./max.
Output Voltage Line/Line
VRMS 0 ... 250 0 ... 500
fundamental wave; @VDC-Bus (nom.)
Nominal Phase Current (±10%) ARMS 15 25 35 45 15 25 35
Peak Phase Current (±10%)
ARMS 30 50 70 90 30 50 70
1.5s ±0.5s
Nominal Output Power kVA 6.5 10.8 15.1 19.5 13.0 21.6 30.3
Efficiency % > 95
Min. Load Inductance μH 200
Output Frequency Hz 0 ... 500
Nominal Switching Frequency kHz 8.5
 6
1.6.2 24VDC Input

24V-Input Unit BSC2000 BSC3000

Input Voltage Range
absolute min./max. VDC 20 ... 29
max. VRipple = ±10%
Input Current; @ 28VDC ARMS 1.6
Surge Current at Power On ARMS 2.5
@ 28VDC; @ 100ms

1.6.3 Velocity Controller

Preamplifier Unit BSC2000 BSC3000

Command Input VDC 0 .. ±10
Drift (velocity controller) rpm/K 0.4
Balance (velocity controller) rpm typ. 8; adjustable to 0

Resolverfeedback Unit BSC2000 BSC3000

Resolution bit 12
Encoder-Simulation ppr 250 / 500 / 1000 / 1024
Signal 5V TTL ; A;A/; B;B/; C;C/
Reference Pulse available; non adjustable

1.6.4 Mechanical Section

Mechanical Unit BSC2000 BSC3000

Mounting - Bookstyle or Thru the Wall
Dimensions mm 105 x 357 x 328 / 140 x 357 x 328 1)
Weight kg 8.5 / 9.5 1)
1) : BSC2045/3035
 7
1.6.5 Environmental Section

Environmental Unit BSC2000 BSC3000

Operating Temperature Range °C +5 ... +45
Storage Temperature Range °C -25 ... +70
Humidity % 10 ... 90; not condensating; according to DIN40 040, Class F
Class of Protection (Enclosure) - IP20; according to DIN40 050 / IEC 144
Max. Installation Altitude / M.S.L. m 1000
Shock - 10G; according to DIN IEC 68-2-6/29
Vibration - 1G; 10 ... 150 Hz; according to DIN IEC 68-2-6/29

Legend:
This is an INFORMATION sign.

If this information is read, installation and / or

amplifier operating problems can be avoided
in advance.
This sign means ATTENTION.

In all cases it must be read and taken into

account.
Non-observance can cause dangerous situations
for equipment and personnel.

2.0 Installation Recommendations

2.1 Mechanical Installation
- For installation of your system use a cabinet with a protection class that suits your environmental conditions.

- As cooling air freely enters the unit, the environment must be free from corrosive chemical substances, oil, vapour,
steam, metal particles and dust.

- Make sure that cooling is provided.

- Make sure that the top of the unit is covered during installation to prevent particles from falling into the unit.

- Keep DC-bus links as short as possible. Therefore always mount BSC2000/3000-combinations side by side.

- Mount all BSC vertical (Terminal blocks to the top).

- Use BSC2000/3000 in stationary groundbased applications only.

 8
2.2 Electrical Installation
 9
3.0 Interconnection Diagram

Content of delivery: mating connector to X1 - 4 and X10. Order-no´s for mating connectors (spare part or completion):
X2: #16000 (20 pole, female); X3: #20506 (8 pole, female); X4: #17934 (10 pole, female); X5: #16215 (9 pole, male)
Connector X4 is reserved for option Multi-Resolver (Absolute positioning). For interconnection diagram refer to manual
Multi-Resolver.
 10
4.0 BSC Wiring
In chapter 4.3 you will find the typical (minimum) wiring of the system . The following pages show some special
applications and the typical wiring in more detail.
This chapter is valid for all BSC versions.

ATTENTION: For the system set up (chapter 6) it is nessesary to wire the system step by step.
It is recommended to follow the system set up procedure, especiallly for users who are not
very familar with the BSC amplifier series.

4.1 Power Wiring

4.1.1 Power Supply
The BSC amplifier will be supplied from a BPS with the DC-bus voltage. The connection between BSC and BPS must be as
short as possible. The wiring can be done with copper bars (#23176).

Wiring Power Supply:

Chapter 4.3 shows the wiring in detail

4.1.2 24VDC - Connection

A BSC2000/3000 needs an external 24V control supply. This voltage supplies the amplifiers control circuits.
The advantage is, if main power is switched off, control circuits are still supplied and position information gets not lost.
This supply must be linked to BSC connector X10 (Pin 1 and 2). The BPS2000/3000 provide the needed 24V output. This
output is for that purpose and has the same denotation on BPS.
If the BSC is not supplied with the BPS, an external power supply must be connected to connector X10.
The external power supply must fullfil certain specifications (see chapter 1.6.2).

Wiring 24VDC-option:

1) The shown BPS, can be replaced by an external 24V-power-supply.

The amount of connected BSC´s (n) which can be connected to one BPS, is "5"
(refer to BPS2000/3000 manual)
2) The wiring of X10 pin 3 and 4 is nessesary for proper BSC operation. For details please refer to chapter
4.2.1.

4.1.3 Motor Wiring

The motor must be connected to the following terminals:

U Phase U
V Phase V
W Phase W
 11
A wiring example is shown in chapter 4.3.

4.2 Control- and Signal Wiring

This chapter is valid for all BSC versions.
The wiring of the control in- and outputs can be achieved with one cable only unlike shown in the pictures below.
The outputs can be wired. But there is no need for BSC operation.

4.2.1 Control Inputs

The control inputs below are optoisolated. The ground return for all inputs is "CREF", connector X2.14.

Control Input Function:

Signalname Connector Switch Position / Function
Pin closed open
ENABLE X2.9 Amplifier enabled Amplifier disabled
EMStop X2.10 Amplifier is active Motor decellerates with torque to velocity 0
CWLimit X2.11 Clockwise direction of rotation enabled Clockwise direction of rotation disabled
CCWLimit X2.12 Counterclockwise direction of rotation Counterclockwise direction of rotation
enabled disabled
CurrentC X2.13 Current Mode active Velocity Mode active
A wiring proposal for the control inputs above you will find in chapter 4.3. The hardware description of the optoisola-
ted input is show in chapter 10.1.

About CurrentC (X2.13):

It is not permitted to activate or deactivate the input during amplifier is operating. The controller behavior
is completely different. The input should be fixed wired.

Functional example of control inputs:

The wiring of the control inputs is also shown in chapter 4.3 .
The picture by-stander shows the function and the two
wiring principles of the control inputs:

The two wiring versions are:

1) Switching to the external control input power supply.
The switch will be linked between the control input
(X2.x) and the external power supply (Vext).
The ground return (GNDext) is permanetly wired
with CREF (X2.14).

2) Switch to the ground return of the external power

supply. The switch will be linked between the control
input and the external ground return (GNDext).
The external power supply (Vext) is permanently
wired with CREF (X2.14).

Voltage range of Vext : +12 ... 29VDC X2.x: "x" for connector pin,
e.g. x=9 → X2.9 = Enable-Input
 12

Control Input Wiring:

Control Input "±BPS Ready"

a) BSC with BPS2000/3000:
The BSC provide as default a control input "BPS Ready". If the BPS2000/3000 has an internal malfunction, the BPS will
disable the connected BSC amplifiers. The input is on connector X10 pin 3 and 4.
Under BPS fault condition, this input will be deactivated and the BSC will show the following state:
LED Ready = RED
Monitor = 2 (Undervoltage)
With this fault indication the BSC will be disabled.

b) BSC with external 24V Power Supply:

If the BSC is not operated with the BPS, an external power supply must be connected to connector X10 as shown below. In
that case, the control input "±BPS Ready" has no more function. Nevertheless the input must be wired. Without the wiring
below, the BSC will indicate fault condition like above (see a)).

4.2.2 Control Outputs

The BSC is equipped with a fault relais. The relais contact can be used to observe the amplifier status. The wiring of the fault
relais contact is optional and not nessesary for proper amplifier operation.

Control Output Function:

Signalname Connector Switch Position / Function
Pin closed open
FAULT+ X2.15 BSC happy BSC not happy
FAULT - X2.16 no fault indication fault indication / monitor

Control Output Wiring:

see chapter 4.3
 13
4.2.3 Command Input
The BSC has an analog command input (±10V). The input can be wired in "single-ended" or in "differential mode".

Wiring of the command input:

4.2.4 Encoder Output

The BSC has an encoder output, which can be used for position- and/or velocity feedback for a superset controller.
The encoder output resolution (pulse per revolution; ppr) can be configured via software. The following binary resolu-tions
are available with the BSC20xx/30xx-Axx version:

250ppr 500ppr 1000ppr1024ppr

Wiring of the encoder output:

A wiring proposal is shown in chapter 4.3.
It is strongly recommended to make the wire connection with twisted pairs and screened cable.
We recommend the use of the BALDOR encoder cable #13036.

4.2.5 Resolver
The resolver must be connected to connector X9.

Wiring of the resolver in- and outputs:

The wiring is shown in chapter 4.3.
We recommend the use of the special BALDOR resolver cable #19413.
 14
4.3 Minimum Wiring Diagram "The wiring proposal gives no warranty for

1) The power supply must be wired according to the BPS2000/3000 manual (#22705A)
2) Motorcable: # 21599: Wire diameter: 1.0mm² / AWG17 Cable outer diameter: (11.6 ±0.4)mm
# 21364: Wire diameter: 2.5mm² / AWG13 Cable outer diameter: (14.5 ±0.5)mm
# 21597: Wire diameter: 6.0mm² / AWG9 Cable outer diameter: (18.5 ±0.6)mm
# 21598: Wire diameter: 10mm² / AWG7 Cable outer diameter: (22.8 ±0.4)mm
3) Terminal box BSM 6R, BSM90A/90B/100A/100B
4) Connector BSM 63/80 Europe
5) The wiring diameter must fit to nominal BPS output current. The connection between BPS and the BSC ampli-
fiers must be as short as possible.
The wiring between BPS and BSC can be done with copper bars (ID-No.: #23176). Also wiring between BSC´s
can be done with copper bars. ID-No´s.: #23177 (105mm housing) #23179 (140mm housing)
 15
“Observance of valid EMI - standards"

6) If a very strong affect of EMI will be expected, it is recommended to connect the inside screens to DGND.
7) Resolvercable: #19413
8) Functional description of the control inputs see chapter 4.2.1. The control inputs must be supplied with an external
voltage source.
9) Control cable not available from BALDOR. Drawing shows the wiring principle only. Can be one or more cables
10) If the wiring is done like shown in the drawing, the motor rotates clock wise (view at motor shaft) with a positive
voltage on X1.1 referenced to X1.2.
11) Encodercable #13036, twisted and screened

ATTENTION: Please note also chapters 4.0. to 4.2.

 16
5.0 Dimensions

not scaled (dimensions in mm)

 17

not scaled (dimensions in mm)

1) Upper and lower fan housing brackets are not contents of delivery. They must be ordered seperately according table
below. The sets below contain both brackets and the screws.

BALDOR ID - Numbers
for Fan Housing Bracket Sets
BSC2015 / 2025 / 2035 BSC2045
BSC3015 / 3025 BSC3035

22570A 23098A
 18
6.0 System Set Up Procedure
6.1 Presets
Before applying power to the system, the following settings must be checked.

6.1.1 Potentiometer Preset

Function adjustable from / to Presets ex factory

P1 Reference Input gain 33 .. 100% Clockwise for max. input gain (100%)
P3 Velocity feedback gain 33 .. 100% Clockwise for max. gain (100%)
P4 Velocity Balance -110mV to +110mV Standstill at zero input command
P5 Velocity loop gain 4.8 .. 100% Anti-clockwise for min. gain
P6 Peak current 9 .. 100% Clockwise for max. current (100%)

6.1.2 DIP - Switch Settings

POLE PAIR SELECT

AS1-1 AS1-2 AS1-3 Number of TYPE OF MOTORS
POLEPAIRS
OFF OFF OFF 1 BSM 2 R
ON OFF OFF 2 *) BSM 63A / 80A / 80B
OFF ON OFF 3 BSM 6 R
ON ON OFF 4 BSM 90A / 90B / 100A / 100B

ENCODER - SIMULATION
AS1-4 AS1-5 PULSES / REVOLUTION
OFF OFF 1024
ON OFF*) 1000
OFF ON 500
ON ON 250
*) Ex factory
- DIP - Switch AS1-6
AS1-6 (ON) switches OFF the Integral- part of the velocity loop. This improves the transient response of the
controller in positioning mode. (ex factory OFF)

- Velocity or current mode select

Ex factory the amplifier is set to operate as a velocity controller. If you want to operate in current control mode,
connect 12..29 VDC to the input X2-13 (CurrentC) in reference to CGND.
 19
6.2 System Set Up Step by Step
With all initial settings completed (chapter 6.1), the set-up procedure can begin.

1. Before you connect the BSC amplifier to the BPS, the BPS must be wired and checked according to the manual

2. Now you can wire the BSC amplifier under observance of chapter 4.
It is not permitted to connect the motorcable yet. On the other hand the resolver must be linked to the motor.

3. Now switch ON the main power. The LED "READY" and the "MONITOR" must show the following:

LED "READY" = GREEN

MONITOR = "•" Decimal point on the lower right corner is illuminating
(Amplifier enabled)

Now switch off main power.

 20
4. Connect the motorcable. Switch ON the main power and activate the ENABLE-Input (X2.9); switch must be closed (see
chapter 4). The monitor will show the state:

MONITOR = "•" Decimal point on the lower right corner is illuminating

Now turn OFF the main power.

5. Now connect a variable DC- voltage (±10 VDC) to the reference input CMD+ (X2-1) and CMD- (X2-2) (see also chapter
4). Turn on the power supply. Apply a voltage between 0..+10 VDC: the motor will rotate clockwise. The DC-voltage level
corresponds with the speed and the polarity corresponds with the direction of the motion.

6.3 System Tuning

The BSC amplifier consists of two control loops; current- and velocity loop. The control loops can be optimized by changing
the variable components. The variable components are located on the ID-module (see chapter 9.0).

a) Current Controller
There are two current controllers for motor phase U and V. The current controller setting depends only on
the motor attached. The controllers are adjusted ex factory to the BSM motors. In general there is no need
for optimization.

b) Velocity Controller
The circuit of the velocity controller is shown below. The velocity controller performance depends on the
motor load. Most of all applications do not need an additional optimization.
With variable components R94 and C19 the velocity controller can be optimized. For this purpose a small
command step (2VDC) should be applied to the command signal input. The step response can be observed
with an oscilloscope on testpoint ICMD (X2.8). Below are shown different step responses. The optimum is
the picture in the middle. R94 and C19 are shown in normalized manner.
For an optimization in more detail, refer to the bode-diagram for velocity controller. It shows all variable
components of the velocity controller and how they act.
 21
Velocity Controller Circuit:

Velocity Controller Response:

 22
Velocity Controller Bode-Diagram

7.0 Status Monitor

For convience of monitoring the performance, the BSCprovides a status monitor. The indicated signs, as well as the LED
Ready have the following meaning:

LED Monitor Status Cause

Ready
Green OFF Amplifier disabled no fault
Green . (DP) Amplifier enabled no fault
Red 1 Overvoltage Missing, damaged or wrong designed
amplifier DC bus voltage regeneration resistor.
Red 2 Undervoltage Missing wiring of X10 or problems with
BPS2000/3000; see also chapter 4.2.1
Red 3 Overcurrent Power stage fault or motor leads short
2x Peak Current Crest Value circiut
Red 4 Over- or Undervoltage; Internal control voltage fault
Internal 15V supply
Red 5 Resolver fault Parting of the cable or resolver leads short
circuit or missing plug-in connection
Red 6 Electronic Fusing (see Fault 7 also) Amplifier or motor active current overload.
Fault detection via software.
Yellow 7 I²t-Limit
If I²t-limit is reached, amplifier will reduce Cycle time between motor acceleration and
output current to it´s nominal value. After deceleration is too short.
1.5s ±0.5s BSC switches off (amplifier
disable) with fault indication "6; electronic
fusing"
Furthermore special display indications for operating modes are available. For detailed informations of these operating mode
indications refer to operating manual.
 23

8.0 Testsignals
To allow you an effective set-up of the amplifier and its control loops (PI-controller) three testsignals are acces-sible. These
testsignals allow you an optimal adjustment of the load versus the motor. Also you can monitor these signals during
operations.

Testpoint Function and Scaling

X2 - 6 Speed - Actual velocity of the motor
± 10V equal ± 6000rpm
X2 - 7 DCurrent Actual output current
0..+10V; 10V equal peak current
X2 - 8 Icmd Output of the velocity controller
± 10V equal peak current

9.0 Identity Modul (ID)

9.1 Component Functions

Components Function Value *)

R38 Scaling of Tacho (4000rpm) 4.99kΩ
D401 Plug-in protection -
R94 P-gain for velocity loop 100kΩ
C19 I-gain for velocity loop 47nF
R22 It-switching threshold (nom.current) -
R765 Special function 26.7kΩ
R43 P-gain for current loop phase U 150kΩ
C17 I-gain for current loop phase U 4.7nF
R44 P-gain for current loop phase V 150kΩ
C11 I-gain for current loop phase V 4.7nF
D402 Plug-in protection -
RES Reserved for special applications -
*) Standard values

-Scaling of tacho (R38):

0Ω for 6000rpm
4.99kΩ for 4000rpm
10.0kΩ for 3000rpm
20.0kΩ for 2000rpm

Applications over 6000rpm on request ex factory Munich.

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- It-switching threshold adjust:

With resistor R22 on the ID-card it is possible to adjust the It-switching threshold (It-Limit) from 0% upto 100%. Table
below shows nom. current to peak current by changing R22:

R22 BSC x015 BSC x025 BSC x035 BSC 2045

Ipeak = 30A Ipeak = 50A Ipeak = 70A Ipeak = 90A
- Inenn = 15,0A Inenn = 25,0A Inenn = 35,0A Inenn = 45,0A
20kΩ Inenn = 12,0A Inenn = 20,0A Inenn = 28,0A Inenn = 36,0A
10kΩ Inenn = 10,0A Inenn = 16,7A Inenn = 23,3A Inenn = 30,0A
5kΩ Inenn = 7,5A Inenn = 12,5A Inenn = 17,5A Inenn = 22,5A
x: 2 or 3; e.g.: BSCx015 stands for BSC2015 and BSC3015

Equation for R22:

9.2 Component Layout

10.0 I/O Hardware Description

- Legend:
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10.1 Input Signals
Analog Input Connector X2
Function Signal PIN Hardware
Ucmd = ±10VDC

Velocity- or CMD+ 1

Current- CMD- 2

Command AGND 3

Digital Inputs Connector X2

Function Signal PIN Hardware

- Low Active:

Enable ENABLE 9

Emergency EMStop 10
Stop

CW-Limit CWLimit 11
- High Active:
CCW-Limit CCWLimit 12

Current CurrentC 13
Control

Ground Return CREF 14

min. Input Impedance RIN = 2.2kΩ;

opto coupled; UIN = 12 .. 29VDC; Delay time Td = 60μs
max. current at 24V; I = 10mA
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RESET - Input Connector X2

Function Signal PIN Hardware

RESET- Reset 19

Input DGND 20

Pull-up to +5V; not opto coupled

Connect RESET to DGND, this resets the following faults:
- Overvoltage
- Undervoltage
- Resolver fault
- Electronic fusing

10.2. Output signals

±15V - Output Connector X2
Function Signal PIN Hardware

+15VDC 4
±15VDC
AGND 3
Outputs
-15VDC 5

CAUTION: A short circuit will generate a "RESET"

Short circuit proof; Imax = 100mA

Digital Outputs Connector X2

Function Signal PIN Hardware

Fault Fault+ 15
Relay Fault- 16

contact is closed, if system works correct

UAC = 110V Imax = 0.3A
UDC = 24V Imax = 0.8A
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Analog Outputs Connector X2

Function Signal PIN Hardware

Testsignals Speed- 6 All testsignals are terminated with a resistor R = 4.7kΩ

see DCurrent 7 and scaled to 10V
chapter 8 Icmd 8 Load resistor R ≥ 100kΩ

Digital Outputs Connector X2

Function Signal PIN Hardware

It - Warning Warn_C 17
Warn_E 18

It-Limit and overtemperature warning

10.3 Encoder Output

Encoder Signals Connector X5
Function Signal PIN Hardware

Encoder CHC/ 3
Channel_C CHC 4

Encoder CHA/ 5
Channel_A CHA 7

Encoder CHB/ 6
Channel_B CHB 8
I/O-standard RS422
TTL-Signal; (f < 275kHz)

10.3.1 Encoder Signals

This drawing shows the encoder signals if the motor shaft rotates clock wise (view at the motor shaft).
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10.4 Resolver
Resolver Signals Connector X3
Function Signal PIN Hardware

Reference REF+ 1
Signal REF- 2

Signal waveform sinusoidal; f = 7.2 .. 8.0kHz;

17.0Vpp ±5% + 0 .. 0.4 VDC; Ipeak = 0.2A; short circuit proof

Resolver Signals Connector X3

Function Signal PIN Hardware

COSINE Cos+ 3
Input Cos- 4

SINE Sin+ 5
Input Sin- 6

Signal waveform sinusoidal;

UIN = 0 .. 10Vpp + 0 .. 0,4VDC; 7.2 .. 8.0kHz