BALDOR MOTORS AND DRIVES BALDOR ELECTRIC COMPANY THE SERVO ANSWER BOOK MAKING SERVOS SIMPLE... A QUESTION AND ANSWER GUIDE TO BALDOR SFRVOSBRUSH-TYPE SERVOMOTORS BRUSHLESS SERVOMOTORS . . SERVO CONTROLS TsO UM and LD . BSC 1000/1100 and DBSC 1000/1100 - BTS 20 . POSITIONING PACKAGES - SMCC and PMC .. « TACHOMETERS . ENCODERS .. RESOLVERS ACCESSORIESThe Servo Answer Book BRUSH-TYPE SERVOMOTORS What is a brush-type servo motor? A brush-type servo motor is a motor which has been designed for very fast response. It includes a feedback device which provides speed or position information to a servo control. What makes the servo motor different than the other motors which Baldor produces? The motor has . . . a smaller diameter for faster response foes PeMMEENt magnets for murs efficient operation ++. Skewed armature/magnetics for smoother operation . « improved slot fill (more wire) for more torque insulated brush caps tor improved reliabuity a feedback device for closed loop control and greater accuracy a lower inertia armature for fast acceleration What is the torque range of Baldor’s brush-type servo motors? The continuous stall torque range of the brush-type servo motors is from approximately 0.6 to 240 Ib-in. What types of feedback devices can be mounted? Tachometers, encoders, and resolvers. What other options are available? There are optional brakes, termination methods (i.e. leadwire, connectors, junction box), and shaft and mounting methods (square/round mounting). Not all options ere eveilable on all motors, co ploace refer to the individual motor’s series far specifics. Also, please note that some options may result in a slightly longer delivery time. In sizing the motor, what is important? The following four items are important: © the continuous RMS torque required for the application © the acceleration torque required (may be termed peak or starting torque) © the operating speed © the application’s load inertia (it is recommended that when comparing toad to motor inertia that this ratio be no larger than 10 to 1) Do you make controls to drive these muturs? Yes. These are often called amplifiers, or servo controls. How is a control selected? First, determine the motor’s current and select a control which is capable of supplying that current. Second, verify that the control's voltage is capable of operating the motor at the desired speed. Page 1The Servo Answer Book BRUSHLESS SERVO MOTORS What is a brushless servo motor? A brushless servo motor is a motor which has been designed for very fast response and does not have brushes or a commutator. It also includes a feedback device that provides speed or position information to a servo control. How does it operate? The control switches power from winding to winding electronically What is the torque range of Baldor's brushless servo motors? The continuous stall torque range of the brushless motors is from approximately 10 Ib-in to 440 Ib-in. What types of feedback devices can be mounted? The typical type of feedback device is a resolver. It is also possible to mount an encoder, if required in the application. ‘What other options are available? There are optional brakes, termination methods (i.e. leadwire, connectors, junction box), and shaft and mounting methods (square/round mounting). Not all options are available on all motors, so refer to the individual motor’s series for specifics. ‘Also, please note that some options may result in a slightly longer delivery time. In sizing the motor, what is important? The following four items are important: © the continuous torque required for the anplication © the acceleration torque required (may be termed peak or starting torque) © the operating speed © the epplication’s load inertia {it ia reeommonded that when comparing load to motor inertia that this ratio be no larger than 10 to 1) Do you make controls to drive these motors? Yes. These are often called amplifiers, or servo controls. How is a control selected? First, determine the motor’s current and select a control which is capable of supplying that current. Second, verify that the control's voltage is capable of operating the motor at the desired speed. Page 2The Servo Answer Book SERVO CONTROLS What different controls are available? Baldor offers both brush-type and brushless controls. In the brush-type, there is the TSD, the LD, the UM-H, and the THM. In the brushless, there is the BTS 20, the BSC 1000/1100, and the DBSC 1000/1100. What are the basic differences? The units are either chassis, panel or rack mount. Mounting | Brushaype Control | Brushless Control cnassis um, Ww none panel 80 BSC, DBSC, BTS 20 rack THM none What is the range of continuous current for each control? Brush-type Control Brushless Control] Continuous Current 5A BSC 1000/1100 | 2A, 5A, 10A, 154 16 nese 1000/1100] 2A, a, 104, 184 6A and 154 BTS 20 | 10, 20, 30, 40, and 50A 20, 30, 40, 60, and 90A| What is the buss voltage for each control? Brush-type Control Buss Voltage Brushless Control Buss Voltage SOV and 100V BSC 1000/1100 320V Lo. 160v DBSC 1000/1100 320V UM 100V and 150V BTS 20 300 THM 180V Page 3The Servo Answer Book SERVO CONTROLS (Continued) What is the continuous power vutput for each control? Brush-type Control | Continuous Pow Brushless Control Continuous Power Ts0 s00w BSC 1000/1100 up to 6.5kW Lo up to 2.3K, BSC 1000/1100 up to 6.5kW UM-H up to 2.3kW BTS 20 up to 18kW. THM up to 16kW What is the PWM switching frequency of each control? All units are in the 9 to 20 KHZ range. Which motors are recommended for each control? Brushless Control Motor [ Brush-type Control Motor Series Tso 2200 and 3300 BSC 1000/1100 | ar, br, 4K, OF, 3A, 80A, 808 Lo 3300, 4000, 45000 UMH. 3300, 4000, 4500 DBSC 1000/1100] 4F, br, 4K, BR, 3A, 80A, 808 THM ‘4500 and 7000 Brush-type Control | Transformer Required BTS 20 GF, 8F, 4R, GR, 90A Which controls require isolation transformers? Brushless Control ic sformer Required 180 not required @SC 1000/1100 | _not required wo DESC 1000/1100] not required uM twansformer required BTS 20 transformer required em ansformer reouted For specifics, please refer to the individual servo control sections in this guide, to the literature for the control, or to the installation and operating manual for the control. Page 4The Servo Answer Book TSsD How many axes will the TED control? The TSD has the ability to control two independent axes, though it may be ordered and configured to drive only one axis. What different configurations are available? There are two different configurations available--one with a 50 VDC rated buss, and one with a 100 VDC rated buss. Both supply 5A continuous and 10A peak. Is a transformer required? No external transformer is required. The unit plugs into a standard 115 VAC outlet, and Raldar eupplies the card and plug Is an international version available? Yes, an optional 220/240 VAC 50 Hz version is available. Are inductors necessary? Inductors are not required as long as the motor has a minimum inductance of 1.5mH. Are auxiliary inputs and outputs available? Os for remote enable, remota reset, overtraval limits, matar cutrant monitor. and differential signal inputs are available. What motors can the TSD drive? The TSD can drive any brush-type servo motor whose rated current values do not exceed the control's rated current. It will operate satisfactorily with the M2200 series of motors with either A or B windings. The TSD can also drive the M3300 series of motors with the B winding (the C and D windings will be torque limited to BA). What signal input is required to operate the TSD? The TSD requires + 10 VOL. nis is an analog voltage ranging trom + 10 VUC to -10 VDC. The amplitude of voltage would be proportional to desired operating speed, and the polarity would determine direction of rotation. Page 5The Servo Answer Book TSD (Continued) What adjustments are necessary? Where aro thoy located? The traditional servo compensation setup adjustments must be made, These include: © balance (or drift) © current (peak and RMS} © raspanse (stabilization) Other adjustments incorporated for design versatility are: © tach (to handle different tachometer voltage constants) © signal (tuning of speed command sensitivity) [All put aujustments ere acecasible from the front panel an the TSD. Optional jumper settings located on the individual boards are: © current foldback © velocity/current mode operation Can the TSD operate with a position controller? Yes. In this mode of operation, the position controller supplies the + 10 VDC current command signal. The TSD would be configured to operate in the current (torque) mode, and the motor supplied would have an encoder (a tachometer would not be necessary). Page 6The Servo Answer Book UM and LD How many ayes will the UM and the LD control? Both the UM and the LD have the ability to control up to six independent axes. What different configurations are available? There are three different configurations available for the UM: the first delivers up to 6A continuous with a buss voltage of 100 VDC, the second delivers up to 15A, continuous with a buss voltage of 100 VDC, and the third delivers up to 15A continuous with a 150 VDC buss voltage. ‘The LD has only one configuration which delivers 15A continuous with a bus voltage of 160V. Is a transformer required? For the UM, a transformer is necessary to provide the input power requirements, which call for 70 VAC for a 100 VDC buss and 105 VAC for a 150 VDC buss. For the LD2, no external transformer is required. For the LD4, a step-down ‘transformer is usually used to accommodate the power requirements (i.e. 230 VAC stepped down to 115 VAC.). Are there any other input power requirements? A separate 115 VAC mut alen he provided for the cooling fan and for tho logie power supply. A transformer is not necessary for this. Aro inductors necessary? Inductors are not required as long as the motor has a minimum inductance of 2mH. Are auxiliary inputs and outputs available? VOs for remote enable, remote reset, overtravel limits, motor current monitor, interlocking signal inputs, differential signal inputs, and auxiliary signal inputs are available. What motors can the UM and the LD drive? Both the UM and the LD can drive any brush type servo motor whose rated current values do not exceed tho control’s rated current. It will operate satisfactorily with any of the M3300 and M4000 series motors. The M4500 series motors work best with the 150 VDC buss control. Larger motors may be used, but their torque sopability may be limited by Ue Cuntinuvus Current capabllity Of the control. Page 7The Servo Answer Book UM and LD (Continued) ‘What signal input is required to operate the UM and the LD? Both the UM and the LD require +10 VDC. This is an analog voltage ranging ‘anywhere from +10 VDC ta - 10 VDC. The amplitude of voltage would be proportional to the desired operating speed, and the polarity would determine direction of rotation. What adjustments are necessary? Where are they located? The traditional servo compensation setup adjustments must be made. These include: © balance (or drift) © current (peak) © response (stabilization) Other adjustments incorporated for design versatility are: © tach (to handle different tachometer voltage constants) © signal (tuning of speed command sensitivity) All pot adjustments are located in the upper corner of each individual control card and are labeled B, C, R, T, and S. Optional jumper settings used to custom tailor the control are located at various positions on the board. These include settings for ‘© normally closeg/normally upeni over iavel switches © foldback current level © velocity/current mode operation Can the UM and the LD operate with a position controller? ‘Yes. In this mode of oporation, the position contraiter sunplies the +10 VDC current command signal. Both the UM and the LD would be configured to operate in the current (torque) mode; and the motor supplied would have an encoder (a tachometer would not be necessary) Page 8The Servo Answer Book BSC 1000/1100 and DBSC 1000/1100 What is the difference between the BSC 1000/1100 and the DBSC 1000/1100? The two main differences are: BSC 1000/1100 | DBSC 1000/1100 urrent Loop analog digital [Tuning Method | potentiometers software How many axes will the BSC 1000/1100 and the DBSC 1000/1100 control? Both the BSC 1000/1100 and the DBSC 1000/1100 have the ability to control one axis, though it is possible to parallel several units from one power supply. Is a transformer required? No external transformer is required. Are inductors necessary? Inductors are not required as long as the motor has a minimum inductance of 1mH. Are auniliary inputs and outputs available? '/Os for remote enable, remote reset, overtravel limits, emergency stop, and differential signal inputs are available. What motors can the BSC 1000/1100 and the DBSC 1000/1100 drive? Both the BSC 1000/1100 and the DBSC 1000/1100 can drive any brushless servo motor whose rated current values do not exceed the control’s rated current. It will operate satisfactorily with the BSM 63A, BSM 80A, BSM 808, BSM 4R, BSM 6R, BSM 4F, or BSM 6F series motors. What electronic commutation method is used? Resolver feedback is used to commutate the brushless motor and to provide speed and position information to the control. Is encoder information available? Yes. A simulated encoder output from the BSC 1000/1100 or the DBSC 1000/1100 is available for use by the customer's host computer or positioner. It is also possible to mount an encoder anta the motor for custam counts per revolution. Page 9The Servo Answer Book BSC 1000/1100 and DBSC 1000/1100 (Continued) What simulated encoder outputs are available? 250, 500, 1000, and 1024 ppr (pulses per revolution) are switch selectable on the BSC 1000/1100 and software selectable on the DBSC 1000/1100. A standard 1 ppr index pulse is also provided. What signal input is required to operate the BSC 1000/1100? Both the BSC 1000/1100 and the DBSC 1000/1100 require + 10 VDC. This is an analog voltage ranging from +10 VDC to -10 VDC. The amplitude of voltage Would be proportional to desired operating speed, aiid tle pularity would determine direction of rotation. What adjustments are necessary? Where are they located? The traditional servo compensation setup adjustments must be made. These include: © velocity balance (or drift) © current (peak) © velocity loop gain (stabilization) Other adjustments incorporated for design versatility are: © tach gain (to handle ditterent tacnometer vortage constants) © input gain (tuning of speed command sensitivity) For the BSC 1000/1100, all adjustments are made with pots that are accessible from the front panel on the BSC 1000/1100. For the DBSC 1000/1100, all adjustments are made with autotuning software. Can the BSC 1000/1100 and the DBSC 1000/1100 operate with a position controller? Yes. In this mode of operation, the position controller supplies the + 10 VOC current command signal. The BSC 1000/1100 or the DBSC 1000/1100 would be configured to operate in the current (torque) mode, and the simulated encoder outpute would be used as inputs to the pasitinn cantraliar far pasitian feedback. Page 10The Servo Answer Book BTS 20 What makes the BTS 20 different compared to the other Baldor controls? The BTS 20 is a panel mount unit, with a greater range of current/power capability, and will control a brushless motor. How many axes the BTS 20 control? The BTS 20 has the ability to control one axis, though it is possible to parallel several servo controls from one power supply. Is a transformer required? Yos. The input voltage requiroment for the BTS 20's power oupply (BPS 20) io 215 VAC, three phase. Are inductors necessary? Yes. Inductors are required for short circuit protection. What motors can the BTS 20 drive? The BTS 20 can drive any brushless servo motor whose rated current values do Not exceed the control's rated current. Ihe BIS ZU will operate satistactorily with any of the BSM 6F, BSM BF, BSM 4R, or BSM 6R series motors. What electronic commutation method is used? Resolver feedback is used to commutate the brushless motor and to provide position information to the control. Is encoder information available? Yes. A simulated encoder output form the BTS 20 is available for use by the customer's host computer or positioner. It is also possible to mount an encoder ‘onto the motor for custom counts per revolution. What simulated encoder outputs are available? 100, 250, 500, and 1000 ppr (pulses per revolution) are switch selectable. A standard 1 ppr index pulse is also provided. Other options are also available by requesting a special EPROM. These options are 128, 256, 512, and 1024 ppr. What signal input is required to operate the BTS 20? ‘The BTS 20 1equltes = 10 VDC. This is att analuy voltage ranging from +10 VDC. to -10 VDC. The amplitude of voltage would be proportional to desired operating speed, and the polarity would determine direction of rotation. Page 11The Servo Answer Book BTS 20 (Continued) What adjustments are necessary? Where are they located? The traditional servo compensation setup adjustments must be made. These include: © velocity balance (or drift) © current (peak) © velocity loop gain (stabilization) Other adjustments incorporated for design versatility are: 1” tach gain (to handle different tachameter valtage constants) © input gain (tuning of speed command sensitivity) All adjustments are made with pote that ore ecceasible from the front panel of tho BTS 20. Can the BTS operate with a position controller? Yes. In this made of operation, the position controller supplies the + 10 VDC current command signal. The BTS would be configured to operate in the current (torque) mode, and the simulated encoder outputs would be used as inputs to the position controller for position foodback. Page 12The Servo Answer Book POSITIONING PACKAGES - SMCC and PMC What Is available fur positioning? Both the "Smart Motion Control Card" (SMCC) and the PMC will provide signals to a servo control to enable positioning control. What is the SMCC? The SMCC is @ printed circuit board with a microprocessor and associated electronics. It is programmable by the customer to perform virtually any type of position move. What is the PMC? The PMC ie a panel-mountable enclosure with an SMCC control card and power supply mounted inside. What servo controls will the SMCC and the PMC interface with? The SMCC and the PMC will interface with any commercially available servo control which requires an analog +10 VOC input. This includes all of the Baldor brush-type or brushless servo controls. What input is required for the SMCC and the PMC? Both the SMCC and the PMC require three inputs: power to the board, encoder feedback for position data, and an input line for communication with the customer's host computer. The communication can be a serial RS 232 ur 6 it parallel input. For the SMCC, power required is +5 VDC and +15 VDC. For the PMC, power required is 115 VAC. How many axes will the SMCC and the PMC control? The SMCC and the PMC configured to operate two axes, but it can be set up to control only one axis. {tis also possible to daisy chain up to 32 axes. What operational capabilities do the SMCC and the PMU offer? The SMCC and the PMC are capable of: © electronic yearing (leader-follower operation) synchronization of up to 32 axes (coordination control) compensation of the servo loop via programming (software tuning) thumbwheel switen input (follower) analog input (+10 VDC) 0000 Page 13The Servo Answer Book POSITIONING PACKAGES - SMCC and PMC (Continued) How are the SMCC and PMC proyranuned? The SMCC and PMC are programmed using a command language that utilizes English abbreviations and a BASIC-like programming structure. The “Monitor” servo interface software is available from Baldor for programming the SMCC and the PMC. What input and output lines are available? There are several dedicated machine input/output (I/O) lines along with lines which can be assigned specific tasks (programmable lines). Ihe outputs are open collector and should be interfaced through opto-isolated devices. The dedicated lines include + end-of-travel limits, enable/disable, fault output, home position, and amplifier current. The seven programmable input and five programmable output lines are assigned 3 task through programming. Options are available to expand the I/Os if necessary. Can any encoder be used with the SMCC or the PMC? A train of digital position pulses is required. This may come from either a simulated encoder signal or from any digital encoder which has a differential line driver +5 VDC output. Page 14The Servo Answer Book TACHOMETERS What tachometer voltage constants are available? The standard tachometer voltage constant available on the M2200, M3300, and M4000 series is 7 V/kRPM. The standard on the M4500 series is 9.5 V/kRPM, and the standard on the M7000 is 31.5 KRPM. What is tachometer ripple? Tachometer ripple is the voltage variation in the tachometer’s output signal when operated at a given speed. The ripple on Baldor tachometers is less than 1%, leasured peak Wu average. Can spare brushes be purchased? Yes. The tachometer brush ring assembly can be purchased as a spare replacement part. This includes the brushes, springs, and lead wires all connected onto the printed circuit board assembly. Due to the design of this assembly, those parts cannot be sold separately. Can a spare armature assembly be purchased? Yes, but only as a complete kit. The kit is sold complete instead of as individual components due to possible damane durin disassembly and repair. The kit includes the armature, magnet field, and tachometer brush ring assembly. Either the TG 200 or TG 300 units may be ordered as replacements. When is the TG 200 ordered, and when is the TG 300 ordered? Order the TG 200 if the tachometer unit to be repaired is for the M2200, M3300, M4000, or M4500 series of motors. Order the TG 300 for the M7000 series. What else should be specified when ordering either the TG 200 or the TG 300? Be sure to indicate the tachometer voltage constant and the hub size of the armature assembly. The hub fits onto the rear shaft extension of the motor. For the TG 200, it could be either 3/8 inch or 1/2 inch (12mm). For the TG 300, it will be 5/8 inch. Page 15The Servo Answer Book ENCODERS What is an uptival encoder? An encoder is a mechanical (rotation) to electrical (digital pulses) conversion device which provides position information. Further information is supplied in the application note Servo Control Facts (MN1205). When would an encoder be used? ‘An encoder is used in positioning applications. For example, the SMCC positioning card requires a digital feedback signal for proper operation. What line counts are available? The standard counte are 500 and 1000 ppr (pulses per ravalition). Other line counts are available, but these are not stocked, and delivery time is longer. The other line counts available are: 100, 200, 300, 360, 400, 512, 600, 720, 800, 900, 1024, 1200, 1250, 1500, 1800, 2000, 2048, and 2500 ppr. What are the output characteristics? Encoders provide a three channel, TTL compatible voltage output (square wave} channel A, channel B, and a zero index marker pulse (plus their compliments). What is the output voltage? Baldor’s standard encoder requires +5 VDC as an input, so the output would be just below this level. However, other voltages are available ana can be special ordered. These voltages are +12 VDC and +18 VDC. Are line drivers included? Yes, this is Baldor’s standard. Keep in mind, though, that other design devices, such as open collector output, are available and can be special ordered. When should a line driver be used? A line driver should be used in any application where the encoder wire length will be greater than three feet. Can the customer mount his own encoder? Yes. Our motors can be equipped to accept either a kit style encoder or a self- contained encoder unit. Page 16The Servo Answer Book ENCODERS (Continued) What are the differences between a kit style encoder and a self- contained encoder? The kit consists of parts, including a disk, which would be mounted onta a shaft and a sensor assembly. These items would be built up and assembled onto the motor's shaft extension. The self contained encoder consists of a complete unit with a shaft. This is simply coupled to the motor’s rear shaft extension. When is a kit encoder recommended over a self-contained encoder? The advantages of the kit encoder are lower price and shorter lenath; the drawback is that it is not suitable for excessive end-play shock situations, so it should be used in a lighter duty application. One advantage of the self-contained encoder is easier in-field service, repair, and replaceability. Another advantage is the ability to handle excessive end-play which allowe the self-contained encoder to handle more severe applications. The price of the unit is slightly higher. What is the standard mounting pattern onto which the encoder can be mounted? For tha kit antinn (specify "kK" under “options” whan ardering\. the standard rear motor shaft extension is .375 inches in diameter with a length of .68 inches. the standard B.C.D. for mounting holes is 1.812 inches. For the self-contained option (specify “E” under “options” when ordering), the standard mounting is via synchro-groove cleat type clamps/screws with flexible cuupling between mutur and encoder. The clamps ore on a 1.9 inch D.C.D. with o pilot of 1.37 inches. The coupling will accept a .25 inch diameter shaft. Page 17‘The Servo Answer Book RESOLVERS What is a resolver? A resolver is an induction type feedback device, similar to a transformer, whose ‘output signal is proportional to angle. Further information is supplied in the application note Servo Control Facts (MN1205). What standard units are mounted onto motors? For the brush-type motors, a size 11, self contained, single speed resolver is standard. On the brushless motors, a frameless single speed resolver is standard. What is meant by single speed or multi-speed resolvers? The “sneed” of a resolver is industry terminoloay for the number of electrical cycles the resolver output signal goes through during one mechanical shaft revolution. A single speed resolver outputs one complete cycle during one mechanical shaft revolution. A multi-spaed resolver outputs several successive cycles during one mechanical shaft revolution. For example, a four speed resolver ‘outputs four successive complete cycles during one mechanical shaft revolution. What combination of primary/secondary windings are available? For the resolver used on the brushless motors, the primary has one winding which is excited while the two secondaries provide a sine and cosine output proportional to the rotor’s angle. For the resolver used on brush-type motors, the primary has two windings (one sine, one cosine) which receive excitation generated by the customer's control. The output of the single ooondary winding provides 2 signal which is the additinn of the sine and cosine in proportion to the rotor’s angle. Page 18The Servo Answer Book ACCESSORIES What accessorles are necessary for a servo package? Besides the servo motor and control, some packages may need inductors and an isolation transformer. Motor and control connectors may also be necessary for customer cabling. What is an inductor used for? An inductor is used to provide short circuit protection for servo controls. Some servo controls have this feature designed in. How is an inductor selected? First, determine the motor’s current, then select an inductor which has the capapiity of nanaing at least that amount of continuous current. What is a transformer used for? A transformer is used to provide isolation protection and to step down the voltage to a level which the power supply/contral can use How is a transformer selected? Take the buss voltage, multiply by the motor’s continuous current, and multiply again by the number of axes. Then divide by 1000 for the KVA rating of the transformer, Is the transtormer design so unique that the customer must buy trom Baldor? No Raldar provides transformers ac a convenience ta facilitate protatyne evaluation. Typically, the customer will have a local source available. Page 19BALDOR MOTORS AND DRIVES BALDOR ELECTRIC COMPANY P.O. Box 2400 Fort Smith, Arkansas 72902-2400 (001) 646-4711 Fax (601) 648-5792 Baldor Electie Company Printed in he USA, mater, 18/94 PRINT SHP 5000,