Applied Motion Products BLuAC5 Hardware Manual

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Contents Contents Contents Contents Contents Safety Instructions ................................................................................................. 5 Introduction ......................................................................................................... 6 Block Diagram ................................................................................................................... 6 Getting Started ..................................................................................................... 7 Status & Error Display LEDs....................................................................................... 9 Serial Comm Tx & Rx LED ......................................................................................... 9 Bus voltage indication LED ......................................................................................... 9 Seven Segment Display Error codes .......................................................................... 9 Seven Segment Display Status codes ...................................................................... 10 Regeneration LED .................................................................................................... 10 Connecting to the PC using RS-232 ............................................................................ 11 Connecting to a host using RS-485 ............................................................................. 12 A Short tutorial on RS-485 & RS-422 .............................................................................. 12 4-wire RS-485/422 Network ...................................................................................... 13 Getting and Connecting a RS-485 4-wire adaptor to your PC ................................... 13 2-wire RS-485 Network............................................................................................. 14 Getting and Connecting a RS-485 2-wire adaptor to your PC ................................... 14 Before You connect the servo drive to your system -................................................. 14 Connecting the AC Power Input ................................................................................. 15 24 Volt Controller Input (Keep Alive).......................................................................... 15 Connecting Single Phase AC input (90-260VAC) ............................................................ 16 Connecting 3-Phase AC input (90-260VAC) .................................................................... 16 Connecting DC input (100-367 VDC) .............................................................................. 16 Connecting the Motor ............................................................................................ 17 Connecting the Encoder & Hall Sensors ....................................................................... 18 Encoder Pinout ......................................................................................................... 18 Connecting a Single-Ended Encoder ........................................................................ 18 Connecting Single-Ended Hall Sensors .................................................................... 18 Connecting Input Signals ........................................................................................ 19 IN/OUT 1 I/O Connector ........................................................................................... 19 With Expanded I/O (IN/OUT 2) ................................................................................. 19 IN/OUT1 & IN/OUT 2 Connector Pinout Diagrams .................................................. 19 High Speed Digital Inputs ................................................................................................ 20 Using High Speed Inputs with 12-24 Volt Signals...................................................... 20 Using Mechanical Switches at 24 Volts. .................................................................... 21 Connecting to PLC with Sourcing (PNP) Outputs ..................................................... 21 Connecting to PLC with Sinking (NPN) Outputs ....................................................... 21 Standard Digital Inputs ........................................................................................... 22 Single Ended Inputs ........................................................................................................ 22 What is COM? .......................................................................................................... 22 User Out 24V supply................................................................................................. 22 Digital Input Connection Examples ........................................................................... 23 Connecting Limit Switches to the BLuAC5 Drives ........................................................... 24 BLuAC5 Limit Input diagram ..................................................................................... 24 Wiring a Mechanical Limit Switch.............................................................................. 24 Wiring a Limit Sensor................................................................................................ 24 Analog Inputs ...................................................................................................... 25 Three dedicated purposes: ....................................................................................... 25 Basic Specifications: ................................................................................................. 25 Wiring a controller with differential output as a single ended input ........................... 26 Wiring a controller with differential output to differential input ................................... 26 Wiring a potentiometer to a single ended input ........................................................ 26 Programmable Outputs ........................................................................................... 27 Encoder Outputs ............................................................................................................. 28

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Expanded I/O board (IN/OUT 2) ......................................................................... 29 Single Ended Inputs ........................................................................................................ 29 What is COM? .......................................................................................................... 29 Connecting to the Aux Analog Input ................................................................................ 31 Programmable Outputs ................................................................................................... 32 Recommended AMP Motors ..................................................................................... 33 Alpha A Series .......................................................................................................... 33 Alpha M Series ......................................................................................................... 33 Alpha N Series.......................................................................................................... 33 Other Supplier's Motors................................................................................................... 33 Setting Drive Current Limits ..................................................................................... 34 What is “Peak Current Limit”? ................................................................................... 34 Using DC Brushed Motors ........................................................................................ 35 Servo Drive Regeneration ........................................................................................ 36 Mounting the Drive ................................................................................................ 37 BLuAC5 (all models) ................................................................................................ 37 Mechanical Outlines .............................................................................................. 38 Technical Specifications......................................................................................... 39

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Safety Instructions Safety Instructions Safety Instructions Safety Instructions Safety Instructions Only qualified personnel are permitted to transport, assembly, commission, and maintenance this equip- ment. Properly qualified personnel are persons who are familiar with the transport, assembly, installation, commissioning and operation of motors, and who have the appropriate qualifications for their jobs. The qualified personnel must know and observe the following standards and regulations: IEC 364 resp. CENELEC HD 384 or DIN VDE 0100 IEC report 664 or DIN VDE 0110 National regulations for safety and accident prevention or VBG 4 To minimize the risk of potential safety problems, you should follow all applicable local and national codes that regulate the installation and operation of your equipment. These codes vary from area to area and it is your responsibility to determine which codes should be followed, and to verify that the equipment, installation, and operation are in compliance with the latest revision of these codes. Equipment damage or serious injury to personnel can result from the failure to follow all appli- cable codes and standards. We do not guarantee the products described in this publication are suitable for your particular application, not do we assume any responsibility for your product design, installation, or operation. • Read all available documentation before assembly and commissioning. Incorrect handling of products in this manual can result in injury and damage to persons and machinery. Strictly adhere to the technical information on the installation requirements. • It is vital to ensure that all system components are connected to earth ground. Electrical safety is impossible without a low-resistance earth connection. • The BLUAC5 contains electrostatically sensitive components that can be damaged by incorrect han- dling. Discharge yourself before touching the product. Avoid contact with high insulating materials (artifi- cial fabrics, plastic film, etc.). Place the product on a conductive surface. • During operation keep all covers and cabinet doors shut. Otherwise, there are deadly hazards that could possibility cause severe damage to health or the product. • In operation, depending on the degree of enclosure protection, the product can have bare components that are live or have hot surfaces. Control and power cables can carry a high voltage even when the motor is not rotating. • Never pull out or plug in the product while the system is live. There is a danger of electric arcing and danger to persons and contacts. • After powering down the product, wait at least ten minutes before touching live sections of the equip- ment or undoing connections (e.g., contacts, screwed connections). Capacitors can store dangerous voltages for long periods of time after power has been switched off. To be safe, measure the contact points with a meter before touching. Be alert to the potential for personal injury. Follow the recommended precautions and safe operating practices included with the alert symbols. Safety notices in this manual provide important information. Read and be familiar with these instructions before attempting installation, operation, or maintenance. The purpose of this section is to alert users to possible safety hazards associated with this equipment and the precautions that need to be taken to reduce the risk of personal injury and damage to the equip- ment. Failure to observe these precautions could result in serious bodily injury, damage to the equipment, or operational difficulty.

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Introduction Introduction Introduction Introduction Introduction Thank you for selecting an Applied Motion Products motor control. We hope our dedication to performance, quality and economy will make your motion control project successful. If there's anything we can do to improve our products or help you use them better, please call or fax. We'd like to hear from you. Our phone number is (800) 525-1609 or you can reach us by fax at (831) 761-6544. You can also email [email protected]. BLuAC5 Features • Digital servo motor driver in complete fully featured package • Operates directly from a 100 to 260 Volt AC input, single phase or three phase • Operates in torque, velocity or position mode • Accepts analog signals, digital signals and RS-232/485 serial commands • Motor current to 15.0 amps peak, 5.0 amps continuous • Seven optically isolated digital inputs (15 inputs with expanded I/O board) • Three optically isolated digital outputs (7 outputs with expanded I/O board) • ±10 volt analog input for position, speed and torque control • 0-5V aux analog input Block Diagram motor encoder to RS-485 host RS-485 IGBT PWM Power Amplifier User Out 24 VDC X1/STEP/PWM X2/DIR X3/SVEN X4/ALMRST X5 X6/CCWLMT X7/CWLMT to PC ANALOG+ ANALOG– Y1/BRAKE Y2/INPOSN Y3/ALARM RS-232 Optical Isolation ENCODER OUT Line Drivers DSP Optical Isolation Internal Logic Supply AC Input Power Converter 100 - 260 VAC DC Bus LED Internal Regen Clamp External Regen Resistor External Brake Resistor Input 24 VDC Regen LED Seven Segment Status Display Rx Status LED Tx Status LED

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Getting Started Getting Started Getting Started Getting Started Getting Started This manual describes the use of three different drive models. What you need to know and what you must have depends on the drive model. For all models, you must have the follow- ing: • a compatible servo motor • cables to connect the motor to the drive. If you are using an Applied Motion “Alpha” motor, use BLUENC and BLMTR cables (one of each). • a small flat blade screwdriver for tightening the connectors (included). • a personal computer running Microsoft Windows 95, 98, NT, Me, 2000 or XP. • The Applied Motion CD that was included with your BLu servo drive • An Applied Motion programming cable (included) If you’ve never used a BLu servo before, you’ll need to get familiar with the drive and the set up software before you try to deploy the system in your application. We strongly recom- mend the following: 1. Install the QuickTuner™ software from the CD. 2. Launch the software by clicking Start...Programs...Applied Motion Products...QuickTuner. 3. Connect the drive to your PC using the programming cable supplied. 4. Connect the drive to the AC power source (may be switched). 5. Connect the drive to the motor. 6. Apply power to the drive. 7. Follow the instructions in the QuickTuner™ manual. (On the CD) The connectors and other points of interest are illustrated on the next page. Depending on your drive model and application, you’ll need to make connections to various parts of the drive. These are detailed later in the manual.

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual DC Bus Motor Encoder IN / OUT 1 IN / OUT 2 PC/MMI RS-485/422 C B A GND TX- TX+ RX- RX+ COMM Status Regen GND +24VDC Input 320V pk User Out +24VDC GND CLAMP RES EXT BUS BRAKING L1 L2/N L3 AC POWER G Error Codes Position Limit CCW Limit CW Limit Over Temp Over Voltage Under Voltage Over Current Current Limit Hall Bad Encoder Bad Memory Failed Regen Failed Comm Error Position Mode Velocity Mode Torque Mode Step Mode Operating Modes Front View X COMMON X7 / CW Limit X3 / Servo Enable X5 X4 / Alarm Reset Analog IN- Analog IN+ X2 / DIR- X2 / DIR+ X1 / STEP / PWM+ X1 / STEP / PWM- GND GND A+ A- B+ B- Z+ Z- +5V OUT Y COMMON Y3 / ALARM Y2 / INPOSN Y1 / BRAKE 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 2 3 1 19 20 21 22 23 24 25 Encoder Outputs X6 / CCW Limit 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 2 3 1 19 20 21 22 23 24 25 +5V Out 1- Out 2+ Out 1+ Ain Com N/C Ain 1 IN 8- COM IN 5 IN 6 IN 7+ IN 8+ IN 7- IN 4 IN 1 COM IN 2 COM IN 3 Out 2- Out 3+ Out 3- Out 4+ Out 4- enabled when flashing Drive Disabled Si Mode INT rotating segment indicates Q program running. IN/OUT 2 IN/OUT 1 DB-25 connector #1 • digital inputs • digital outputs • analog inputs • encoder output HD-15 connector • motor feedback screw terminal plugable connector • motor plugable screw terminal connector • RS-485 port comm status LEDs • Rx (Green) • Tx (Amber) RJ11 connector • RS-232 port Always use the blue & white Applied Motion screwdriver to tighten the screw terminal connectors. Larger screwdrivers may remove the plastic dimples that prevent the screws from falling out. plugable screw terminal connector • AC input 100-260VAC • DC input 90-367VDC plugable screw terminal connector • Dynamic Braking Resistor plugable screw terminal connector • External Regen Resistor DB-25 connector #2 Expansion I/O • digital inputs • digital outputs • analog input Status LED • Regen Seven Segment LED • status codes • error Codes Status LED • DC Bus Voltage present plugable screw terminal connector • User 24 volt output plugable screw terminal connector • 24 volt (Keep Alive) input Standard on BLuAC5-Si Option on -S, -Q

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Status & Error Display LEDs Status & Error Display LEDs Status & Error Display LEDs Status & Error Display LEDs Status & Error Display LEDs Serial Comm Tx & Rx LED Indicates that data is being received or transmitted through the RS-232 or RS-485 serial ports. Green indicates “Receiving”. Amber indicates “Transmitting” Bus voltage indication LED Indicates when there is DC Bus voltage present on the drive. The servo drive cover should not be removed when this LED is illuminated. (See “WARNINGS” at end of manual) Seven Segment Display Error codes Note: codes with a ”*” indicate drive has faulted and flash at a 0.5 second rate. *Over Current: The Motor phase current has exceeded the 20 amps (RMS). The drive will be faulted. *Under Voltage: The DC Bus voltage has gone below 100 Volts. *Over Voltage: The DC Bus voltage exceeded 400 Volts. The drive will be faulted after this error. *Regeneration Error: While attempting to “dump” power into the regeneration shunt resistor the device limits were reached (based on settings) or, there is no regeneration shunt resistor attached. *Over Temperature: The Drive PCB temperature has exceeded 75° C. This will cause the drive to fault and cannot be cleared until the temperature drops below the limit. CW Limit: The Clockwise limit has been triggered. This will depend on the CCW/CW Input settings. Use “DL” Host command or QuickTuner™ “I/O” panel to enable usage. CCW Limit: The Counter Clockwise limit has been triggered. This will depend on the CCW/CW Input settings. Use “DL” Host command or QuickTuner™ “I/O” panel to enable usage. *Position Limit Error: Indicates the Servomotor has exceeded the “Position Limit” value, set by QuickTuner™ “Drive” panel or the “PF” Host command. Current Limit: The Motor phase current has exceeded the “Peak” current time limit (As set by the CP Host command or QuickTuner™). *Hall Pattern Bad: Indicates that the Hall sensor (commutation track) inputs are incorrect. Drive only accepts 120° Hall sensor patterns. Could also indicate a failed sensor. *Encoder Failure: Indicates that the Encoder inputs are not providing the correct states. This feature can be enabled or disabled using the QuickTuner™ Setup utility, “Single Ended” checkbox. Memory Fault: When reading or writing to “Flash” memory an error occurred. This is an indicator of memory problems that are typically induced with too many write cycles (>100,000). Serial Comm Error: Indicates a Serial Communication error. This error is also indicated by the Comm Tx and Rx LEDs flashing an alternating pattern. This could result from a number of different conditions such as incorrect Baud Rate, electrical noise or faulty wiring.

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Seven Segment Display Status codes Regeneration LED This LED indicates when the drive is actively applying the regeneration clamp. The clamp is the internal circuitry that shunts the DC bus to a power resistor. The power resistor can be either internal or external. (See “Servo Drive Regeneration” in this manual for more details) Positioning Mode: The drive is in Positioning Mode. This is the mode used when performing “point to point” moves. Velocity Mode: The drive is in Velocity Mode. This is the mode used when “Jogging” or Analog com- manded Velocity. Torque Mode: The drive is in Torque Control Mode. This is the mode used for Analog commanded Torque operation. Step & Direction Mode: The drive is in Step and Direction Control Mode. This is the mode used for “Encoder Following” or Positioning using Step and Direction input. Si Positioning: When in Si Programmer mode or running an Si program this code typically appears. Drive Disabled: The drive output is disabled. Q Program Running: An outside segment will be rotating around the display. The rotate rate is about 0.2 seconds per segment. Drive Start-up test pattern: This pattern is displayed for a short period of time at drive start-up.

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Connecting to the PC using RS-232 Connecting to the PC using RS-232 Connecting to the PC using RS-232 Connecting to the PC using RS-232 Connecting to the PC using RS-232 • Locate your computer within 6 feet of the BLu servo drive. • Your drive was shipped with a black adapter plug. It has a telephone style jack at one end and a larger 9 pin connector at the other . Plug the large end into the COM1 serial port of your PC. Secure the adapter with the screws on the sides. If the COM1 port on your PC is already used by something else, you may use the COM2 port for the drive. On some PCs, COM2 will have a 25 pin connector that does not fit the black adapter plug. If this is the case, and you must use COM2, you will have to purchase a 25 to 9 pin serial adapter at your local computer store. • Your drive was also shipped with a 7 foot telephone line cord. Plug one end into the adapter you just attached to your PC, and the other end into the RS-232 jack on your drive. If you need to locate your drive farther from the PC, you can replace the 7 foot phone cord with a longer one. Do not exceed 50 feet. • If your PC does not have an RS-232 COM port but provides a USB connection, there are many USB to RS-232 adaptors available that will do the trick. Never connect a BLu servo drive to a telephone circuit. It uses the same connectors and cords as telephones and modems, but the voltages are not compatible. (5) GND (4) Drive TX (3) +5 Volt output for MMI & HUB (2) Drive RX 2 3 5 6 DB9 to RJ11 Adaptor Pin assignments DB9 female Signal Name RJ11 Signal Name 2 RX 4 TX 3 TX 2 RX 5 GND 5 GND Servo Drive RJ11 1 (2) PC TX (3) No Connection (4) PC Rx (5) PC Ground 1 Adaptor RJ11 6 Adaptor DB9 Front View Front View Front View PC DB9 to Servo Drive RJ11 Adaptor NOTE: Pins 1 & 6 are not connected

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Connecting to a host using RS-485 Connecting to a host using RS-485 Connecting to a host using RS-485 Connecting to a host using RS-485 Connecting to a host using RS-485 RS-485/422 allows you to connect more than one drive to a single host PC, PLC or other computer. It also allows the communication cable to be long (more than 1000 feet). But the device to which you connect must have an RS-485/422 port. A Shor A Shor A Shor A Shor A Short tutorial on RS-485 & RS-422 t tutorial on RS-485 & RS-422 t tutorial on RS-485 & RS-422 t tutorial on RS-485 & RS-422 t tutorial on RS-485 & RS-422 There is a bit of confusion on the implementation of the these two serial interface specifica- tions. RS-485 in the strictest definition is a “2-wire” interface that allows multi-node connec- tions limited to “Half-duplex” serial communications. Up to 32 nodes that both transmit and receive can be connected to the network. RS-422 also in the strictest definition is a “4-wire” point to point connection that allows “Full-duplex” serial communications when connected to a single node. RS-422 has one node that is the driver or transmitter and up to 10 nodes that are receivers. RS-422 was not designed for a true multi-node network. 2- wire interfaces require one more significant feature. A network node, master or slave, must be able to tristate it’s transmitter to allow other nodes to use the network when re- quired. For high speed baud rates this must be done very quickly to avoid communication collisions. 4-wire interfaces can go beyond the simple point to point and do multi-node networks if the slave nodes are capable of tri-stating their transmitters as required in the 2-wire networks. Some RS-485 devices are set up to do this and can be used in a 4-wire configuration. On the AMP Servo drives the RS-485 can be implemented with either “2-wire” or “4-wire”. When using 4-wire it is possible to operated in “Full Duplex” but in practice should be lim- ited to “Half Duplex”. Half Duplex avoids possible communication collisions. 2-wire is al- ways limited to Half-duplex. 4-wire implementations can sometimes be easier due to the greater number of Host RS-232 to RS-485 adaptors that support the 4-wire interface. They are also easier to use because the Host PC or system does not have to tristate (disable) it’s transmitter. 2-wire implementations may require special Host adaptors that support “Auto enable” of the adaptor transmitter. This is because PC software typically doesn’t support tri- stating the output of the serial adaptors. In both 2-wire and 4-wire systems one extra wire is always required to connect the “Grounds” of all the nodes on the network. Even though in both cases the signals are sent differentially a command ground connection is absolutely required. One more consideration must not be neglected. Proper cable shielding is a must. High voltage, high frequency, high current signals that are present on the servo motor cables can emit a significant amount of electrical interference. Without proper shielding these signals can disrupt even “noise tolerant” differential line drivers. NOTE: RS-485 is only available on the -S and -Q drive versions

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual 4-wire RS-485/422 Network Our RS-485 implementation is a 4-wire multi-drop network with separate transmit and receive wires. One pair of wires connect from the host computer's TX+ and TX- signals to each drive's RX+ and RX- terminals. Another pair connect the TX+ and TX- drive terminals to the host computer's RX+ and RX- signals. A common ground terminal is provided on each drive and can be used to keep all drives at the same ground potential. This terminal connects internally to the DC power supply return (V-), so if all the drives on the RS-485 network are powered from the same supply it is not necessary to connect the logic grounds. You should still connect one drive's GND terminal to the host computer ground. Before wiring the entire system, you'll need to connect each drive individually to the host computer so that a unique address can be assigned to each drive. Proceed as follows: (Also see figure #1 below) 1. Connect the drive TX+ to the PC's RX+ terminal. 2. Connect the drive TX- to PC RX-. 3. Connect RX+ to TX+. 4. Connect RX- to TX-. 5. Connect GND to GND. Getting and Connecting a RS-485 4-wire adaptor to your PC Model 117701 from Jameco Electronics (800-831-4242) works well. This adaptor is for a 25 pin serial port. If you are like most people and have a 9 pin serial port on your PC, you will also need to purchase Jameco cable 31721. Connect as follows: adaptor drive 1 RX+ 2 RX- 3 TX- 4 TX+ Set the switches for DCE and TxON,RxON. Don't forget to plug in the DC power adaptor that comes with the unit. +RX- +TX- GND +RX- +TX- GND +RX- +TX- GND to PC TX+ to PC TX- to PC RX+ to PC RX- to PC GND Drive #1 Drive #2 Drive #3 4-Wire multi-drop RS-485 Figure #1

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual 2-wire RS-485 Network You can also connect the drive to the Host computer using only a 2-wire interface. In this case you must first connect the TX+ to the RX+ and the TX- to the RX- on the servo drives before connecting to the Host adaptor. Usually RS-485 2-wire interfaces are labeled “A” & “B”. (See figure #2 below) Getting and Connecting a RS-485 2-wire adaptor to your PC Model 485-25E from Integrity Instruments (800-450-2001) works well. It comes with every- thing you need. Connect as follows: adaptor drive A TX+/RX+ B TX-/RX- +RX- +TX- GND +RX- +TX- GND +RX- +TX- GND to PC TX+/RX+ or A to PC TX-/RX- or B to PC GND Drive #1 Drive #2 Drive #3 2-Wire multi-drop RS-485 Figure #2 Before You connect the servo drive to your system - With the RS-232 cable connected between your PC and the Servo drive, on your PC, start the SCL Setup Utility software. Select the proper comm port (1,2,3 or 4) then apply power to the drive. Press the Caps Lock key. The drives only accept commands in uppercase. Type RV then press ENTER. If the drive has power and is properly wired, it will respond with "RV=x". Where x is the firmware version of your drive. If the drive responds, you're home free: the RS-485 network is functioning. Next, you must choose an address for this drive. Any of the "low ASCII" characters (many of which appear above the number keys on a PC keyboard) is acceptable: ! " # $ % & ' ( ) * + , - . / 0 1 2 3 4 5 6 7 8 9 : ; < > ? @ To find out what address is in the drive now, type DA then press enter. The drive will re- spond with DA=x, where x is the address that was last stored. (For example, the response might be DA=@ or DA=!). To change the address, type DAy, where y is the new address character, then press ENTER. To test the new address, type yRV, then press ENTER. For example, if you set the address to % and want to test that, type %RV. The drive should respond just as it does to RV, the global revision level request. Once all the drives have been assigned unique addresses, you can proceed to wire the whole system together.

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Connecting the AC Power Input Connecting the AC Power Input Connecting the AC Power Input Connecting the AC Power Input Connecting the AC Power Input The AC input to the servo drive will accept a broad range of variations. The AC source voltage can range for 90VAC RMS to 260VAC RMS, the Frequency from 50 to 60 Hz and the phase from single to three phase. The AC input voltage is the most significant attribute of the AC input to affect the power that is available from the drive. At lower AC inputs the DC bus voltage is reduced and therefore will limit performance of higher voltage AC servo motors. As a general rule AC inputs of 120 VAC will permit continuous operation of 500 Watt servo motors while AC inputs of 240VAC will operate 1K Watt servo motors. It is wise to match as closely as possible the AC input and the Servo Motor voltage rating. AMP has a number of servo motors designed to operate at both 120 and 240VAC input (See list in the BLuAC5 data sheet available on our website) When available, three phase input is recommended for its lower ripple on the DC bus volt- age. This saves wear and tear on the DC bus capacitors and spreads out the current on the AC input rectifiers. DC voltages can also be connected directly to the AC inputs. The range in this case is limited to 100 to 367 VDC. WARNING: Exceeding the DC Bus voltage of 367 VDC may cause the internal regen- eration circuitry to activate. This may result in a drive fault or some cases can result in drive failure. 24 Volt Controller Input (Keep Alive) The BLUAC5 servo drives offer a 24 volt input that will supply “Keep Alive” power to the controller section of the drive. AC power can be removed without shutting down the servo controller. This function can be used to maintain motor position information. When AC power is restored to the drive the servo motor can be re-enabled and the original position reestablished. NOTE: When 24 volt input is present and the AC input is removed the drive will display a “U” error code.

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual 2.65" DC Bus C B A Input 320V pk User Out +24VDC GND CLAMP RES EXT BUS BRAKING L1 L2/N L3 AC POWER G aile m Error Front View X COMMON mit Servo Enable X5 arm Reset X2 / DIR- X2 / DIR+ X1 / STEP / PWM+ X1 / STEP / PWM- GND GND A+ A- B+ B- Z+ Z- +5V OUT Y COMMON Y3 / ALARM Y2 / INPOSN Y1 / BRAKE 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 2 3 1 19 20 21 22 23 24 25 Encoder Outputs W Limit 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 2 3 1 19 20 21 22 23 24 25 +5V Out 1- Out 2+ Out 1+ Ain Com N/C Ain 1 IN 8- COM IN 5 IN 6 IN 7+ IN 8+ IN 7- IN 4 IN 1 COM IN 2 COM IN 3 Out 2- Out 3+ Out 3- Out 4+ Out enabled flashing INT indicates Q ng. IN/OUT 2 N/OUT 1 Connecting Single Phase AC input (90-260VAC) Connecting 3-Phase AC input (90-260VAC) 2.65" DC Bus Motor C B A 320V pk User Out +24VDC GND CLAMP RES EXT BUS BRAKING L1 L2/N L3 AC POWER G ew D GND A+ A- B+ B- Z+ Z- +5V OUT Y COMMON Y3 / ALARM 2 / INPOSN BRAKE 8 13 12 1 19 20 21 22 23 24 25 Encoder Outputs 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 2 3 1 19 20 21 2 +5V Ou Out 1 Ain Com N/C Ain 1 IN 8- COM IN 5 IN 6 IN 7+ IN 8+ IN 7- IN 4 IN 1 COM IN 2 COM IN 3 INT IN Connect Earth (Green) to “G” “Hot” (Black) to “L1” “Neutral” (White) to “L2/N” Connect Earth (Green) to “G” “Phase 1” (Black) to “L1” “Phase 2” (White) to “L2/N” “Phase 3” (Red) to “L3” Connecting DC input (100-367 VDC) Connect Earth (Green) to “G” “+V” to “L1” “-V/GND” to “L2/N”

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Connecting the Motor Connecting the Motor Connecting the Motor Connecting the Motor Connecting the Motor WARNING: Never connect or disconnect the motor while the power is on. Applied Motion motor: To connect an Applied Motion servo motor to your BLu Servo, you'll need a set of mating cables called the BLUENC and the BLMTR. Connect the small twist lock motor connector to one end of the BLMTR cable. The other end of the BLMTR has lead wires that connect to the drive’s screw terminal connector as follows: A = red wire B = white wire C = black wire "-" = green wire Connect the large motor connector to one end of the BLUENC cable. The other end of the BLUENC plugs into the BLu servo. Non-Applied Motion motor: Connect the motor leads to the screw terminal connector as follows: A = motor phase A, R or U B = motor phase B, S or V C = motor phase C, T or W "-" = ground wire Motor

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Connecting the Encoder & Hall Sensors Connecting the Encoder & Hall Sensors Connecting the Encoder & Hall Sensors Connecting the Encoder & Hall Sensors Connecting the Encoder & Hall Sensors Encoder Pinout The encoder connections use a HD-15 connector as shown in the pinout. When connect- ing the Encoder and Hall sensors use high quality shielded cables. Connect cable shield to the HD-15 connector backshell. The BLuAC5 servo drive is designed for “Differen- tial” inputs on both the encoder signals and hall sensors. It is highly recommended that encoders with “Differential Line Drivers” be used to provide maximum noise immunity. Using the BLUENC cable with AMP servo motors provides the best opportunity for minimizing connection problems. encoder Z+ (5) Hall 1-(10) encoder B- (4) Hall 1+ (9) encoder B+ (3) Hall 3+ (13) Hall 3- (14) NC (15) (12) Hall 2- (11) Hall 2+ (6) encoder Z- (1) encoder A+ (7) +5VDC 200mA (2) encoder A- (8) GND Connecting a Single-Ended Encoder Single-ended encoders may be connected to the servo drive as shown below. It some cases this may cause loss of encoder data. Typically the single ended encoders source impedance is high and cannot drive a terminated transmission line. Because of this single- ended signals may be more susceptible to “Ground” and induced noise. Single Ended Encoder encoder A (3) GND (1) +5VDC (4) encoder B (5) index (2) Encoder Connector (8) GND (5) Z+ (3) B+ (1) A+ (7) +5V (4) B- (6) Z- (2) A- NC NC NC 3.3k Vcc 330 Vcc 220 Typical Input Circuit NOTE: Not recommend in “High Noise” environments Connecting Single-Ended Hall Sensors Single-ended Hall sensors may be connected to the servo drive as shown below. The output of each Hall sensor must be able to “sink” 10 mA of current in order to properly drive the hall sensor inputs. Typically “Open Collector outputs are best suited to driving the hall sensor inputs. Encoder Connector Pinout Single Ended Hall Sensors V or B U or A GND W or C Encoder Connector (7) +5V NC NC NC 220 Vcc 220 Typical Input Circuit +5V (8) GND Open Collector Outputs Vcc (10) Hall 1- (9) Hall 1+ (13) Hall 3+ (14) Hall 3- (12) Hall 2- (11) Hall 2+

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Connecting Input Signals Connecting Input Signals Connecting Input Signals Connecting Input Signals Connecting Input Signals The BLu servo drives have four types of inputs: • high speed digital inputs for step & direction or PWM commands, 5 volt logic • digital inputs for other signals, 12 - 24 volt logic • analog inputs for torque and speed commands, ±10V • analog input (0 to 5 volts) on “IN/OUT 2” connector ( available on -S & -Q drives with I/O Expansion) IN/OUT 1 I/O Connector This connector include seven digital inputs, three digital outputs and two analog inputs. The inputs and outputs are programmable on the drive. A number of the I/O lines are configurable for either “Dedicated” or “Programmable” operation. Dedicated Inputs: CW & CCW Limit: can be used to inhibit motion in a given direction, forcing the motor and load to travel within mechanical limits. PWM & DIR: digital signal commanding torque, velocity or position. Servo Enable: servo is active when closed. Motor is disabled (turns freely) when open. Alarm Reset: Close this signal momentarily to reset a drive fault (alarm). Dedicated Outputs: Brake: Activates or releases a mechanical brake when servo drive is enabled or disabled. In Position or Moving: Indicates when the servo drive is performing a “Move”. Alarm or Fault: Indicates when the servo drive has a alarm the has resulted in a fault. Analog In: analog torque, velocity or position command signal With Expanded I/O (IN/OUT 2) The BLuAC5 I/O expansion board adds eight programmable inputs, 4 programmable out- puts and one analog input on a male DB-25 connector. (Standard on BLuAC5-Si) Front View X COMMON X7 / CW Limit X3 / Servo Enable X5 X4 / Alarm Reset Analog IN- Analog IN+ X2 / DIR /CCW Jog- X2 / DIR /CCWJog+ X1 / STEP / CW Jog+ X1 / STEP / CW Jog- GND GND A+ A- B+ B- Z+ Z- +5V OUT Y COMMON Y3 / ALARM Y2 / INPOSN Y1 / BRAKE 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 2 3 1 19 20 21 22 23 24 25 Encoder Outputs X6 / CCW Limit IN/OUT 1 IN/OUT1 & IN/OUT 2 Connector Pinout Diagrams 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 2 3 1 19 20 21 22 23 24 25 +5V Out 1- Out 2+ Out 1+ Ain Com N/C Ain 1 IN 8- COM IN 5 IN 6 IN 7+ IN 8+ IN 7- IN 4 IN 1 COM IN 2 COM IN 3 Out 2- Out 3+ Out 3- Out 4+ Out 4- IN/OUT 2 Note - this connector is standard on Si version and only on S and Q versions with expanded I/O.

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLU Servo Drive IN/OUT 1 DIR+ DIR+ DIR- DIR- STEP+ STEP- STEP+ STEP- Indexer with Differential Outputs BLU Servo Master Encoder GND DIR- DIR+ STEP- STEP+ GND B- B+ A- A+ Using High Speed Inputs with 12-24 Volt Signals Most PLCs don't use 5 volt logic. You can connect signal levels as high as 24 volts to the STEP and DIR inputs if you add external dropping resistors, as shown below. • For 12 volt logic, add 820 ohm, 1/4 watt resistors • For 24 volt logic, use 2200 ohm, 1/4 watt resistors WARNING: The maximum voltage that can be applied directly to a high speed input terminal is 5 volts. Never apply high voltage AC to an input terminal. BLU Servo Drive IN/OUT 1 COM DIR- DIR DIR+ STEP- STEP STEP+ Indexer with Sourcing Outputs Connecting to Indexer with Sinking Outputs (includes Applied Motion Si-1 Indexer) BLU Servo Drive IN/OUT 1 +5V OUT DIR+ DIR DIR- STEP+ STEP STEP- Indexer with Sinking Outputs High Speed Digital Inputs The BLuAC5 drives include two high speed inputs called STEP (Pulse) and DIR. They accept 5 volt single-ended or differential signals, up to 2 MHz. Normally these inputs con- nect to an external controller that provides step & direction command signals. You can also connect a master encoder to the high speed inputs for following applications.

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Connecting to PLC with Sinking (NPN) Outputs (Most PLC's use 24 volt logic) (Most PLC's use 24 volt logic) (Most PLC's use 24 volt logic) (Most PLC's use 24 volt logic) (Most PLC's use 24 volt logic) BLU Servo Drive +12-24V DIR+ DIR DIR- STEP+ STEP STEP- PLC with Sinking Outputs R R Using Mechanical Switches at 24 Volts. BLU Servo Drive + DIR+ DIR- STEP+ - STEP- +24VDC Power Supply 2200 2200 direction switch run/stop switch (closed=run) Connecting to PLC with Sourcing (PNP) Outputs (Most PLC's use 24 volt logic) (Most PLC's use 24 volt logic) (Most PLC's use 24 volt logic) (Most PLC's use 24 volt logic) (Most PLC's use 24 volt logic) BLU Servo Drive +12-24V GND DIR- OUT1 DIR+ STEP- OUT2 STEP+ PLC with Sourcing Outputs R R

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Standard Digital Inputs Standard Digital Inputs Standard Digital Inputs Standard Digital Inputs Standard Digital Inputs As we mentioned in the previous section, the high speed STEP and DIR inputs are config- ured for five volt logic. All other digital inputs are designed for operation between 12 and 24 volts DC. This includes five inputs on the main board and the eight digital inputs on the expanded I/O board (IN/OUT 2). Single Ended Inputs The BLUAC5 servos include single ended, optically isolated input circuits that can be used with sourcing or sinking signals, 12 to 24 volts DC. This allows connec- tion to PLCs, sensors, relays and mechanical switches. Because the input circuits are isolated, they require a source of power. If you are connecting to a PLC, you should be able to get power from the PLC power supply. If you are using relays or mechanical switches, you will need a 12-24 V power supply. This also applies if you are connecting the inputs to the programmable outputs of another Si product from Applied Motion. What is COM? "Common" is an electronics term for an electrical connection to a common voltage. Some- times "common" means the same thing as "ground", but not always. In the case of the BLu Servo, if you are using sourcing (PNP) input signals, then you will want to connect COM to ground (power supply -). If you are using sinking (NPN) signals, then COM must connect to power supply +. User Out 24V supply The BLuAC5 has a 24 Volt 100 mA isolated output that can be used for powering Digital Inputs or outputs. This convenient power supply can be used in place of an external supply. Note: If current is flowing into or out of an input, the logic state of that input is low or closed. If no current is flowing, or the input is not con- nected, the logic state is high or open. The diagrams on the following pages show how to connect the inputs to various commonly used devices. 2200 2200 2200 2200 2200 inside BLu Servo COM SRVOEN ALMRST USER CWLIM CCWLIM 8 7 6 5 3 4

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLU Servo PNP Proximity Sensor IN output + – COM 12-24 VDC Power Supply - + BLu Servo IN COM Si-1 indexer MOTION+ MOTION– 12-24 VDC Power Supply - + BLU Servo IN COM Si drive OUT+ OUT– 12-24 VDC Power Supply - + BLU Servo NPN Proximity Sensor IN COM output + – 12-24 VDC Power Supply - + BLU Servo switch or relay (closed=logic low) X3..X7 COM User Out +24 VDC Supply BLU Servo +24VDC GND Digital Input Connection Examples

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Connecting Limit Switches to the BLuAC5 Drives The CWLIMIT and CCWLIMIT inputs are used for connecting end of travel sensors. These inputs are differential, which allows you to use signals that are sinking (NPN), sourcing (PNP) or differential (line driver). By connecting switches or sensors that are triggered by the motion of the motor or load, you can force the motor to operate within certain limits. This is useful if a program or operator error could cause damage to your system by travel- ing too far. The limit inputs are optically isolated. This allows you to choose a voltage for your limit circuits of 12 to 24 volts DC. This also allows you to have long wires on limit sensors that may be far from the drive with less risk of introducing noise to the drive electronics. The schematic diagram of the limit switch input circuit is shown below. BLuAC5 Limit Input diagram 2200 2200 inside BLU Servo COM CWLIM CCWLIM 8 3 4 BLU Servo + 5-24 VDC SUPPLY - CW LIMIT- COM CCW LIMIT- Wiring a Mechanical Limit Switch You can use normally open or normally closed limit switches. Either way, wire them as shown here. Wiring a Limit Sensor Some systems use active limit sensors that produce a voltage output rather than a switch or relay closure. These devices must be wired differently than switches. If your sensor has an open collector output or a sinking output, wire it like the example left: BLU Servo + DC Power Supply – Limit Sensor output + – COM CW LIMIT If the sensor output goes low at the limit, select the option “closed” (in the software). If the output is open, or high voltage, choose “open”. Other sensors have sourcing outputs. That means that current can flow out of the sensor output, but not into it. In that case, wire the sensor this way: BLU Servo + DC Power Supply – Proximity Sensor output + – CW LIMIT COM

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Analog Inputs Analog Inputs Analog Inputs Analog Inputs Analog Inputs The BLuAC5 has two ±10 Volt analog inputs that can be used individually as single ended inputs or differentially as one input. Analog inputs are used by the servo drive for a number of dedicated purposes for controlling the servo or they can be used as general purpose analog input signals. Three dedicated purposes: • Analog Torque Mode • Analog Velocity Mode • Analog Positioning Mode. Each of these three modes uses the analog input(s) for “Commanding” the servo drive. Other uses include using an analog signal to stop a move when using any of the “Feed to Sensor” type moves and waiting on a analog signal using the “Wait on Input”. +10V to -10V signal signal return BLU Servo GND AIN+ Single Ended Input BLU Servo GND/Shield GND ±10V AIN+ Differential Input ±10V AIN- BLU Servo GND 20k ohms A_CH1 A_CH2 +5 AIN+ AIN- 20k ohms Basic Specifications: • Each input can accept ±10 Volt. • The inputs have an impedance of 20K ohms. • Because of the nature of the design, the input will exhibit a 1.4V offset when not driven by an analog source. • Low source impedance is important for minimiz- ing analog errors, 100 ohms or lower is recom- mended. WARNING - Analog inputs must be used with care. They are not optically isolated and may operate improperly or could be damaged when system grounds are not compatible.

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLU Servo GND/Shield GND ±10V AIN+ Differential Input ±10V AIN- +10V to -10V signals Differential Output +10V to -10V signal signal return BLU Servo GND AIN+ Single Ended Input Differential Output NC BLU Servo GND AIN+ 1-5kW pot cw ccw +5 Wiring a controller with differential output as a single ended input If both inputs are to be used for different purposes differential outputs can be connected to a single input: Wiring a controller with differential output to differential input Care must be taken here to establish a good ground connection. The system ground in this case can be used for the cable shield. Wiring a potentiometer to a single ended input The +5 Volt power supply from the servo drive should be used to minimize ground and voltage difference effect.

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLu Servo YCOM OUT+ 1N4935 suppression diode + – Programmable Outputs Programmable Outputs Programmable Outputs Programmable Outputs Programmable Outputs The BLuAC5 drives feature three digital outputs: Brake: controls an electric brake relay, automatically releasing and engaging as the drive requires Alarm: closes when a drive fault or alarm condition occurs. The red and green LEDs will flash an error code. In Position: indicates that the drive has achieved a desired goal, such as a target position. The BLuAC5 optional I/O expansion board adds four additional programmable outputs (refer to the section on the Expanded I/O board). The outputs can be used to drive LEDs, relays and the inputs of other electronic devices like PLCs and counters. The BRAKE, ALARM and INPOSN outputs can only sink current. The COM terminal must be tied to power supply (-). Diagrams of each type of connection follow. Do not connect the outputs to more than 30VDC. The current through each output terminal must not exceed 100 mA. inside BLU Servo BRAKE COM ALARM INPOSN 14 17 15 16 BLu Servo YCOM OUT+ 5-24 VDC Power Supply + – Load

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Encoder Outputs In some applications you may wish to read the encoder signals being generated by the motor, perhaps to feed to another drive set in following mode. The DB-25 I/O connector includes encoder output signals for this purpose. The outputs are “Differential Line Driven” signals that provide buffering from the source encoder signals. GND A+ A- B+ B- Z+ Z- Front View 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 2 3 1 19 20 21 22 23 24 25 Encoder Outputs

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Expanded I/O board (IN/OUT 2) BLuAC5 Expanded I/O board (IN/OUT 2) BLuAC5 Expanded I/O board (IN/OUT 2) BLuAC5 Expanded I/O board (IN/OUT 2) BLuAC5 Expanded I/O board (IN/OUT 2) Single Ended Inputs The BLu servos include single ended, optically iso- lated input circuits that can be used with sourcing or sinking signals, 12 to 24 volts. This allows connection to PLCs, sensors, relays and mechanical switches. Be- cause the input circuits are isolated, they require a source of power. If you are connecting to a PLC, you should be able to get power from the PLC power sup- ply. If you are using relays or mechanical switches, you will need a 12-24 V power supply. This also applies if you are connecting the inputs to the programmable outputs of another Si product from Applied Motion. What is COM? "Common" is an electronics term for an electrical con- nection to a common voltage. Sometimes "common" means the same thing as "ground", but not always. In the case of the BLu Servo, if you are using sourcing (PNP) input signals, then you will want to connect COM to ground (power supply -). If you are using sinking (NPN) signals, then COM must connect to power supply +. Note: If current is flowing into or out of an input, the logic state of that input is low or closed. If no current is flowing, or the input is not connected, the logic state is high or open. The following diagrams show how to connect the inputs to various commonly used devices. The BLuAC5-S and the BLuAC5-Q can be fitted with an optional I/O expansion board. This adds l 8 Digital Inputs l 4 Digital Outputs l 1 0-5V auxiliary input This board is standard on the BLUAC5-Si. 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 2 3 1 19 20 21 22 23 24 25 +5V Out 1- Out 2+ Out 1+ Ain Com N/C Ain 1 IN 8- COM IN 5 IN 6 IN 7+ IN 8+ IN 7- IN 4 IN 1 COM IN 2 COM IN 3 Out 2- Out 3+ Out 3- Out 4+ Out 4- IN/OUT 2 Note - this connector is standard on Si version and only on S and Q versions with expanded I/O. The maximum voltage that can be applied to an input terminal is 24 volts DC. Never apply AC voltage to an input terminal. Maximum current is 20 mA per input. !

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Connecting an Input to a Switch or Relay Use normally open momentary switch to trigger drive using Wait Input instruction. Use single throw switch for parameter selection using If Input instruction. Use normally open momentary switch for jogging. Connecting another Si Drive (When output closes, drive input goes low). Connecting an NPN Type Proximity Sensor to an input (When prox sensor activates, drive input goes low). IN/OUT2 switch or relay (closed=logic low) IN COM 5-24 VDC Power Supply - + IO/OUT2 IN COM Si3540, 7080i, Si5580, etc OUT+ OUT– 12-24 VDC Power Supply - + IN/OUT2 NPN Proximity Sensor IN COM output + – - + NPN Proximity Sensor IN COM output + – 12-24 VDC Power Supply - +

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Connecting to the Aux Analog Input The auxiliary analog input on the BLuAC5 IN/OUT 2 connector can be used by “Feed to Sensor” commands and other input functions when operating the drive in “Host” mode. The analog input can also be read back to the “Host” using the “IA” immediate type and “RA” buffered type Host commands. Readings are in Volts. See “BLu Servo Host Command Reference” for more information. +5 volt DC is provided for powering potentiometers. A 1000 to 10000 ohm potentiometer is recommended and should be connected as shown below. A 0 to 5 volt analog signal may also be used. Usually this signal comes from a PLC, a PC with data acquisition card or a motion controller. Connections are shown below. The +5V terminal is an output. Do not connect it to a power supply. Connecting an Analog Input to a Potentiometer 0 - 5V speed signal signal return BLU-Si GND AIN 1-10kΩ pot cw ccw BLU-Si GND AIN +5 Connecting an Analog Input to an Active Signal Connecting a PNP Type Proximity Sensor to an input (When prox sensor activates, drive input goes low). IN/OUT2 PNP Proximity Sensor IN output + – COM - + PNP Proximity Sensor IN output + – COM 12-24 VDC Power Supply - +

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLu-Si OUT- OUT+ 1N4935 suppression diode 5-24 VDC Power Supply + – relay BLu-Si OUT- OUT+ 5-24 VDC Power Supply + – Load Programmable Outputs The expanded I/O board adds four additional programmable outputs. The outputs can be used to drive LEDs, relays and the inputs of other electronic devices like PLCs and counters. On the IN/OUT 2 connector outputs, both the “+” (collector) and “-” (emitter) terminals of each transistor are available on the connector pins. This allows you to configure each output for current sourcing or sinking. Diagrams of each type of connection follow. Do not connect the outputs to more than 30VDC. The current through each output terminal must not exceed 100 mA. inside BLu-Si OUT1+ OUT1- OUT2+ OUT2- OUT3+ OUT3- OUT4+ OUT4- PLC BLu-Si 12-24 VDC Power Supply + – OUT- OUT+ IN COM

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Alpha A Series Part Current Voltage Size Number amps V mm A0400-101-4 5.2A 100 60 A0400-102-4 3.2A 200 60 A0600-102-5 4.2A 200 80 A0800-102-5 4.6A 200 80 A0950-102-5 4.5A 200 80 Alpha M Series Part Current Voltage Size Number amps V mm M0400-101-4 5.6A 100 60 M0400-102-5 2.7A 200 80 M0600-102-5 4.5A 200 80 M0750-102-5 4.9A 200 80 Alpha N Series Part Current Voltage Size Number amps V NEMA N0400-101-B 5.6A 100 23 N0400-102-C 2.7A 200 34 N0600-102-C 4.5A 200 34 M0750-102-C 4.9A 200 34 Note: to connect AMP motors to a BLu servo drive, an extension cable is required. They are available in standard lengths of 4, 10 and 20 feet, custom lengths available upon re- quest. Please contact your distributor or call the factory to order. Recommended AMP Motors Recommended AMP Motors Recommended AMP Motors Recommended AMP Motors Recommended AMP Motors Other Supplier's Motors If you want to use a motor other than those recommended here, it must be a three phase motor with 120° commutation timing. The motor must also have an incremental encoder (index signal is not required) with no fewer than 50 lines and no greater than 32,000 lines. The halls and encoder must operate from +5VDC, 200 mA max (supplied by the BLu drive). The hall signals may be single-ended or differential. We strongly recommend that the encoder have differential line driver outputs, but single-ended may be acceptable if you use a shielded cable. The BLu servo drives feature sine commutation, which makes motors run more smoothly than trapezoidal drives. If you choose a low cost motor with internal hall effect devices instead of a quality motor with precision commutation tracks on the encoder disk, your performance may suffer.

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Setting Drive Current Limits Setting Drive Current Limits Setting Drive Current Limits Setting Drive Current Limits Setting Drive Current Limits The BLuAC5 allows the user to set both the Continuous and Peak motor current limits. Current settings are an RMS value. Using the QuickTuner™ the current settings can be uploaded and downloaded. Setting the current limits requires the user know the limitations of the motor. In most cases referring to the motor manufacturers specification will give the proper information. For AMP motors, motor settings are available in parameter files that are placed on the PC where QuickTuner™ was installed. What is “Peak Current Limit”? The BLuAC5 uses this current value to establish the maximum possible RMS current that will be driven to the motor. The peak current time is One second. That is, if the drive at- tempts to run at peak current for more than one second it will fold back the current to the continuous current setting. The peak current time is actually calculated on a curve using an I²/T method. For current values that are less than the peak but greater than the continuous setting, the current foldback value is calculated from the peak and continuous settings. As shown in the dia- gram below, current values below the peak value can be used for longer periods of time. Peak Current Continuous Current I²/T Calculation AMPS TIME 1 Sec.

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Using DC Brushed Motors Using DC Brushed Motors Using DC Brushed Motors Using DC Brushed Motors Using DC Brushed Motors DC Brushed motors can be used with the servo drive simply by connecting the motor and encoder to the drive as shown below and configuring the drive using the AMP QuickTuner™ configuration tool. Before connecting the Brushed motor to the servo drive you need to determine the motor’s polarity. That is, you need to know which wire is positive and which is negative. When apply- ing DC power to the motor it needs to spin clockwise. After determining this, the wire con- nected to the positive of the DC power should be labeled as such. Connect the wires as shown. Positive to “A” phase and negative to “B” phase. If an Encoder is being used, connect it to the Encoder input as explained earlier in this manual. Using QuickTuner™ configure the drive for a “Brush Motor” in the “Motor - Encoder” tab. Remember to enter the counts per turn in the “Encoder” set- ting. If the encoder is “Single Ended” be sure to check the box. Motor

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Ser Ser Ser Ser Servo Drive Regeneration vo Drive Regeneration vo Drive Regeneration vo Drive Regeneration vo Drive Regeneration The BLuAC5 servo drive comes with a regeneration clamp circuit and power dump resistor built in. The circuit is designed to handle any power level that the drive is able to provide but the internal power dump resistor is not. The internal power resistor is rate at a continuous 50 watts. This may not be sufficient in cases where the load has a high inertia content and very little frictional content. For these cases an external power resistor may be connected to the drive. When using an external power resistor the regeneration parameters must be changed using the AMP QuickTuner™ configuration tool. Now comes the first question. How do I know if an external power resistor is needed? There are two methods: 1. Calculation - Based on your load and the conditions you will be operating in you can calculate the power in watts that will be regenerated. (I know everybody will choose this method) 2. Trial & Error - After operating the system the drive faults and displays a “Regen” error (small “r”). Keep sizing up the resistor until it can withstand the regeneration. And the second question is - How do I hook it up? See the diagram below. External Resistor Assembly Regen Connector Bus Clamp NC Internal R External R DC Bus NOTE: Jumper as shown is set to use the internal power dump resistor

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Mounting the Drive Mounting the Drive Mounting the Drive Mounting the Drive Mounting the Drive BLuAC5 (all models) These drives can be mounted on the narrow side or the wide side. Either way, you’ll need two #6 screws to secure the drive using the 0.2” mounting slots. The hole pattern and drive outline are shown on page 42 Never use your drive in a space where there is no air flow or where other devices cause the sur- rounding air to be more than 70 °C. Never put the drive where it can get wet or where metal particles can get on it. Always provide air flow around the drive.

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Mechanical Outlines Mechanical Outlines Mechanical Outlines Mechanical Outlines Mechanical Outlines

BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual BLuAC5 Hardware Manual Sine commutation IGBT. 16 kHz PWM. 90 - 260 VAC, 100 - 367 VDC input 5A continuous, 15A peak Step/PWM & Direction: differential, optically isolated, 5V logic. 330 ohms internal resistance. 0.5 µsec minimum pulse width. 2 µsec minimum set up time for direction signal. All other digital inputs: optically isolated, 12 - 24V logic. 2200 ohms. Maximum current: 10 mA ±10VDC, 12 bit ADC With Expanded I/O (IN/OUT 2): 0 to 5 VDC, 1K - 10K recommended impedance. 10 bit ADC Photodarlington, 100 mA, 30 VDC max. Voltage drop: 1.2V max at 100 mA. 24VDC @ 100ma 26C31 line driver 2.70 x 4.848 x 7.80 inches overall. 2 lb 3.1 oz (0.995 Kg) Ambient temperature range: 0 to 40° C. Motor/Regen: Mating connector included. Phoenix P/N 1767012. AC Input: Mating connector included. Phoenix P/N 1767025. Brake: Mating connector included. Phoenix P/N 1766990. RS-485: Mating connector included. PCD P/N ELVP05100. IN/OUT 1: DB-25 male. Mating connector included. AMP P/N 747912-2. IN/OUT 2: DB-25 female. Mating connector included with Si version and Expanded I/O kit. NORCOMP P/N 171-025-202-001 Shell Kit: AMP P/N748678-3. Motor feedback: HD-15 male. Norcomp P/N 180-015-102-001. Shell Kit AMP P/N 748678-1. TTTTTechnical Specifications echnical Specifications echnical Specifications echnical Specifications echnical Specifications Amplifier Digital Inputs Analog Inputs Outputs 24V Output Encoder Output Physical Mating Connectors

404 Westridge Drive Watsonville, CA 95076 Tel (831) 761-6555 (800) 525-1609 Fax (831) 761-6544 www.appliedmotionproducts.com