Drive System Packages: DC Servo Drives and Servo Motors

UnoDrive servo drive system with DC motors, torques up to 3.8 Nm. In the back a 19" plug-in module
with 9 axes and power supply unit. In the front a UnoDrive servo drive with connection via front panel,
together with a MB 2133 and a MB 2224 motor.

Products, Consultation, Service Applications

ESR drive packages consist of servo drives and Positioning and feed movements with high dy-
servo motors, position sensors, gearboxes, and namics and accuracy in
brakes. They are supplemented by power sup- C Handling and assembly systems
ply units (if not included in the drive), connec- C Optical discs production machinery (CDs,
tors, and connecting cables (ready-assembled DVDs, ...)
on request). All parts of the packages are
matching and have been tested as combina- C Electronics production machinery
tions. This delivery from a single source guaran- C Semiconductor production machinery
tees trouble-free commissioning, reliable opera- C Measuring and testing machinery
tion, and a definite system responsibility on the C Machine tools and metal working machinery
part of only one supplier. C Packaging machinery
Our services include an individual drive system C Textile machinery
configuration. With many years of experience,
we will be pleased to assist you at choosing the C Plastics processing machinery
appropriate servo drive system for your applica- C Coiling machinery
tion. C and many other applications

ESR Pollmeier GmbH

www.esr-pollmeier.de ESR. The Dynamic Solution
2 UnoDrive Data Sheet 6540.250 V 2.0

C Fast motor acceleration, deceleration, and revers-

Main Characteristics ing by short-term current increase to twice the
Four power classes rated current
C Easy error diagnosis via LEDs for fault, readiness,
Servo Drives Servo Motors and overload
IN UZk MN PN C Convenient commissioning due to adjustable
feedback, speed, zero, and current limit
6A 40 V up to 0.3 Nm up to 0.1 kW C Load and speed monitoring possible via current
6A 100 V up to 0.4 Nm up to 0.2 kW and speed monitor outputs

12 A 40 V up to 1.6 Nm up to 0.4 kW Options:

12 A 100 V up to 3.8 Nm up to 1.0 kW C Standstill monitoring with “motor standstill” output
C Protection against stop overrun by connection for
two directional limit switches with braking effect
Characteristics of the drive system packages C Input for drive enable, also with braking effect
C Low-price, high-quality drive system packages C Setpoint ramp
consisting of drive, motor, and accessories C Input for external current limitation
C High dynamics due to motors with low capacity-to-
weight ratio and drives with highest dynamics Characteristics of the servo motors
C CE identification due to design in compliance with
the Low Voltage Directive (tested according to C High motor dynamics for quickly responding drives
EN 50178) and the EMC Directive (tested accord- C Low capacity-to-weight ratio requires little space
ing to EN 61800-3) C Optionally low-price motors with barium ferrite
C Options for drives and motors facilitate adaptation magnets or motors with particularly high power
to various tasks density due to samarium cobalt magnets
C High safety: position sensor signal monitoring C High speed control range
C Monitoring of the workflow via error messages in C Long brush service life due to generously dimen-
case of motor blocking sioned collector and long brushes
C No bearing problems due to grease filling of the
Characteristics of the servo drives ball bearings for the entire service life and protec-
tion of the ball bearings against brush dust
C Re-adjustment is not required when drives are C Design with flange
replaced due to plug-in customer module with
C Any mounting position
setting components
C Easy adaptation to special tasks with plug-in op-
tion module Characteristics of the gearboxes
C Easy adjustment of switching inputs and outputs to Standard worm gear, ratio 1 : 6 to 1 : 80
the PLC with 24 V signal voltage using plug-in C output torques up to 350 Nm
PLC module
C special gearboxes
C High performance at small dimensions due to use
of surface mounting devices and state-of-the-art
power transistors
C Clearly arranged wiring for devices with front Servo Drives
connection as all connections are made at the
front panel Enclosure and Installation
C 19" plug-in wiring and plain front panel for devices
with rear connection UnoDrive servo drives are compact devices for
installation into control cabinets. Depending on the
C Protection of drive and motor via adjustable cur- series, the devices are designed for front or for rear
rent limitation connection. Suitable 19" power supply units and
C Safe operation due to protection and monitoring matching transformers are also available.
circuits with fault memory for short circuit, earth
leakage, drive overheating, and faulty voltages

ESR Pollmeier GmbH, 64372 Ober-Ramstadt, phone +49 6167 9306-0, fax +49 6167 9306-77, www.esr-pollmeier.de
Data Sheet 6540.250 V 2.0 UnoDrive 3

Fig. 1: Example of a 84 PU slot, devices with front connection for installation into 19" control cabinets

Interfaces of the servo drives as well as an 8-pin Combicon connector for con-
necting
The connectors of the BN 6540 to BN 6548 devices
C control signals
are located at the front panel. The connectors of the
BN 6550 to BN 6558 devices are located on a With the BN 6550 to BN 6558 devices, these con-
multipoint plug according to DIN 41612, series D, at nectors are located on the back side.
the back. With all devices, the
C fault
C ready
Servo Motors
C overload
LEDs and the trim potentiometers for Design of servo motors and encoder systems
C feedback The servo motors described herein are permanent-
C speed magnet collector motors. The low-cost motors for
C zero standard applications are equipped with ferrite
C current limit magnets. If smallest dimensions and very fast
acceleration and deceleration are required, motors
C I×R compensation
with samarium cobalt magnets are used. The mo-
are located at the front panel. tors are delivered for flange mounting.
The front panel of the BN 6540 to BN 6548 devices The tachogenerator is installed directly on the motor
is additionally equipped with a 15-pin SUB D female shaft. The close coupling with the motor results in
connector for connecting high system dynamics.
C motor Connection is made via 1 m long cables led directly
out of the enclosure. The tachometer cable is
C speed indicator shielded. Special designs with connectors or, for
C operating voltage larger motors, with terminal box on request.

ESR Pollmeier GmbH, 64372 Ober-Ramstadt, phone +49 6167 9306-0, fax +49 6167 9306-77, www.esr-pollmeier.de
4 UnoDrive Data Sheet 6540.250 V 2.0

More information on the motors is provided in the Protection and Monitoring Circuits
corresponding data sheets and the internet on
www.esr-pollmeier.de. Standard protection and monitoring circuits guaran-
tee that the servo drives are not damaged even in
Motor accessories extreme situations and switched off in case of a
fault. The following is monitored:
C Incremental encoder C short circuit,
– coupled directly with the motor, preferably with C earth fault,
own bearing
C drive overheating, and
C DuoDrive encoder
C faulty voltages.
– position and speed sensor in a 32 mm enclo-
If one of these faults occurs, the drive is shut down
sure
immediately. The fault is stored and reported.
C Brakes
– permanent-magnet brakes, designed as holding
brakes; occasional load braking, e. g. in case or
an emergency stop, is permitted Adaptation Using Modules
C Gearboxes
The UnoDrive servo drives can be adapted to differ-
ent requirements using plug-in modules. In addition
to the generally installed customer module de-
Functions of the Servo Drives scribed in the previous section, the following mod-
ules can be installed optionally:
Control C add-on module
C polarity module (PLC module)
The servo drive can be operated as speed control-
ler or as current controller. An externally supplied
Z1, Z2 add-on modules
rated value (–10 V to +10 V) determines speed or
torque via the motor current. The speed feedback In the standard version (Z0), an add-on module is
from the coupled tachogenerator permits a good not installed. If additional functionality such as
load-independent speed accuracy and provides the C second setpoint input
prerequisite for an operation with precise position-
ing controls. C two directional limit switches with braking effect
In contrast to the AC servo drives with collectorless C setpoint ramp
motors described in other data sheets, the Uno- C standstill monitoring via “motor standstill” input
Drive DC servo drives described herein work with is required, the additional circuitry parts are in-
permanent-magnet collector motors. For powers up stalled on an additional plug-in module.
to 1 kW, DC servo drives with collector motors are
often preferred because of their low price, espe- Polarity module (PLC module)
cially as in many servo applications the service life
of the brushes is more than sufficient. The switching inputs of a servo drive (e. g. “motor
standstill”) are mostly realized via transistors
Customer module switching towards zero. The external switches for
the switching inputs (e. g. for the enable signal) also
An exchangeable customer module carries setting
switch towards zero.
elements, LEDs, and components of the applica-
tion-specific controller circuitry. If a device is ex- Programmable logic controllers (PLC) switch the
changed, the customer module can be removed other way round: the transistors switch towards
and plugged on the new device. Thus, controller positive, the loads are on zero. The UnoDrive servo
circuitry and set values are preserved and nothing drives described herein can be supplied for both
needs to be re-adjusted except for the zero. polarities of input and output signals. In the stan-
dard version, the output transistors switch towards
A special customer module with I×R compensation
zero, the input loads are on positive. The PLC
is available for simple drive tasks. Another special
compatible version is equipped with a PLC module
customer module switches the servo drive to cur-
which correspondingly reverses the switching direc-
rent control which is required for some digital posi-
tions of inputs and outputs.
tioning controls or for building up a torque control
instead of a speed control.

ESR Pollmeier GmbH, 64372 Ober-Ramstadt, phone +49 6167 9306-0, fax +49 6167 9306-77, www.esr-pollmeier.de
Data Sheet 6540.250 V 2.0 UnoDrive 5

C Multipoint socket connectors according to

Accessories DIN 41 612 for the devices with rear connection:
C Chassis, 4 HU high, with fan unit for the installa- a 32-pin connector (D series) for the servo drive,
tion of up to nine drives and one power supply a 15-pin connector (H series) for the power sup-
unit or up to eight drives and two power supply ply unit.
units. For devices with front connection, a rear C Motherboards for devices with rear connection.
wall with mounting lug for control cabinet Conversion of the connections on a 15-pin SUB D
mounting is available. connector for control signals, a 5-pin Combicon
C Mounting brackets for control cabinet installation connector for motor and speed indicator, and
of a single BN 6540 to BN 6548 module. connectors for operating voltage. Other mother-
boards for other connection types are available.
C Power supply units for front and rear connection
with rectifiers, charge capacitors, monitoring C Motor supply cables with separate shield for
circuit, and shunt regulator including the shunt motor and tachogenerator supply lines and 6
resistor which absorbs the energy fed back when additional cores.
the motor is braked. For higher braking powers, C Motor chokes for motors with a particularly low
an external shunt resistor is available. inductance.
C Isolating transformers for supplying the power Detailed information on ESR products and corre-
supply units. For 230 V or 3 × 400 V, other volt- sponding accessories can be found in the internet
ages on request. on www.esr-pollmeier.de.
C Connector sets consisting of the required SUB
D connectors incl. screwable housings and
Combicon connectors.

Drive system packages (selection), most important technical specifications and order numbers
In addition to the motors stated below, a number of other motors is available. More information on the motors
is provided in the corresponding data sheets and the internet on www.esr-pollmeier.de.

Flange Rated Peak Shaft

Order Number Speed Order Num-
dimension Torque Torque Power
Motor (r.p.m.) ber Drive
(mm) (Nm) (Nm) (kW)
MB 2112 3,000 0.3 0.6 94 BN 6540
i 58
MB 2113 3,000 0.4 0.8 125 BN 6550
MB 2132 3,000 1.1 2.2 345
i 84
MB 2133 2,900 1.5 3.0 455 BN 6548
MB 2152 2,800 2.7 5.4 791 BN 6558
100 × 100
MB 2153 2,700 3.7 7.4 1046

The rated torques refer to the stated speed. For lower speeds, the torques are higher. We recommend to select the best combination for
the respective application together with us. We will be pleased to configure and design a suitable drive system for you.

ESR Pollmeier GmbH, 64372 Ober-Ramstadt, phone +49 6167 9306-0, fax +49 6167 9306-77, www.esr-pollmeier.de
6 UnoDrive Data Sheet 6540.250 V 2.0

Servo drives, most important technical specifications and order numbers

Servo drives with front connection BN 6540 BN 6542 BN 6546 BN 6548

with rear connection BN 6550 BN 6552 BN 6556 BN 6555
Rated input voltage 55 V 125 V
Rated output voltage 40 V 100 V
Min. DC-bus voltage 20 V 40 V
Max. perm. DC-bus voltage 80 V 170 V
Rated current (rms value) 6A 12 A 6A 12 A
Peak current (crest value) 12 A 24 A 12 A 24 A
Current limitation setting range 1 .. 6 A 2 .. 12 A 1 .. 6 A 2 .. 12 A
Clock frequency / current ripple frequency approx. 17/34 kHz
Available auxiliary voltages +15 and –15 V per 20 mA
Permissible ambient temperature 40 ºC
Width standard 8 PU, 40.5 mm
optional with reduced requirements 6 PU, 30.5 mm
Height incl. front panel 3 HU / 128 mm
Depth (without connectors) front connection: 165 mm, rear connection: 173 mm
Weight 0.45 kg

Power supply units, technical specifications and order numbers

Power supply unit with front connection BN 3240 BN 3246

with rear connection BN 3250 BN 3256
Suitable for servo drive BN 6540/42 BN 6546/48
BN 6550/52 BN 6556/58
Mains connection via isolating transformer* 40 V~ or 3 × 40 V~ 90 V~ or 3 × 90 V~
For DC-bus voltage 55 V 125 V
Response threshold of surge limitation 70 V 160 V
Maximum permissible permanent current 24 A
Maximum permanent braking power 30 W
Pulse braking power, 2% ED, 2 s 200 W
Width 10 PU / 51 mm
Height 3 HU / 128 mm
Depth (without connectors) 165 mm 173 mm
Weight approx. 0.5 kg

* Up to approx. 0.5 kW, the power supply units can be connected single phase. For higher powers, three-phase connection is
recommended. The mains transformers listed on the next page have been selected accordingly.

ESR Pollmeier GmbH, 64372 Ober-Ramstadt, phone +49 6167 9306-0, fax +49 6167 9306-77, www.esr-pollmeier.de
Data Sheet 6540.250 V 2.0 UnoDrive 7

Mains transformers, technical specifications and order numbers

Transformer BN 3840 BN 3842 BN 3846 BN 3833

single-phase connection
Mains connection, primary 230 V, single-phase
Output voltage 1 40 V 90 V 40 V
Output voltage 2 – – 90 V
Load current at power supply unit
6A 12 A 6A 6/6 A
output1
Weight 5 kg 8 kg 10 kg 11 kg
Suitable for servo drive BN 6540 BN 6540/42 BN 6546 BN 6540/46
BN 6550 BN 6550/52 BN 6556 BN 6550/56
combination2

Transformer BN 3843 BN 3848 BN 3849 BN 3834 BN 3835

three-phase connection
Mains connection 3 × 400 V, three-phase
Output voltage 1 3 × 40 V 3 × 90 V 3 × 40 V
Output voltage 2 – – 3 × 90 V
Load current at power supply unit
24 A 12 A 24 A 12/12 A 24/24 A
output1
Weight 14 kg 19 kg 24 kg 20 kg 26 kg
Suitable for servo drive BN 6540/42 BN 6546/48 BN 6540/42/46/48
BN 6550/52 BN 6556/58 BN 6550/52/56/58
combination2 combination2 combination2
1
Maximum permissible current at the output of the downstream power supply unit.
2
For combinations, the following applies: The currents of the devices working simultaneously at full power are added up, the
correspondingly reduced currents of the devices working with partial load are added to that. The current sum determines the required
transformer. Do not connect more than one power supply unit to one transformer winding.
For the operation of servo drives with different output voltages, transformers with two secondary windings are available. For the loading
of the individual windings, the statement of 2 applies.

Accessories

Description Order Number

Chassis 54 and 84 PU, empty, with and without fan unit BN 8651
Compact enclosure with built-in power supply unit on request
Connector set for UnoDrive servo drives with front connection ST 6540
Multipoint socket connector for UnoDrive servo drives with rear connection ST 6550
Motherboard for rear connection (15-pin SUB D, Combicon, terminals) BN 8190
2
Motor tacho connection cable, 1.0 mm , motor and tacho line shielded, 6 cores,
BN 8802
shield
Motor supply cables on request
2
Tacho supply cable, 2.5 mm , 2 cores, shield BN 8827
Motor chokes for installation into an enclosure BN 3749

ESR Pollmeier GmbH, 64372 Ober-Ramstadt, phone +49 6167 9306-0, fax +49 6167 9306-77, www.esr-pollmeier.de
8 UnoDrive Data Sheet 6540.250 V 2.0

Type code of the UnoDrive servo drives

Example
BN 65 40 . 1023 - K1 - Z0 - P0

40
Connection Power
4x front connection (Combicon, SUB D) x0 40 V, 6 A
5x rear connection (VG strip) x2 40 V, 12 A
x6 100 V, 6 A
x8 100 V, 12 A

1023
Assembly code
Internal coding of ESR, given for various feature combinations. Statement of the assembly code is not required if all
other features unequal zero are stated and the customer-specific equipment is described. For above-mentioned
example ”BN 6540-K1” would be sufficient.

K1
Controller circuitry (customer module)
K0 none (device not ready for operation)
K1 speed control, tacho 6 V per 1000 r.p.m. (standard)
K3 speed control, tacho 14 V per 1000 r.p.m.
K5 I×R compensation (operation without tachogenerator)
K6 current control
KK customer-specific

Z0
Optional equipment (options module)
Z0 none (standard)
Z1 limit switch, ramp
Z... further options, on request
ZK customer-specific

P0
Input/output polarity (PLC module)
P0 switching towards 0 (standard)
P1 PLC compatible
PK customer-specific

Type codes of the servo motors

are included in the separate data sheets of the respective motors, they are also available in the internet on
www.esr-pollmeier.de.

The statements in this data sheet are for information, only. They do not guarantee properties. We reserve the
right to make changes without notice.
Data Sheet 6540.250 V 2.0, KS, 2006-01-09

ESR Pollmeier GmbH Lindenstr. 20 Phone +49 6167 9306-0 www.esr-pollmeier.de

Servo Drive Technology 64372 Ober-Ramstadt / Germany Fax +49 6167 9306-77 info@esr-pollmeier.de