UniDrive® Basic Motor Control – Generation II

“BMC-2” Guide to Installation and Use

Product 110163 Rev. 1.1

User Interface Organization

1. Motor Connection This guide is organized in three sections. The first sec-
2. Smart Input/Output (I/O) tion is General Notes. The numbers from 1 – 10 corre-
3. DC Power Input Connector spond to the features listed on the User Interface to the
4. Blown Fuse Indicator left and to the illustration above. The second section is
5. Replaceable 5A Fuse Operation. This describes how the motor will respond to
6. Potentiometer for Speed Control inputs to the Control. The third is Diagnostic and Trou-
7. Diagnostic LEDS bleshooting Notes related to use of the indicator LEDs on
8. Function Control Switches the board for troubleshooting purposes.
9. Mounting Plate/Heat-sink
10. Cover If you need additional assistance, call 931-537-3950.

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 General Notes direction of rotation is defined as being viewed
from the back of the motor.
1. The Motor is provided with a pre-wired cable as- *The Smart Outputs are always PNP type.
sembly. Do not disassemble. If the cable is dam- *Switches are read only at power-up, so if you
aged and on-site repairs are required, the wiring se- need to change the functionality of a control; dis-
quence is (from position 1 on the left through position connect power, set the switch and then reconnect
8 on the right): Green, Gray, Blue, Violet, Yellow, power.
Brown, Red, Black. *Off is to the left, On is to the right.
!Use of extension cables may cause permanent 9. Mounting Plate – For mounting the control assem-
damage and will void the warranty. bly to the conveyor frame using two ¼” bolts.
2. Smart Inputs and Outputs (I/O) (4 position plug *If mounting on a curve use washers between the
supplied – Phoenix PT1.5/4-PVH-3.5) mounting plate and the conveyor frame to assure that
2.1. Smart Inputs (Positions 1 & 2) are PNP only. the mounting plate is not distorted, causing damage
2.2. Smart Outputs (Positions 3 & 4) are PNP only. to the enclosed printed circuit board assembly.
*Always leave the connector in place to avoid acci- 10. Cover – This cover is designed to prevent inciden-
dentally shorting the pins. tal damage to the control by foreign objects. It is
3. Power (2 position plug supplied – Phoenix neither waterproof nor dustproof.
PT1.5/2-PVH-3.5) *Removal of the cover will void the warranty.
3.1. Position 1 (on the left) is for + DC between +22
and +28 VDC. While there is some polarity protec- Set-Up/Operation
tion on the board it is not fool-proof, so it is impor-
tant to make this connection correctly. The control is pretty simple. Set up the control as fol-
*The function control switches are only read at lows:
power-up, so make the power connection after all A. Mount the control in a location so that the motor
other connections are in place. reaches the connection position without putting
3.2. Position 2 (on the right) is for the DC Ground. strain on the cable or connector.
!This input is not fused. Connecting +DC to this B. Set the switches:
position followed by shorting another pin to ground a. Switch 1 for the required direction of rotation.
may cause catastrophic damage to the control. b. Switches 2-4 for the maximum speed.
4. Blown Fuse Indicator – see Diagnostic Notes. (Key: SW2=Switch 2, SW3=Switch3,
5. Replaceable 10A fuse – Replace with Littelfuse SW4=Switch 4.)
part number 0451010. SW2 SW3 SW4 Speed
6. Speed Control Potentiometer – Switches 2-4 are Off Off Off 350
used in combination to set the maximum speed for Off Off On 315
the UniDrive® Motor in discrete 35 RPM steps from Off On Off 280
350 RPM down to 105 RPM. The potentiometer is Off On On 245
used to adjust the speeds downward from those On Off Off 210
speeds. Fully clockwise the control will be at the On Off On 175
speed set by the switches, turning the pot counter- On On Off 140
clockwise will adjust the speed down by as much as On On On 105
35 RPM, thus making it possible to select any *Remember that the switches are only read at
speed from 350 down to 70 RPM using the switches power-up. Set switches, then connect power to
and pot in combination. the board.
7. Diagnostic LEDs – see Diagnostic Notes. C. Plug the motor connector into the 8 pin header on
8. Function Selector Switches – Switch 1 always the board, oriented as shown in the illustration.
functions as follows: D. Connect the power leads to the two position con-
8.1. When Switch 1 is Off the motor rotates counter- nector with the correct polarity and when all the
clockwise (CCW) for forward motion. On sets the controls in the system are prepared and the
forward direction as clockwise (CW.) Note that the switches have been set, turn on the power.

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 E. Connect PNP Inputs to operate motor – In direct
response to two inputs the motor does one of four
things: Brake and Hold, Run forward; Run reverse;
or Coast.

Brake and Hold: This is the default state with no
inputs to either Smart 1 or Smart 2.

Run Forward: An input to Smart 1, in the ab-
sence of an input to Smart 2 will result in the mo-
tor operating in the direction set by Switch 1.

Run Reverse: An input to Smart 2, in the ab-
sence of an input to Smart 1 will result in the mo-
tor operating in the direction opposite the direc-
tion set by Switch 1.

Coast: Simultaneous inputs to Smart 1 and
Smart 2 will result in the motor coasting with no
braking action.
Diagnostic & Troubleshooting Notes
There are four LEDs on the board shown in the illustra-
tion as positions 4 and 7.1 – 7.3 that may be useful in di-
agnosing various wiring and connection problems. If
power is connected there will always be at least one LED
illuminated or flashing. No LEDs = no power.
4. Blown Fuse LED (Red) – This will be illuminated
constantly if the fuse (5) is blown and power is ap-
plied with the proper polarity. Replace the fuse with
Littelfuse 0451010.
*Note that this fuse will not blow under normal cir-
cumstances. Inspect all wiring connections to as-
sure that there are no short circuits.
7. Three LEDs are located directly over the speed
control potentiometer. The LED on the far left will
be referred to as 7.1 and then sequentially 7.2 and
7.3.
7.1. Fault LED (Red) – This is off under normal cir-
cumstances but will provide one of 5 signals if a
problem is detected.
7.1.1. 1 flash in 4 seconds = The board has a
hardware problem. Return it to your supplier.
7.1.2. 2 flashes in 4 seconds = The input voltage
is too high. Adjust voltage.
7.1.3. 3 flashes in 4 seconds = The input voltage
is too low. Adjust voltage.
7.1.4. 4 flashes in 4 seconds = There is a problem
with the motor cable or connection. Check to
see that the cable is not damaged and that all
of the wires are secure. If the cable has been
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cut or the wires disconnected refer to section
1 in the General Notes.
7.1.5. Constantly on = Either the motor is stalled or
the sensor is continuously blocked. Check
for mechanical obstructions.
7.2. Motor LED (Amber)
7.2.1. 4 flashes in 4 seconds = Components on
the board have overheated and the circuit is
limiting the power to the motor to about ½ of
normal. This problem will correct itself when
the board has cooled adequately. Check for
mechanical obstructions.
7.2.2. Constantly on = Motor current is at the
maximum allowed and is being electronically
limited. Check for mechanical obstructions.
7.2.3. Flickering = If the motor starts under signifi-
cant load, the current may be limited briefly
causing the LED to flicker. If the LED flickers
constantly, this is an indication that the motor
is operating at it’s upper limit and may never-
reach the full speed as set by the potentiome-
ter. This is not a critical cause for concern
and no corrective action is required.
7.3. Power LED (Green) should be constantly on when
power is properly applied as long as the fuse is not
blown.
LED Start-up Sequence – 3 LEDs are used to commu-
nicate the firmware revision of the control assembly dur-
ing the start-up sequence. Each time that power is ap-
plied to the board, the green and red LEDs will turn on
for one second, then the Amber LED will flash on for
0.75 seconds followed by an off period. An off period of
1.5 seconds represents a decimal point separating major
revisions from minor revisions.
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Rev. 1.1 Dec. 08, 2009
 The sequence above is an example that would repre- 1.0 Revisions:
sent firmware revision 1.2. The current revision for 1.0 Original Release
product 110155 (SCC-2) is 1.1. 1.1 Incorporated changes to improve low speed
torque. No changes in operating instructions or
When the red LED turns off, the start-up sequence has logical functions.
ended and normal operation will commence.
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