Brusatori Br series Service manual

Brushless servomotors

Installation, use and maintenance manual

English version

vers. BR02.00.EN (05-08-2022)

User’s manual –BR motors - vers. BR02.00.EN (05-08-2022) 2

User’s manual –BR motors - vers. BR02.00.EN (05-08-2022) 3 
Table of contents 
 
 
 
Table of contents ........................................................................................................................................................................ 3 
General....................................................................................................................................................................................... 7 
1 Information......................................................................................................................................................................... 7 
2 Symbols used..................................................................................................................................................................... 8 
3 Intended use ...................................................................................................................................................................... 8 
4 European directives ........................................................................................................................................................... 9 
5 Harmonized standards....................................................................................................................................................... 9 
6 UL certification ................................................................................................................................................................... 9 
Order key...................................................................................................................................................................................10 
Nameplate .................................................................................................................................................................................12 
1 Motor nameplate...............................................................................................................................................................12 
2 Nameplate code key .........................................................................................................................................................12 
Technical data............................................................................................................................................................................13 
1 Main features ....................................................................................................................................................................13 
2 Available options...............................................................................................................................................................14 
3 Field weakening................................................................................................................................................................14 
4 Electrical data....................................................................................................................................................................15 
4.1 Electrical data BR03.................................................................................................................................................15 
4.2 Electrical data BR05.................................................................................................................................................16 
4.3 Electrical data BR07.................................................................................................................................................17 
4.4 Electrical data BRV7.................................................................................................................................................18 
4.5 Electrical data BR08.................................................................................................................................................19 
4.6 Electrical data BRV8.................................................................................................................................................20 
4.7 Electrical data BR09.................................................................................................................................................21 
4.8 Electrical data BRV9.................................................................................................................................................22 
5 Overall dimensions............................................................................................................................................................23 
5.1 Overall dimensions –BR03......................................................................................................................................23 
5.2 Overall dimensions –BR05......................................................................................................................................24 
5.3 Overall dimensions –BR07......................................................................................................................................25 
5.4 Overall dimensions –BRV7......................................................................................................................................26 
5.5 Overall dimensions –BR08......................................................................................................................................27 
5.6 Overall dimensions –BRV8......................................................................................................................................28 
5.7 Overall dimensions –BR09 (except BR098304)......................................................................................................29 
5.8 Overall dimensions –BR098304..............................................................................................................................30 
5.9 Overall dimensions –BRV9 (except BRV98284) .....................................................................................................31 
5.10 Overall dimensions –BRV98284..............................................................................................................................32 
6 Characteristic curves torque-speed...................................................................................................................................33 
6.1 Curves motor series BR03 .......................................................................................................................................34 
6.1.1 Curves BR032 –230V .........................................................................................................................................34 

User’s manual –BR motors - vers. BR02.00.EN (05-08-2022) 4 
6.1.2 Curves BR032 –400 V ........................................................................................................................................35 
6.1.3 Curves BR034 –230 V ........................................................................................................................................36 
6.1.4 Curves BR034 –400 V ........................................................................................................................................37 
6.1.5 Curves BR036 –230 V ........................................................................................................................................38 
6.1.6 Curves BR036 –400 V ........................................................................................................................................39 
6.1.7 Curves BR038 –230 V ........................................................................................................................................40 
6.1.8 Curves BR038 –400 V ........................................................................................................................................41 
6.2 Curves motor series BR05 .......................................................................................................................................42 
6.2.1 Curves BR051 –400 V ........................................................................................................................................42 
6.2.2 Curves BR052 –400 V ........................................................................................................................................43 
6.2.3 Curves BR053 –400 V ........................................................................................................................................44 
6.2.4 Curves BR054 –400 V ........................................................................................................................................45 
6.2.5 Curves BR055 –400 V ........................................................................................................................................46 
6.2.6 Curves BR056 –400 V ........................................................................................................................................47 
6.2.7 Curves BR057 –400 V ........................................................................................................................................48 
6.2.8 Curves BR058 –400 V ........................................................................................................................................49 
6.3 Curves motor series BR07 .......................................................................................................................................50 
6.3.1 Curves BR071 –400 V ........................................................................................................................................50 
6.3.2 Curves BR072 –400 V ........................................................................................................................................51 
6.3.3 Curves BR073 –400 V ........................................................................................................................................52 
6.3.4 Curves BR074 –400 V ........................................................................................................................................53 
6.3.5 Curves BR075 –400 V ........................................................................................................................................54 
6.3.6 Curves BR076 –400 V ........................................................................................................................................55 
6.3.7 Curves BR077 –400 V ........................................................................................................................................56 
6.3.8 Curves BR078 –400 V ........................................................................................................................................57 
6.4 Curves motor series BRV7.......................................................................................................................................58 
6.4.1 Curves BRV71 –400 V........................................................................................................................................58 
6.4.2 Curves BRV72 –400 V........................................................................................................................................59 
6.4.3 Curves BRV73 –400 V........................................................................................................................................60 
6.4.4 Curves BRV74 –400 V........................................................................................................................................61 
6.4.5 Curves BRV75 –400 V........................................................................................................................................62 
6.4.6 Curves BRV76 –400 V........................................................................................................................................63 
6.4.7 Curves BRV77 –400 V........................................................................................................................................64 
6.4.8 Curves BRV78 –400 V........................................................................................................................................65 
6.5 Curves motori serie BR08 ........................................................................................................................................66 
6.5.1 Curves BR082 –400 V ........................................................................................................................................66 
6.5.2 Curves BR084 –400 V ........................................................................................................................................67 
6.5.3 Curves BR086 –400 V ........................................................................................................................................68 
6.5.4 Curves BR088 –400 V ........................................................................................................................................69 
6.6 Curves motori serie BRV8........................................................................................................................................70 
6.6.1 Curves BRV82 –400 V........................................................................................................................................70 
6.6.2 Curves BRV84 –400 V........................................................................................................................................71 
6.6.3 Curves BRV86 –400 V........................................................................................................................................72 
6.6.4 Curves BRV88 –400 V........................................................................................................................................73 
6.7 Curves motor series BR09 .......................................................................................................................................74 

User’s manual –BR motors - vers. BR02.00.EN (05-08-2022) 5 
6.7.1 Curves BR092 –400 V ........................................................................................................................................74 
6.7.2 Curves BR094 –400 V ........................................................................................................................................75 
6.7.3 Curves BR096 –400 V ........................................................................................................................................76 
6.7.4 Curves BR098 –400 V ........................................................................................................................................77 
6.8 Curves motor series BRV9.......................................................................................................................................78 
6.8.1 Curves BRV92 –400 V........................................................................................................................................78 
6.8.2 Curves BRV94 –400 V........................................................................................................................................79 
6.8.3 Curves BRV96 –400 V........................................................................................................................................80 
6.8.4 Curves BRV98 –400 V........................................................................................................................................81 
Parts and components...............................................................................................................................................................82 
1 Cooling fan (optional)........................................................................................................................................................82 
1.1 Fan connection diagrams.........................................................................................................................................83 
2 Holding brake (optional)....................................................................................................................................................84 
2.1 Brakes: general safety notes....................................................................................................................................84 
2.2 Safety and maintenance notes for permanent magnet brakes.................................................................................85 
2.3 Permanent magnet brakes.......................................................................................................................................86 
2.4 Spring brake (emergency brake)..............................................................................................................................87 
3 Position sensor..................................................................................................................................................................88 
3.1 Transducer operating temperature...........................................................................................................................88 
3.2 Resolver (standard)..................................................................................................................................................88 
3.3 Encoder SinCos (optional)........................................................................................................................................89 
3.4 Encoder Hiperface (optional)....................................................................................................................................89 
3.5 Encoder EnDat (optional).........................................................................................................................................89 
4 Thermal protection............................................................................................................................................................90 
4.1 Thermistor PTC (standard).......................................................................................................................................90 
4.2 Bimetal switch (optional)...........................................................................................................................................91 
4.3 Bimetal switch (optional for ventilation starting)........................................................................................................91 
4.4 Thermo-resistance Pt100 or Pt1000 (optional).........................................................................................................91 
5 Bearings............................................................................................................................................................................92 
6 Maximum radial load on 20000 hours of operation ...........................................................................................................92 
Electrical connections................................................................................................................................................................94 
1 Instructions on safety ........................................................................................................................................................94 
2 Power connection..............................................................................................................................................................96 
2.1 Power connection with connector M23 8 poles (standard).......................................................................................96 
2.2 Power connection with connector MIL 4 poles (optional without brake) ...................................................................96 
2.3 Power connection with connector MIL 6 poles (optional with brake) ........................................................................96 
2.4 Power connection with terminal board (standard / optional).....................................................................................97 
3 Signal connection..............................................................................................................................................................99 
3.1 Resolver with connector M23 –12 poles (standard) ..............................................................................................100 
3.2 Resolver with connector MIL series –19 poles (optional) ......................................................................................100 
3.3 Encoder SinCos with connector M23 –17 poles (standard)...................................................................................101 
3.4 Encoder SinCos with connector MIL series –19 poles (optional)...........................................................................101 
3.5 Encoder Hiperface with connector M23 –12 poles (standard)...............................................................................102 
3.6 Encoder Hiperface with connector MIL series –19 poles (optional).......................................................................102 
3.7 Encoder EnDat01 with connector M23 –17 poles (standard) ................................................................................103 

User’s manual –BR motors - vers. BR02.00.EN (05-08-2022) 6 
3.8 Encoder EnDat01 with connector MIL series –19 poles (optional)........................................................................103 
3.9 Encoder EnDat22 with connector M23 –17 poles (standard) ................................................................................104 
3.10 Encoder EnDat22 with connector MIL series –19 poles (optional)........................................................................104 
3.11 Incremental encoder + Hall sensor and connector M23 –17 poles (obsolete).......................................................105 
3.12 Incremental encoder + Hall sensor and connector MIL series –19 poles (obsolete) .............................................106 
4 Flying connectors (optional)............................................................................................................................................107 
4.1 Flying power connector M23 8 poles (optional)......................................................................................................107 
4.1.1 Flying power connector 8 poles BSTA078FR05420100000...............................................................................107 
4.1.2 Flying power connector 8 poles BSTA078FR35590100000...............................................................................107 
4.1.3 Mounting instructions flying power connector BSTA078FR05420100000..........................................................108 
4.1.4 Mounting instructions flying power connector BSTA078FR35590100000..........................................................109 
4.2 Flying power connector 4/6 Poles MIL series (optional).........................................................................................110 
4.2.1 Flying power connector MIL 4 poles MS3106PHM211810SA23........................................................................110 
4.2.2 Flying power connector MIL 6 poles MS3106PHM211806SA23........................................................................110 
4.3 Flying signal connector M23 12/17 poles (optional) ...............................................................................................111 
4.3.1 Flying signal connector M23 12 poles ASTA021FS04400166000 .....................................................................111 
4.3.2 Flying signal connector M23 17 poles ASTA035FS04400166000 .....................................................................111 
4.3.3 Mounting instructions flying signal connectors M23 12/17 poles........................................................................112 
4.4 Flying signal connector 19P MIL series (optional)..................................................................................................113 
4.4.1 Flying signal connector MIL 19 poles 62IN16PHM111419S4416 ......................................................................113 
Transport and storage..............................................................................................................................................................113 
1Transport conditions........................................................................................................................................................113 
2 Storage conditions ..........................................................................................................................................................113 
Installation................................................................................................................................................................................114 
1 Mounting .........................................................................................................................................................................114 
2 Commissioning................................................................................................................................................................115 
3 Balance...........................................................................................................................................................................116 
Operating conditions............................................................................................................................................................117 
1 Environmental conditions................................................................................................................................................117 
2 Derating of the motor in function of temperature / altitude ..............................................................................................117 
3 Safety information...........................................................................................................................................................118 
Maintenance........................................................................................................................................................................119 
1 Maintenance instructions ................................................................................................................................................119 
2 Troubleshooting ..............................................................................................................................................................120 
Disposal...............................................................................................................................................................................121 
Certifications........................................................................................................................................................................121 
1 RoHS directive................................................................................................................................................................121 
2 EMC directive..................................................................................................................................................................121 
3 EU Declaration of Conformity..........................................................................................................................................121 
4 Quality management system ISO 9001: 2015.................................................................................................................121 
5 UL/CSA Certificate of compliance (optional)...................................................................................................................121 
Contacts ..............................................................................................................................................................................123 
 
 

User’s manual –BR motors - vers. BR02.00.EN (05-08-2022) 7

2. General

2.1 Information

WARNING!

All tasks like transport, storage, connection, commissioning and maintenance on the motor

must be carried out by qualified personnel, which must be provided with protection equipment,

trained for the job and must be familiar with all operations and safety rules.

You must read this manual carefully before any operation.

This manual is available to the user and includes every motor of the Brusatori BR series.

Non-observance of safety instructions can damage people and equipment.

In case of any doubt, uncertainty or miscomprehension, stop any operation immediately and contact our technical

department.

Follow national standards and requirements of your country and environment.

WARNING!

Technical specifications of special versions and design variations may differ from motors

described in the manual.

If you have any doubt, contact our customer service, providing us type and serial code of the

motor.

Brusatori Srl reserves the right to change/adapt specifications and technical data without prior notice.

Special variations agreed with the customer may have priority over the content of this manual.

Machinery’s manufacturer must incorporate safety guidelines required for end customers into the operating

instructions.

User’s manual –BR motors - vers. BR02.00.EN (05-08-2022) 8

2.2 Symbols used

DANGER

CAUTION

WARNING

ELECTRICAL DANGER

SUSPENDED LOADS DANGER

MAGNETIC FIELDS DANGER

HOT SURFACE DANGER

2.3 Intended use

Electric motors in this manual comply with LOW VOLTAGE DIRECTIVE 2014/35/EU and are intended to be used in

standard industrial systems.

They also comply with Directive 2011/65/EU (RoHS) and EMC Directive 2014/30/EU.

Motors are designed and built to be incorporated with other machines or to be assembled with other machinery to

make a machine, according to standard MACHINERY DIRECTIVE 2006/42/EC.

If used for other purposes, take the necessary precautions to ensure safety in the intended environment.

WARNING!

Use is prohibited until it has been determined that the machine complies with the provisions of

MACHINERY DIRECTIVE 2006/42/EC.

Machinery’s manufacturer must also verify that the machine complies with EMC DIRECTIVE

2014/30/EU.

WARNING!

Permanent magnets in the motor can interfere with pacemakers and other devices.

Take the necessary precautions in order to avoid damage to people or things, keeping them

distant from the magnets.

This document is intended for the machine’s manufacturer, not for the end user.

Machine manufacturer in which the motor will be incorporated must provide to end user proper documentation about

installation, use and maintenance.

User’s manual –BR motors - vers. BR02.00.EN (05-08-2022) 9

2.4 European directives

LOW VOLTAGE DIRECTIVE (LVD) 2014/35/EU

Compliance

RoHS DIRECTIVE 2011/65/EU

and following Delegated Directives

Compliance

MACHINERY DIRECTIVE 2006/42/EC

Responsibility on machinery’s manufacturer

EMC DIRECTIVE 2014/30/EU

Compliance (if equipped with electronic feedback)

Responsibility on machinery’s manufacturer

2.5 Harmonized standards

CEI EN 60034-1: 2011

Rotating electrical machines - Part 1: Nominal and operating

characteristics

CEI EN 60034-5: 2021

Rotating electrical machines - Part 5: Degree of protection

provided by cases of rotating machines (integral project) (IP

Code) -Classification

CEI EN 60034-6: 1997

Rotating electrical machines - Part 6: Cooling methods

CEI EN 60034-7: 1997 / A1:2001

Rotating electrical machines - Part 7: Classification of types

of constructions and mounting arrangements (IM Code)

CEI EN 60034-8: 2008 / A1:2015

Rotating electrical machines - Part 8: Marking of terminals

and rotation sense

CEI EN 60204-1: 2018

Safety of machinery - Electrical equipment of machines - Part

1: General requirements

UL 1446 *

Standard for Systems of Insulating Materials - General

CAN/CSA 22.2 No. 0-M91 Appendix B *

General Requirements - Canadian Electrical Code, Part II

UL 1004-1 *

Rotating Electrical Machines –General Requirements

UL 1004-6 *

Servo and Stepper Motors

CAN/CSA C22.2 No. 100-14 *

Motors and Generators

*Only for UL and CSA certified motors (Optional)

2.6 UL certification

On request

OBJY2/8

Certificated UL/CSA insulation system

File E316823

On request (BR 7-8-9)

PRHZ2/8

UL/CSA certification of the motor

File E526644

User’s manual –BR motors - vers. BR02.00.EN (05-08-2022) 10

3. Order key

Configuration of a BR series motor is described with the following order key:

Type

Length

Voltage

Shaft

+ Key

Brake

Progressive

code

↑

■

■■

■

■■

■

■■

■

■■■

↓

Size

Speed

Position

sensor

Mounting

+ IP Degree

Certification

Type

BR■□□□□□□□□□□□□□□□□

Motor BR0

Motor BRV

Without ventilation

Air forced ventilation

Size

BR□■□□□□□□□□□□□□□□□

Size 3

Size 5

Size 7

Size 8

Size 9

Length

BR□□■□□□□□□□□□□□□□□

Length 1

Length 2

Length 3

Length 4

Length 5

Length 6

Length 7

Length 8

Speed

BR□□□■■□□□□□□□□□□□□

1000 rpm

1500 rpm

2000 rpm

2800 rpm

3000 rpm

4000 rpm

6000 rpm

Voltage

BR□□□□□■□□□□□□□□□□□

230 V

400 V

Transducer

BR□□□□□□■■□□□□□□□□□

Resolver / Encoder type

(Ref. chapter 7.3 of this manual)

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