Electro-Craft BRU Series User manual

BRU-200 and BRU-500
Brushless Drives
Instruction Manual
Electro-Craft Servo Products
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( Electro-Craft
BRU-200 and BRU-500
Brushless Drives
Instruction Manual
P/N 0013-1028-001 Revision B
Reliance
Motion Control, Inc.
6950 Washington Avenue South
Eden Prairie, MN 55344
612-942-3600
Technical Support: 800-328-3983

DANGER
ONLY QUALIFIFED ELECTRICAL PERSONNEL FAMILIAR WITH THE
CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS
INVOLVED SHOULD INSTALL, ADJUST, OPERATE OR SERVICE THIS EQUIPMENT.
READ AND UNDERSTAND THIS MANUAL AND OTHER APPLICABLE MANUALS
IN
THEIR ENTIRETY BEFORE PROCEEDING. FAILURE TO OB_SERVE THIS
PRECAUTION COULD RESULT
IN SEVERE BODILY INJURY OR LOSS OF LIFE.
WARNING
THE USER MUST PROVIDE AN EXTERNAL, HARDWIRED EMERGENCY STOP
CIRCUIT OUTSIDE THE CONTROLLER
CIRCUITRY THIS CIRCUIT MUST DISABLE
THE SYSTEM
IN CASE OF IMPROPER OPERATION. UNCONTROLLED MACHINE
OPERATION
MAY RESULT IF THIS PROCEDURE IS NOT FOLLOWED. FAILURE TO
OBSERVE THIS PRECAUTION COULD RESULT
IN SEVERE BODILY INJURY.
Copyright© Reliance Motion Control, Inc. 1995. All rights reserved.
The information contained in this manual
is subject to change without notice.
Electro-Craft is a registered trademark
of Reliance Electric Company or its subsidiaries.
Tandy is a registered trademark
of Tandy Corporation.
IBM is a registered trademark
of International Business Machines Corporation.
INTEL
is a trademark of Intel Corporation.
AMP is a trademark
of AMP Incorporated.
Molex
is a registered trademark of Molex Incorporated.
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Table of Contents
TABLE OF CONTENTS
SECTION I - INTRODUCTION
1.1 Purpose ............................................... .. ........................................................................................................ 1
1.2 Product Descripti
on .......... .. ....................................................... .. ............................. .. .... .. .... ...... .. . ... ....... .. ... 1
1.2.1 Power Supply Modules (BRU-500 Only) .................................................
.. ........... .. . .. ......... .. .......... 2
1.2.2 Drive
Mcx:lules .......................... .. ........ .. ...... .. ................................. ... ...................................... .. .... .... 2
1.2.3 Motors and Encoders..............................................................................................................
.. ...... 3
1.2.4 Transformers .........................................................................................................
.. ........................ 3
1.2.5 Auxiliary Power Supply (BRU-500 Only) ........................................................................................ 3
SECTION 11- SPECIFICATIONS
2.1 Drive Mcx:lule Specifications......................................................................................................................... 4
2.2 Power Supply Module Specifications
(BRU -500 Only).................. .. ....... ...... ................... .. .... .. .. .... .............. 5
2.3 S-Series Motor Specifications (TENV) .....................................
.. ......................... .. ................... .. .. ... .... ......... 6
2.4 F-Series Motor Specifications (TENV).......................................................................................................... 7
2.5 1-Series Motor Specifications (BRU-500 Only) ..............................
.. .. ...........................................................7
2.6 Encoder Specifications.................................................................................................................................8
2.7 Transformer Specifications.....
.... .................................................................................................................. 8
2.8 Maximum Power Losses
.... ................... ... .................. .. .................................................................................9
SECTION Ill-INSTALLATION
3 .1 Mounting the Power Supply and Drive Modules ............................. ... ....................................................... 10
3.2 Power Wiring ....
.. .... .. ......................................................... ... ........... .. ........ ... ............................................... 10
3.2.1 BRU-500 Power Wiring....................................................................................
... ........................... 10
3.2.2 BRU-2
00 Power Wiring.............................................................. ...................... .. ............................ 11
3.3 Motor Mounting and Wiring ........................................................................................................................ 11
3.4 External Shunt Mounting and Wiring (BRU-200 DM-30 Opt ion Only) ...................................................... 11
BRU-200 /B RU-500 Bru sh less Dr ives Instruction Manual iii

Table of Contents
SECTION IV -INTERFACE CIRCUITRY
4 .1 Drive Module Interface Connectors............................ .. ..... ... .. .................................................................. .. 15
4.2 Drive Module Interface Signal Specifications .................................... .. ...................................................... 16
4.3 Power Supply Module Interface Connector
(BRU -500 Only)........................................................... .... ..... 20
4.4 Power Supply Module Interface Signal Specifications (BRU-500 Only) ................................................... 20
SECTION V- START-UP AND ADJUSTMENTS
5.1 Initial Start-Up Procedure ... .. ... ...................... ... ..................................................................... .. ................... 21
5.1.1 Initial Start-Up Procedure (BRU-500) .................................... .. ..................................................... 21
5.1.2 Initial Start-Up Procedure (BRU-200) .... ... .......... .. ............ .. .......................................................... 22
5.2 Adjustments............................
.. ............................................................ ... ....................... .. ....... ... . .. .............. 23
5.
2.1 Power Supply Module Adjustments (BRU-500 Only) . ... .. .......... .. .......... .. ....................................23
5.2.2 Drive Module Adjustments.....................................................................
.. .................. ... . .. ........ .. ... 23
5.2.3 Serial Interface Operation ......................................................................
.. ... .. . .. .. ................... .. .. ... . 27
5.2.3.1 User Terminal Requirements ..................................................................................
.. ...... 27
5.2.3.2 Operating the User Terminal..................................
.. ....................................................... 27
5.2.3.2 .1 Help Page .. ..................................................... ... ... .. ... .. ...................................... 27
5.2.3.2.2 Status Page
.. ......................................................................................................29
5.2.3.2.3 Setup Page ...........................................................
.. ................... .. ....... .. . .. ... ... .... 31
5.2.3.3 Multi-Drop Host Mode Serial Protocol .. ......................................................................... 35
5.3 Tuni
ng Procedure................................................................... ... .. ................................................................36
5.3
.1 Using Auto-Tune Mode ............................................... .. ................................................................ 36
5.3.2 Using Tune Mode..........................................................
.. .............................................................. 38
5.4 Personality Module Installation.......................
.. ....................... ... . .. .............................................................43
SECTION VI -TROUBLESHOOTING AND MAINTENANCE
6.1 Introduction............................... .. ........................ .. ......................................................................... .... ......... 44
6.2 LED Diagnostic lnfonnation..........................................................
... ............................................. ... . .. .... .. .. 44
6.2.1 Power Supply Module LEOs (BRU-500 Only)
.. ................... .. .......................................................44
6.2.2
Dr iv e Module LEOs ............................................................................. .. .................. .. .....................44
6.3 Serial
Unk Diagnostic Information.............................................................................................................. 45
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Table of Contents
SECTION VII -OPTIONAL ACCESSORIES
7.1 PRO-Series Controller Kit Installation Instructions ............... .. ................................................................... 46
7.2 Spindle Orient and Auxiliary Function Card Installation Instructions
(BRU-500 Only) ..............................................................................................................................46
7.3 BRU-Series Control Station .....................
... ............................................................ .. .................................. 47
7.4 RS232C/RS422 Converter..............................................................................
.. .. .. ......... .. ............ .. . ... .. ....... 49
SECTION VIII- APPLICATION GUIDELINES
8.1 Torque Sharing Operation of BRU-Series Drives.......................................................... .. ... .. .. .. ... . .... .......... 50
8.1.1 General Description
.. ... .. ................... ... ................................. .. . ... .. . ... ... .... .. ....... ... .. .. .. ................... 50
8.1 .2 Theory of Operation .......................... .. .... .. .. .... .. ... .. ... .................. ... ............................................... 50
8.1.2.1 Multiple Slave Drives .......................................................................................................
51
8 .1 .2.2 Unequal Tor que Sharing .. .. . ... ......... ... ..... ... ... .. ................................................. .. ........... .. 51
8.1.3 Set-Up Procedure.......................... ... ........... ... ...... .. ...................................................... .. . .. ... .. .... .. . 52
8.1.
3.1 Wiring Instructions.................... .. ........... ... ............................................................... ... ..... 52
8.1.3.2 Tuning.................................................................
.. . .. ... .. ................................................. .. 52
SECTION IX- REPLACEMENT PARTS
9.1 Power Supply Modules (BRU-500 Only) .. .. .. ..... ... ................. .... ... ... ......................... ... ............................ ... 55
9.2 Drive Modules........
.. ....................................................................................................................................55
9.3 Personality Modules..........
.. ........................................................................................................................56
9.4 Motors
.. ......................... .. ................. .. ..................................................... .. ................................. ... . .. ...... ... ... 56
9.5 PRO-Series Kits .................................................................................................................................
.. .. .. .... 57
9.6 Spindle Orient and Auxiliary Function Card (BRU-500 Only).................................................................... 57
9.7 Cables.................
... ........................................................................................................................... ... ........ 57
9.8 Transformers ....................................................................................................................................
.. .. ....... 58
9.9 Motor Mating Connectors
.. ............................... ... . ... . ... ........ .. ......................... .... ........................................ 58
9.10 Motor Shaft Seal Kits
.. ............................................................................................................................... 58
SECTION X- CUSTOMER REFERENCE DRAWINGS
10.1 List of Drawings.................... .. ................. ... ................. .. .. ....... .. .................................................... .. . .. ... .... . 59
BRU-200/BRU-500 Brushless Drives Instruction Manual v

Table of Contents
INDEX
Index.................................................................................................................................... .. ............................. 54
LIST OF FIGURES
Figure 1-1 BRU-500 Series Servo and Spindle Drives.......................... ... ........ ... ............................................... 1
Figure 1-2 BRU-200 Series Servo Drives..
... .......................................................................................................2
Figure 3-1 S-Series Motor Connections.................................................................................................
.. ........ 12
Figure 3-2 F-Series Motor Connections...........................................................................................................
13
Figure 3-3 I-Series Motor Connections ............................................................................................................ 14
Figure
5-1 PSM Jumper Locations•.................................................................. ... ............. .. .............................. 25
Figure 5-2
OM Jumper and Personality Module Locations...................... ... ........................ ... .. ................. ... ...26
Figure 5-3 Serial Terminal HELP PAGE............................................................................................................ 28
Figure 5-4 Software and Personality Module Identification.............................................................................28
Figure 5-5 Serial Terminal STATUS PAGE ....................................................................................................... 29
Figure 5-6 Serial Terminal STATUS PAGE After Fault..................................................................................... 29
Figure 5-7 Serial Terminal SETUP PAGE (Velocity Mode) ..............................................................................
31
Figure 5-8 Serial Terminal SETUP PAGE (Torque Mode) ............................................................................... 32
Figure 5-9 Serial Terminal SETUP PAGE (Tune Mode) .....................................
.. ............................................ 32
Figure 5-10 Serial Terminal SETUP PAGE (Auto-Tune Mode)........................................................................ 32
Figure
5-11 Control Block Diagrams of Operating Modes..................................... ... ................ ................... ... 39
Figure 5-
12 Typical Small-Signal Response for Well-Tuned System.............................................................. 42
Figure 5-13 Personality Module lnstallation ..................................................................................................... 43
Figure
7-1 Sp indle Orient and Auxiliary Function Applica tion (BRU-500 Only).............................................. 46
Figure
7-2 BRU-Series Control Station.............................................................. ... . ... ........................................ 47
Figure 7-3
BRU -Series Control Station Connection Diagram ......................................................................... 48
vi BRU-200/BRU-500 Brushless Drives Instruction Manual

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Table of Contents
LIST OF FIGURES (Cont.)
Figure 8-1 Examples of Torque Sharing Operation......................................................................................... 51
Figure 8-2 Recommended Wiring for Torque Sharing
when Motors Rotate in Same Direction..............................................................................................
... 53
Figure 8-3 Recommended Wiring
for Torque Sharing when Slave
Motors Rotate Opposite
of Master Motor .............................. .. ............................................................. 54
Figure
9-1 Personality Module Model Number Description ......................................................... .. ................. 56
Figure 9-2
Motor Model Number Description .................................................................................................. 56
LIST OF APPENDICES
APPENDIX A- Getting Started With the Tandy 102 Terminal ................................ .. ........................................60
APPENDIX
8- User Terminal Communication Codes ..................................................................................... 61
APPENDIX C Getting Started With an IBC PC Terminal..................................................................................62
APPENDIX D Communication Problems and Possible Cures ......................................................................
.. 63
BRU-200/BRU-500 Brushless Drives Instruction Manual
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Introduction
SECTION I - INTRODUCTION
1.1 Purpose
This manual describes the Electro-Craft BRU-Series brushless servo drives and spindle drives along with
standard Electro-Craft motors recommended for
use with the BRU-Series drives. The manual is intended
for use
by qualified engineers or technicians directly involved in the installation, operation, and field level
maintenance of the drives and motors.
1.2 Product Description
The BRU-500 is a high performance sinusoidal brushless industrial drive employing a modular package
suited
to single or multi-axis applications. The drive modules can powerS-Series and F-Series permanent
magnet synchronous motors as servo drives
or 1-Series squirrel cage induction motors as spindle drives.
All drives share a common power supply
to achieve the most economical system package. 1-1
shows the standard BRU-500 components.
The BRU-200 is a high performance sinusoidal brushless industrial drive employing a
modu l ar package
suited
to single or multi-axis applications. The drive modules power S-Series and F-Series permanent
magnet synchronous motors. Figure 1-2 shows the standard
BRU -200 components.
For single axis positioning applications, the Electro-Craft PRO-Series controller cards are available as PRO-
Series Controller Kits
to be integrated into the BRU-Series drive module. This eliminates the need for a
separate controller package.
Figure 1-1 BRU-500 Series Servo and Spindle Drives
BRU-200/BRU-500 Brushless Dr ives Instruction Manu al 1

2
Introduction
Figure 1-2 BRU-200 Series Servo Drives
A brief description of the BRU-Series major components follows.
1.2.1 Power Supply Modules (BRU-500 Only)
The power supply module (PSM) can supply DC power to as many as slx servo or spindle drive modules.
The
AC voltage input to the PSM is non-isolated or isolated three phase power. The output, which is daisy-
chained
to the drive modules, is a two wire DC bus. The PSM requires no adjustments, protects itself,
provides trouble-shooting diagnostics, and has a built-in solid-state "soft charge•
of the DC bus capacitors
to reduce AC inrush currents. It also includes a built-in dissipative shunt regulator that provides quick
discharge
of the DC bus capacitors and doubles as an emergency synchronous motordynamic brake.
1.2.2 Drive Modules
The drive modules (OM) provide control and power for either S-Series and F-Series permanent magnet
synchronous motors
or !-Series squirrel cage induction motors (BRU-500 only). The OMs are available in a
range of current ratings
to best complement the variety of available motors. The OM control circuitry
utilizes a 16 bit microprocessor
to provide high performance and a simple serial interface from a host
computer
or user programming terminal to the servo drive.
All set-up and tuning is performed by a personality module
(PM) which plugs into the DM. The PM
customizes the DM for each specific motor and encoder type. The standard decimal line count encoders
are factory-installed on the motors.
BRU-200/BRU-500 Brushless Drives Instruction Manual

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Introduction
A standard RS-232/RS-422 serial interface is used to modify tuning, change limit values, or monitor
variables/status in the BRU-Series
dr ive modules. Any changes made through the serial interface can
then be stored in the PM. A VT-52 compatible serial terminal is required for the easy-to-use menus.
Refer to Secti
on 5.2.3.1 for user terminal requirements. Alternatively, a multi-drop host mode
communication protocol is also available for direct connection to computer hosts. Refer to Section
5.2.3.3.
1.2.3 Motors and Encoders
A wide range of Electro-Craft S-Series and F-Series permanent magnet synchronous motors and 1-
Series induction motors are available for use wi th BRU-Seri es dr ives. Each motor includes an internally
mounted encoder. The BRU-Series also provides the encoder signals for the position controller
to use
for the most economical system. Most motors are available with optional spring-set brake, optional
shaft oil seals, and/or optional fanpack. The synchronous motors have a rear shaft available for
mounting optional feedback devices.
1.2.4 Transformers
Multi-tap three phase isolation transformers are available in a variety of power ratings for line voltage
matching for the BRU-500. A multi-tap single phase isolation transformer is available for line voltage
matching for the BRU-200.
1.2.5 Auxiliary Power Supply
An auxiliary power supply module (PSM-AUX) is available to supply DC power to the logic supplies of
up to four DMs if the PSM is turned off. The PSM-AUX uses single phase 115 VAC power as the input.
The PSM-AUX option
is used if DM logic power must stay on even when the motor supply (the PSM) is
turned off. Absolute positioning with PRO-Series controller kits is one example where the PSM-AUX
would
be used . Another example would be maintaining DM logic power so that the DM serial interface
could
be used for trouble-shooting and diagnostics. See drawing 91 01-0134 in Section X for additional
information
on use of the PSM-AUX and the optional PSM-AUX isolation transformer.
The auxiliary power supply is built into the BRU-200 drive modules
as standard equipment. See
drawing
91 01-1329 in Section X for additional in formation.
BRU -200/BRU-500 Brushless D ri ves Instruction Manual 3

4
Specifications
SECTION II -SPECIFICATIONS
2.1 Drive Module Specifications
BRU-500 Model
Continuous
Amps[1]
Peak Amps[1
I
Bus Voltage
Command Signal
Input Range
Ambient Temp.
Weight
BRU-200 Model
Continuous
Amps [1]
Peak Amps
[1 1
Input Volts
Internal DC
Bus Voltage
Command Signal
Input Range
Continuous
Shunt Power
[21
Peak Shunt Power
[21
Ambient Temp .
We ight
DM-25
20
25
DM-50 DM-100
40 50
50 100
125-375 VDC
(325 VDC with 230 VAC input)
± 10 VDC (13.3k Ohms impedance)
32o-122oF (0°-50°
C)
24.2 lbs (11 .0 kg)
DM-20
10
DM-30
15
10 20
100-240 VAC RMS (Single Phase)
141-340 VDC
(325 VDC with 230 VAC Input)
± 10 VDC (13.3k Ohms impedance)
sow
4. 5kW
32°-122oF (0 °-50° C)
15 lbs (6.8 kg)
30
peak value
of sine wave per phase
DM-150 DM-150X
65 85
150 150
[1 1
[2 ] DM-30 has provision
for optional external shunt resistor that provides 200 W continuous and
6000 W peak shunt power. See drawing 9101-1328 in Section X
for additional details.
BRU-200/BRU-500 Brushless Drives Instruction Manual
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Specifications
2.2 Power Supply Module Specifications {BRU-500 Only)
BRU-500 Model PSM-50 PSM-125
Input Volts 88-265
VAC RMS (Three Phase)
Output Volts 125-375 VDC
(325 VDC
with 230 VAC Input )
Continuous
Amps (DC) 50 100
Peak Amps (DC) 150 450
Continuous
600W 1200W
Shunt Power
Peak Shunt Power
20kW 40kW
Ambient Temp. 32· -122· F (o • -so · C)
Weight 26.2
lbs (11 .9 kg )
BRU-200/BRU-500 Brush/ess Dr ives Instruction Manual 5

6
Specifications
2.3 S-Series Motor Specifications (TENV} [5]
[1 1
[2]
[3]
[4]
[SJ
Model S-2003 5-2005 5-3007 S-3016 5-4030
stall
Torque
(ll>-inl
2. 7 5. 0 7. 0 20 30
(Mal
0.30 0. 56 0. 79 2. 26 3. 39
Speed
00
(rpll)
6000
6000 5000 5000 4000
Kt
121
1. 17 1.17
2. 5 2.5 4. 4
(Ha/A)
0.13 0. 13 0 .28 0.28 0.50
Ke
C3l
(V/lCrpll)
16 16 34 34 60
A
lohu)
7.3 2. 6 6. 6 1.3 2.0
L
t.HI
9. 7 4.1 12.0 3 . 4 9. 0
J
(lll-1n-s2J 0.
00007 0. 00013 0.00027 0. 00072 0 . 0022
(kg-112) .
000008 0. 00003 0.00008 0.00025
BRU-500
--
DM-25 Dlt-25 DM-25
BRU-200 DM-10 DM- 10 DM-10 DM-20 DM-20
maximum continuous operati ng speed
peak amps
of per phase sine wave
peak volts
of line to line sine wave
phase
to phase
totally enclosed nonventilated
5-4050 5-4075
60 90
6. 78 10 .2
4000 3000
4.4
6 . 7
0 .
50 0. 76
60 90
0.8 0.9
3.3 5.4
0.0041 0. 006
0.00046 0.00068
DM-50 DM-50
DM-30 OM-30
S-6100 S-6200
100
200
11.3 22.6
3000 3000
6 . 0 5 . 8
0.68
0.66
82 80
0.49 0. 18
4.4 2 . 2
0.012 0.021
0. 0013 0.
0024
llM-50 DM-100
--
BRU-200jBRU·500 Brushless Drives Instruc ti on Manual
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S-6300 S-8350 s-esoo
325 350 450
36.7 39.5 50.8
3000 2000 2000
6.2 7 . 6 8 . 2
0.
70 0. 86 0 . 92
85
104 112
0.12 0 . 13 0 . 10
1 .2 2 . 5 2 . 4
0.030
0.056 0.083
0 .0034 0. 0063 0. 0094
DM-150 DM-100 DM-150
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Specifications
2.4 F-Series
Motor Specifications (TENV) [5]
HodeL F-4030 F-fOSO F-4075 F-6100 F-6200 F-6300
StaLL
31 6l 82
1l5
175 245
a.> 3.5 6. 9 9. 3 t3.0 19.8 27.8
4000 4000 3000 3000 3000 3000
J::t
(2)
Clb-lniA>
4.8 4.8 6.5
6.3
6.2
6. 5
(IWA)
0.54 0.54 0. 73
0. 11
0. 10 0.73
ao
CV/Itrpa) 66
66 89 86 8S 89
R
C4l
(en.>
2. 24 0. 89
0.98 o.51 0.26
0.16
L
C4l
c.tO
6.8 3.3 3.<1 3. 3 1.7 1.1
J
Clb-1,...2)
0. 009 0.019 0.029 0.057 o.oss O.t<l.f
ctv--2 > 0.
001 o.002t 0.0032 0.0064 0.0107 0.0162
8R0-500 DI'I-2S 01'1-50 01'1-50 01'1-50
01'1-100 01'1-100
BRU-200 01'1-20
01'1-30
DH-30
---
(1] maximum continuous operating speed
[2] peak amps of per phase sine wave
[3] peak volts of line to line sine wave
(4] phase to phase
[5] totally enclosed nonventilated
2.5 1-Series Motor Specifications (BRU-500 Only)
Cont. 30 Hin. Bose Hox.
Rotor
HodeL
Power Rot ing Speed Speed
Inertia Weight Drive
Kg-m2f
kg /L bs
Module
kW IH P
kWIHP
RPH RPH
lb-in-s
2
I-5300
5. 517 .4 7.5110 . 0 7500 6000 0.037 / 701154
DH-100
TEA0
0)
0.269
I-6600
11/14.7 151 20 7500 6000
0.073 1 108/238
DH-150X
TEA0
0)
0.643
[ 1] totally enclosed air over (TEAO)
BRU-200/BRU-500 Brushless Drives Instruction Manual 7

8
Specifications
2.6 Encoder Specifications
Motor Type 1-Series S-Series F-Series
2000 [1] 2000 [1]
UneCount
Supply
Une Driver
1000 [1]
5VDC 5 VDC (190mA DC max)
26LS31
5 VDC (245mA DC max)
26LS31
{1) standard line count
CAUTION
THE ENCODERS MOUNTED INSIDE THE S-SERIES AND F-SERIES
SYNCHRONOUS MOTORS ARE FACTORY AUGNED AND MUST
NOT BE MOVED OR IMPROPER OPERATION MAY RESULT.
HOWEVER, THE ENCODERS MOUNTED ON THE I-SERIES
INDUCTION MOTORS MAY BE MECHANICALLY REAUGNED TO
ANY ARBITRARY POSITION IF DESIRED.
2.7 Transformer Specifications
BRU-500
.Rating(kVA) 3.0 6.0 12.0
Input 208/230/240/380/460/480
VAC RMS (Three Phase)
Output 115/230 VAC
RMS (Three Phase)
Ambient Temp.
32°-122° F (0° -sao C)
Weight
86lbs 1351bs 200ibs
(39 kg) (61 kg) (91 kg)
18.0
325lbs
(148 kg)
Refer
to drawing 9101-0131 and drawing 9101-Q132 in Section X for transformer outline drawings and load
regulation data.
BRU-200
Rating(kVA)
Input
Output
Ambient Temp.
Weight
3.0
220/230/240/440/460/480 VAC RMS (Single Phase)
115/230 VAC
RMS (Single Phase)
32° -122° F
(Oo -sao C)
62 lbs (28 kg)
Refer
to drawing 9101-1056 and drawing 9101-1057 in Section X for transformer outline drawing and load
regulation data.
BRU-200/BRU-500 Brushless Drives Instruction Manual
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Specifications
2.8 Maximum Power Losses
Maximum Watts Loss
DM-10 50 + dissipative shunt
DM-20 100 + dissipative shunt
DM-30 150 +·dissipative·shunt
3
kVA Transformer (1 Phase) 350
DM-25 120
DM-50 180
DM-100 275
DM-150 300
DM-150X 350
PSM-50 110 + d i
ss ipative shunt
PSM-125 240 + dissipative shunt
3
kVA transformer (3 Phase) 350
6 kVA transformer (3 Phase) 600
12 kVA transformer (3 Phase) 950
18 kVA transformer (3 Phase) 1200
The maximum
power losses are shown to help in sizing a NEMA 12 (o r equivalent) enclosure and any
required ventilation. Typical power losses are about one-half maximum power losses.
As an additional aid in sizing an enclosure with no active method of heat dissipation, the following
approximate equation is used:
T = 4.08*(0/ A) + 1.1
where T is
the temperature difference between inside air and outside amb ient (" F) , Q is heat generated in
enclosure (watts),
and A is enclosure surface area (tt2). The exterior surface of all six sides of an enclosure
is calculated as:
A =
(2dw + 2dh + 2wh)/144
where d (depth), w (width), and h (hei
ght ) are in inche s.
BRU-200 /B RU-500 Bru sh l ess Drives Instruction Manual 9

Installation
10
SECTION Ill-INSTALLATION
3.1 Mounting the Power Supply and Drive Modules
The BRU-500 power supply and drive modules and BRU-200 drive modules are designed for simple
installation
on a flat surface such as the back wall or plate of an enclosure. The environment in the
enclosure must
be clean and free of oil mist, coolant mist, conductive particles, and corrosive chemicals.
For industrial applications, a NEMA
12 or equivalent enclosure is recommended. The enclosure must
also
be properly sized (and ventilated if required) to insure that the BRU-500 and BRU-200 maximum
ambient temperature is not exceeded.
Drawings
91 01-0409 and 91 01-0410 illustrates a typical BRU-500 installation showing space
requirements between modules for cover removal
and around modules for wiring and air flow. The
power supply module should
be centrally located to minimize the distance between it and the drive
modules. It is also recommended that the higher current rating drive modu les
be located closest to the
power supply module.
Drawi
ng 9101-1300 shows the BRU-200 drive module dimensions including space requ irements around
the drive module for wiring and air flow.
3.2 Power Wiring
3.2.1 BRU-500 Power Wiring
WARNING
DANGER OF ELECTRICAL SHOCK OR BURN. ONLY QUALIFIED
INDIVIDUALS SHOULD WORK ON THIS EQUIPMENT.
DISCONNECT
ALL POWER BEFORE WORKING ON
EQUIPMENT. DANGEROUS VOLTAGES MAY EXIST AFTER
POWER IS REMOVED! CHECK
DC BUS VOLTAGE OF BRU-500
EACH TIME POWER
IS REMOVED BEFORE WORKING ON
EQUIPMENT.
Drawing 9101-0411 illustrates the only required power wiring for a typical four axis installation. The
phasing
of the three phase input L1, L2 , and L3 to the power supply module is arbitrary, but the DC bus+
and -polarities must be connected as shown . Also, the phasing of the three phase drive module outputs
R, S, and T must conform to the motor
R, S, and T leads for proper operation. Connect the earth ground
as shown to insure a safe and proper installation.
The
DC bus connection wires (substituti on not permitted) are provided with each drive module.
Selection
of transformer, line fuses, and wi re gauges is covered in drawing 9101-0411 . The optional
auxiliary power supply wiring is covered
in drawing 9101-0134.
BRU -200/BRU-500 Brushless Drives Instruction Manual

(
r
( Installation
3.2.2 BRU-200 Power Wiring
WARNING
DANGER OF ELECTRICAL SHOCK OR BURN. ONLY QUALIFIED
INDIVIDUALS SHOULD WORK ON THIS EQUIPMENT.
DISCONNECT ALL POWER BEFORE WORKING
ON EQUIPMENT.
DANGEROUS VOLTAGES MAY EXIST AFTER POWER
IS
REMOVED!
Drawing 9101-1329 illustrates the only required power wiring for a typical installation. The phasing of the
three phase drive module outputs R, S, and T must conform to the motor R. S, and T leads for proper
operation. Connect the earth ground as shown to insure a safe
and proper installation.
The AC-AUX auxiliary power input is used
if DM logic power must stay on when the motor supply is
turned off . Absolute positioning with PRO-Series controller kits is one example where this would be
used . Another example would
be maintaining DM logic power so that the DM serial interface could be
used for trouble-shooting and diagnostics. The auxiliary AC input must be isolated or be the same phase
as the main AC power
to the drive module or damage can result. If multiple BRU-200 drive modules are
used, and AC power is distributed from more than
one phase, the AC auxiliary input for each drive must
be from the same phase as the main power for that drive. You may not use a single auxiliary AC source
for drives
on more than one supply phase, even if the auxiliary AC source is isolated. See drawing 9101-
1329
for additional information and examples showing use of the AC-AUX power input.
Selection
of transformer, line fuses, and wire gauges is covered in drawing 9101-1329.
3.3 Motor Mounting and Wiring
Motor outline drawings for the S-Series, F-Series, and 1-Series motors are shown in drawings 9101-0129,
9101-0332, and 9101-0130 respectively.
Some motor mounting considerations are as follows:
1
.) Do not run motor unmounted. Attach all motor cables after motor is mounted.
2.) Mount motor with connectors pointing downward to keep liquids flowing away from connectors
and use a drip-loop in cables to allow liquids to flow away from connectors.
3.) Consider motor case temperature
if necessary to safeguard operator and maintenance staff.
Maximum case temperature is about 1
oooc (212°F) for a motor used at continuous rating in a
40°C ambient.
Motor connections are shown in Figure
3-1 , Figure 3-2, and Figure 3-3.
3.4 External Shunt Mounting and Wiring (BRU-200 Option Only}
The External Shunt is designed to be mounted on a flat surface. The same mounting restrictions apply
to the External Shunt as to the BRU-200.
Drawing 9101-1328 shows the External Shunt Resistor dimensions and connection diagram. Note that
the jumper between pins 1 and 2
of TB2 on the DM connects the internal shunt resistor when an External
Shunt Resistor is not being used.
BRU-200/BRU-500 Brushless Drives Instruction Manual
11