Electro-Craft BRU-200 User manual

BRU-200 and BRU-500
Brushless Drives
Instruction Manual
Electro-Craft® Servo Products

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

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 OBSERVE 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 mghts 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 subsidianes.
Tandy is a registered trademark of Tandy Corporation.
IBM is a registered trademark of Intemational 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.

Table of Contents
TABLE OF CONTENTS
SECTION | - INTRODUCTION
V7 PUPPOSC oo eee eceeeee nee n ee nnetee pee ceeeseceuevee HnMAcHensHenRO Hea Enea LdCAnSOnNAcucaNSA Ene LOE CCEA CnEOH SHEE CnEEH ALU DRREEAAAESReud HE SEDREREE EEO EA RE
1.2 Product Description... . sea eee tease teeeeceecavceneancoeennepeseenneee vet ne set sagee peta nseates ene
1.2.1 Power Supply Modules (BRU- 500 Only)... dacneeeseveceescaecenecsessesnesetnsanenersnatengesaneseesutssntenteesnnees &
1.2.2 Drive Modules... ccc ccccercseceescueesareeseceseecescaeeseeseeesseserensesecoegse seadsguaggessansaasasapeamasensaeasebenenenens
1.2.3 Motors amid Encoders.i....cccccccsscecesetcesecececeaseseseceecasascecnsseseecsecsenssnnaensenecauaneeassrepenenésedeeseestaseoeese se
1.2.4 Transformers ... pence ceneaeacceneneag cae cncetsaeseenetinereesenseereaerbeddeaeseseabieeasaaneees
1.2.5 Auxiliary Power ‘Supply (BRU- 500 Only)... enue sus cesuassesesceneasseseeccsscecaesatansesaesssaessetuaseaeeseceasvansstesenacates 3
SECTION II - SPECIFICATIONS
2.1 Drive Module Specifications «oes cc cececcneeeceeeeeeseoceseecaesoeneseneneeeetersecrereceesecess or ttsaviseeameaqsseneeaseneansees
2.2 Power Supply Module Specifications (BRU-500 Only)... cece cee ccee cee nesee rece enesvanseerenasinaeesenererersnenas Dl
2.3 S-Series Motor Specifications TTENV) .......c:ccecssescesssssseeesessesseesesessseeseessceseseecsevasseeeeecavavisasersasrensertacesissese O
2.4 F-Series Motor Specifications (TENV)........cccsscsceccscsssnecnensestsscecnesecescensavsveceesseseecscoesnsnetecesstsatpensetsncesnnee B
25 I-Series Motor Specifications (BRU-5SO0 Only)... ccsccesssssssssesecesssseesessesescessseseeesecueenteenesceereerseecenesceneneaees 7
2.6 Encoder Specifications ............cccscceccccecssseescscsnesnesseestesesscenensessecsceascnesscenseseeessenecaessenenenssueqeeteteratencesiyeateneees
2.7 Transformer Spechications.......0.1..ccccsccecccsessscscssesescsesenesssenensusasevenesseeenscoatvaceusausaaceusersteteseenseseeterecgeeenes B
2.8 Maximum Power LOSS@S. ...........ccccccccccsce ses ceeeececeesceee veseeceesessaeescaseserseeecseseseeessescencevesereerseeseeciesessnasevsanes
SECTION Ill - INSTALLATION
3.1 Mounting the Power Supply and Drive Modules «...........-.-c-cceseesecseeecceeesusceneaaeeseeenseeeceesenaeeesaecavaeceenseaeers 10
3.2 Power Wiring... venue ceeenneeeseneneeeasinesecursapeeeesessgneeudegeegseqcennsessseesenseseeenetassctsaemesesnesanernte TO
3.2.1 BRU 500 ‘Power Wiring... cece seecaneeesoueeeusesenceneseecassneccenepeesaaeesssscesenstessieseneveertestsamenteraseaneenees TQ)
3.2.2 BRU-200 Power Wiring.... besos ta caeeeeasesessacesnecae sua tasccnerensageeseeeceseeensenstsntennencsstereteriesacre TT
3.3 Motor Mounting amd Wiritig nce. csccsceesesssecesecececeecsesesesessesceseaesesesaeceneseseececesceeceeceseaceererscaeavasenetes 11
3.4 External Shunt Mounting and Wiring (BRU-200 DM-30 Option Only) 0.0... ccccececeseetetetecsteeeseessenetane TY
BRU-200/8RU-500 Brushless Drives instruction Manual iii

Table of Contents
SECTION WV - INTERFACE CIRCUITRY
4.1 Drive Module interface Commectors........ccc ccc ee ccceeecececoessasesseussucueceeessunnsesgueseeserecssgenneenrasesansnerecevens
4.2 Drive Module Interface Signal SpecifiCations ...........ccccccecccccsceeceeeceeecesuceseneecsuceenrceesaseeneees
4.3 Power Supply Module interlace Connector (BRU-S00 Only)... eeeccsee teens sssseencesseeeennarieerereaeeeee rane
4.4 Power Supply Module Interface Signal Specifications (BRU-500 Only) oo... ee cieceecrcsesereanseenssseeeensees
SECTION V - START-UP AND ADJUSTMENTS
5.1 Initial Start-Up Procedure ...
§.1.1 Initial Start-Up Procedure (BRU- 500) ...
5.1.2 Initial Start-Up Procedure (BRU-200) ...
5.2 AGIUSTMONNS. 0. eee eetetec eee cneensareneeneseeenercnsonessseatanessusanaseenseessnecaneeetanenersseseasencesseesensenseeeeeeneeeesmaesareaaeaetaee
5.2.1 Power Supply Module Adjustments (BRU-500 Only) oo... ceceeeeeeseseeseseneesereseceersarteceanetaeararies
5.2.2 Drive Module Adjust ments........---:cscsssrscsserssetavensenesessesseneseeesocecesaeedee seeaeceeseceeaeees see caeeaneesenenates
5.2.3 Serial Interface Operation... seaepeteesnevenaseanseaae seeseeesescerasnaeceestveasaetseaesereaaeesseeeseeesereee
5.2.3.1 User Terminal Requirements ... qevansuasaecesensesee cssecenetacsusersucssatersscseeecesstecsevenes ees
5.2.3.2 Operating the User Terrminal................sccccccceccssesccecseeeceeeseeeaenansecenenanesensenaasececoeescneesrensess
§.2.3.2.1 Help Page oo... csi eceeceeccctee cue ce ceacereee esta ceeeesacteunaecenaeneesgesanaaesestentanseraepenees
5.2.3,2.2 Status PAGO... ceeccccccccececcsseecetecessctassactecsennectacaecneaneconaesecegeaetacaaeveseeneeuseeeneras
5.2.3.2.3 S@tup Page wes cceeessnsessceneseenssseneeseseescesssssscesscesseeescerssseeeecessanesssseseeseassae
5.2.3.3 Multi-Drop Host Mode Serial Protocol «oo... ceecnecececesceensa so eteveceatenceavecsaeeacssnen
5.3 Tuning Procedure... seccccscccceeeeens ceseeaeedecestanetce eeeseenesasteeaeseseeneeeueeseetesestaneenenyeeeiusnnnedsidaageas cid geneaseccnsenee
5.3.1 Usitig Auto-Tune Mode .......eecsncesescscencenneeeseenereneeteegeecneensaeeseesenenseeaequen nesteanaatsaaeneneaseesereass
5.3.2 USing Tune MOde uc ce cseetsserecscesererssascesessscnenseeneneeseecsegteegeenemseseeestiess pened nadenasasatsunvonet treeseneaan
5.4 Personality Module Installation... cece ccccseneteeeseesesrsneeenecevaneeeensrseseseeeaeeesassaeaeanassntaesansnsanseerneensesasens
SECTION VI - TROUBLESHOOTING AND MAINTENANCE
B21 PR OCUCHION 20... ccecse tee eeseeesecesseensssansecescoeaeeesansececeaevecescnsgecesnaaesavensesstesescaseaseenesaceatatanaecacaneaeccnssaascaeeeenes
6.2 LED Diagnostic IMPOrMationi........e eseeceeceeeseeecteesesseeetneneneeessoscesseccestesssuapestiesuaace steam tdededeecsdesuneeeeesssetereeas
6.2.1 Power Supply Module LEDs 's (BAU-500 Only) eaventeseeusenneune sarsesssessetantusseanersetenteauactrovenecsee
6.2.2 Drive Module LEDs... ses ca secacceaecaaenaeeceaseace ceases sens concesatessaseaceeeeneensanqecsatse
6.3 Serial Link Diagnostic INfOrmMmation. ......-- ee eeecccesccceceesecececoscsesecasenttesseneeses coceneeuesastucessassnsesesesenaseceses cate
15
.- 16
20
20
wre 2d
2
23
23
vel
wel
27
27
31
36
36
REE
iv BRU-200/BRU-500 Brushless Drives instruction Manual

7.1
7.2
7.3
7.4
8.1
9.1
9.2
9.3
9.4
9.5
9.6
9.7
GB Transformers ..... 2... cececseececcececeesecnencesesceeeseesseecoesserssavaneaussesesensaauauessaaanansessseseevascensessasenessaseneneesecenstrerees
9.9 Motor Mating Conmectors........... eect ceecceccescsseeeeeeseneesaeessneaseessansanesatanaestensesoaeerasssscenensdevacaceetuqusaatcocetsense
9.10 Motor Shaft Seal Kits... esesessssseseeccnsneenversareenssuseusensensusavaneraseuseesssonnssessevarsueeanssstusauteateecengateateae
10.1 List of Drawings... access ceene cece cece coevscaaeesauseessessseneesseeeeteeceneeseesasedseesiseteenasearsnsetsaneeeetenetones
SECTION VIl - OPTIONAL ACCESSORIES
PRO-Series Controller Kit Installation INStructions ......0..-:00::ccccaccessessesssesseesseeecsetensresenee
Spindfe Orient and Auxiliary Function Card Installation Instructions
BRU-Series Cortrol Station oo... cceccecceescncseeecsrssvesceecneesceauecasseqensangesssteepeneusceseussessencareseuaeeevenssereneenees
RS232C0 /RS422 COMVOrter we cceecccccessessscecesececeesestesseseeneessasecaeesececcecaeeeedeqacneiesessenseceatseceaeeneertnestenees
SECTION Vtll - APPLICATION GUIDELINES
Torque Sharing Operation of BRU-Series Drives... ce eeceece ese eees cee reses ss eeeenenneeeesnseneressnreneessseseneeeee
8.1.1 General Description ...
8.1.2 Theory of Operation... .:
8.1.2.1 Multiple Slave Drives...
8.1.2.2 Unequal Torque Staring...
8.1.3 Set-Up Procedure... eoseseecetereteeeteenensoeecoesansaerenenaneecaenes?
8.1.3.1 Wirng Instructions...
8.1.3.2 Tuning...
SECTION IX - REPLACEMENT PARTS
Power Supply Modules (BRU-500 Only) oo... ccsccscsssssssnsecsssssvanesaescseaseesscseeseessestaseceseaueaeessesdesnaceseesecseese
Drive Modules... ccc cscs cee ceseseseecceeeeeceasnavenesssenssaaesens veaesesesentesspesscneseasaseesccscarereessseseseeasaneeneseeeneneeetessetsaes
Personality MOdUIGS..... ec cetcccenecesceeeecseesenessaneusesassaneuasensaeseeansessestersereseneeeteassteeseccsasaesanessanscaneetinesentees
MOLOrS....... see ecececaseeeceeseceeneeereesssepeeesesnsseenanenssesenesesiesscstnecsisesee susseenbeseesnesersessvesteceatsseceeesseaeeatstanseeesseenannes 56
PRO-Series Kits... 2... .cccceccssecersesseeceeecceceseeteeescseeeacausesseeeseescseeueeestiesededieendseueeeeennscenscssrarcsesarenstecesegeeteeateenaes
Spindle Orient and Auxiliary Function Card (BRU-500 Only)... eee cee eceeneneneeneeesteeeasareeeerneeesetasiegs
CADDIES ccc ecceccecceneteceseeneeeten casas crea scntenten sessed etssenescasasessosceceusatudecesetendascenesansvevsseycecesusevaaucasessaneasanesaasas
SECTION X - CUSTOMER REFERENCE DRAWINGS
Table of Contents
cave nenaeveneeeteaenscaes 46
46
47
49
50
.. 00
see 5
sed
52
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wee 52
55
57
57
57
58
58
58
59
BRU-200/8RU-500 Brushless Drives instruction Manual

Table of Contents
INDEX
OX ooo secccesesneenscesusscesnnuescsassnaseaessuessesesateeeereasanerssennuasunenreusnatesueaeeeseeaneesregdaesesececedsogeeeeaseneseceeeapeses sesaenessteseecees 64
Figure 1-1
Figure 1-2
Figure 3-1
Figure 3-2
Figure 3-3
Figure 5-1
Figure 5-2
Figure 5-3
Figure 54
Figure 55
Figure 5-6
Figure 5-7
Figure 5-8
Figure 5-9
LIST OF FIGURES
BRU-500 Series Servo and Spindle Drives... cece ccceceesscceeneseacnesseasaeeaeteereanenessceneesssrasaatearaee
BRU-200 Series Servo Drives... ec ccccecccccscepeccsveceeesesacceensscaceees suasceetaccuasenacesseseuaneqessseuessesaneesensaeees
S-Series Motor COnmmections.......... ccc ceceeecerceeeseeneeccneeaneeecetaredeneersecheaesceeentetaunesessasecdcaeeeedssenanens
F-Series Motor Connections... ec scsessseessensensssessenerssenenecssseseuscauonsessusevarseneneansevensesangeaesasener
I-Series Motor Connections «02... ececescscecsesercereneeececesseneenesensenseeaeaneseresanensssnceresneseeesnesssennneneceecenees
PSM Jumper Locations... cece cee eeeneneseteeaceseneee nts ceeenqessceaesecencatang seeeeseensenaneeeeiresenee:eraneseneet
DM Jumper and Personality Module Locations «0... ce eececeeeeceseseeeeseene nessa see sineeaeeeeen ents
Serial Terminal HELP PAGE... eee eeenscecrs teens tesccegsesees teegsnenaecesenenetenensneaes saaeeesensneasaeas
Software and Personality Module Identification... eee escsesceneceeceesaneaeeeseeeeeeeteseeeeteretacnenees
Serial Terminal STATUS PAGE ..........cceceseceetssescserersessceeeereete cesses cr cencea erseceraneaeessterstsaseeeeeesenseaess
Serial Terminal STATUS PAGE After FaUtt .......ccscssssscecsssscseseceevsnsnstenseccesveteseseeesnsnnnustescurensereets
Serial Terminal SETUP PAGE (Velocity Mode) woeeceeed see netecovesestnseceonseeseeeteceareteseasssstsnensennisseaneetsat
Serial Terminal SETUP PAGE (Torque Mode) .......ccccccssescecsstesecsesseesssuacenesacsnceatersececaencavenaacassaeaes
Serial Terminal SETUP PAGE (Tune Mode) 0.0... eececesesecsseconecenserscesencaecareoternsnsseneneasanesensneness
Figure 5-10 Serial Terminal SETUP PAGE (Auto-Tune Mode) ..........-..ecsscceccoeecoteseecoeceenereceneeserersuaeececenenenetes
Figure 5-14 Control Block Diagrams of Operating MOde@S .............-cescccceececceceeeceneea ces ceecesesenentenseceaneeseaeeseseoes
Figure 5-12 Typical Small-Signa! Response for Well-Tuned Systerm...........cccccscscceesescesseeseteerseseeneevensersesesess
Figure 5-13 Personality Module Installation oo... ccc cesses sseeeecsteceeseeseessesuceuessecaeersseresegecbaressnardetacateceseasates
Figure 7-1
Figure 7-2
Spindle Orient and Auxiliary Function Application (BRU-500 Only)... cesses cs eeecnessseseeeacees
BRU-Series Control Station... cece cesses ceceeeseececo eevee nsseaus en sees saeevecsarsnseenessebayeneusssesererenense
wd
2
12
-13
14
25
26
28
28
31
32
32
32
39
42
43
46
47
Figure 7-3 BRU-Senes Control Station Connection Diagram ........ cc cecscccescaececeeseueccrscetecetaceceeeecarentaneeeats 48
vi BRU-200/BRU-500 Brushiess Drives Insiruction Manual

Table of Contents
LIST OF FIGURES (Cont.)
Figure 8-1 Examples of Torque Sharing Operation... cc ceeesesessecseneeserseeeseeresseeeeesseserscenssensasaneenes peesseaneates 51
Figure 8-2 Recommended Wiring for Torque Sharing
when Motors Rotate in Same Direction... ccscsssseecsses creer cecececee sesceeseeseseeessaneasasearscsssaseeasasneneseee 53
Figure 8-3 Recommended Wiring for Torque Sharing when Slave
Motors Rotate Opposite of Master MOtor ...........cccccccceescsescecsesceueececeaeeseecuescecseeeseeeanssenererteeeatsenanaesena ees 54
56 Figure 9-1 Personality Module Model Number Description ...0.....cccccc eects eeeeee tence tee reese ebeenecenereentnacaeaense
Figure 9-2 Motor Model Number Description ....... eect cerreee eee teens testeeneessernnrereseneaceaesserenetitecasser eases: OG
LIST OF APPENDICES
APPENDIX A - Getting Started With the Tandy 102 Termiitial ...........c:c-ce:cccseceeceeececeeccenececeneesraneseascateatcovenenenes 60
APPENDIX B - User Terminal Communication Codes ...0....:.ccccccccssesscseescssssseceseneeseeseneneneet’ venavensesasesanansaceesees 6t
APPENDIX C Getting Started With an IBC PC Terminal... ccccccccccceccsccsessessecscecesanneaescaesaseraeeeetnseeeseseeeees 62
APPENDIX D Communication Problems and Possible Cures .00....0....cccccccecscesesseesceseeneststeneeceesssseesseetareeees BS
BRU-200/8RU-500 Brushless Drives instruction Manual vii

4)
3393
9992992992393
2

introduction
SECTION | - INTRODUCTION
1.1 Purpose
This manual describes the Electro-Craft BRU-Senies 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 ievel
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 multtaxis applications. The drive modules can power S-Series and F-Series permanent
magnet synchronous motors as servo drives or !-Series squirrel cage induction motors as spindle drives.
All drives share a common power supply to achieve the most economical system package. Figure 1-1
shows the standard BRU-500 components.
The BRU-200 is a high performance sinusoidal brushless industrial drive employing a modular 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-Senes controller cards are available as PRO-
Senes Controller Kits to be integrated into the BRU-Series drive module. This eliminates the need for a
separate controller package.
a
AF
a
ls
eh
Le
Figure 1-1 BRU-500 Series Servo and Spindle Drives
BRU-200/BRU-500 Brushless Drives instruction Manual 1

introduction
Figure 1-2 BRU-200 Series Servo Drives
A brief descnption 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 six servo or spindle drive modules.
The AC voltage input to the PSM is non-isclated 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 motor dynamic brake.
1.2.2 Drive Modules
The drive modules (DM) provide control and power for either S-Series and F-Series permanent magnet
synchronous motors or t-Series squirrel cage induction motors (BRU-500 only). The DMs are available in a
range of current ratings to best complement the vanety of avaiable motors. The DM 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 periormed 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.
2 BRU-200/BRU-500 Brushless Drives instruction Manual

Introduction
A standard RS-232/RS-422 serial interface is used to modify tuning, change limit values, or monitor
variables/status in the BRU-Senes drive 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 Section 5.2.3.4 for user terminal requirements. Alternatively, a multi-drop host mode
communication protocol is aiso 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 I-
Series induction motors are available for use with BRU-Series drives. Each motor includes an internally
mounted encoder. The BRU-Series also provides the encoder signals for the position controlier to use
for the most economical system. Most motors are available with optional spring-Set brake, optional
shaft oi] 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 isclation transformers are avaiiable in a variety of power ratings for line voltage
matching for the BRU-500. A multitap 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-AU) is available to supply DC power to the logic supplies of
up to four DMs if the PSM is tumed 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 9101-0134 in Section X for additional
information on use of the PSM-AUX and the optional PSM-AUxX isolation transformer.
The auxiliary power supply is built into the BRU-200 drive modules as standard equipment. See
drawing 9101-1329 in Section X for additional information.
BRU-200/BRU-500 Brushless Drives Instruction Manual 3

Specifications
SECTION Il - SPECIFICATIONS
2.1 Drive Module Specifications
BRU-500 Model DM-25 DM-50 DM-100 DM-150 DM-150X
Continuous 20 40 50 65 85
Amps[1]
Peak Amps/[1] 25 50 100 150 150
Bus Voltage 125-375 VDC
(325 VDC with 230 VAC input)
Command Signal +10 VDC (13.3k Ohms impedance)
input Range
Ambient Temp. 32°-122°F (0°-50°C)
Weight 24.2 tbs (11.0 kg)
BRU-200 Model DM-10 DM-20 DM-30
Continuous 5 10 15
Amps [1]
Peak Amps [1] 10 20 30
Input Volts 100-240 VAC RMS (Single Phase)
Internal DC 141-340 VDC
Bus Voitage (325 VDC with 230 VAC Input)
Command Signal +10 VDC (13.3k Ohms impedance)
Input Range
Continuous 50 W
Shunt Power
[2]
Peak Shunt Power 4.5 kW
[2]
Ambient Temp. 32°-122°F (0°-50°C)
Weight 15 lbs (6.8 kg}
f1] peak vaiue of sine wave per phase
[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 Brushiess Doves Instruction Manual

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 600 W 1200 W
Shunt Power
Peak Shunt Power 20 kW 40 kW
Ambient Temp. 32° -122° F (0° -50° C)
Weight 26.2 Ibs (11-9 kg)
BRU-200/BRU-500 Brushless Drives Instruction Manual

Specifications
2.3 S-Series Motor Specifications (TENV) [5]
woda) s-2003 s-2005 s-3007 5-3016| s-a030| s-a050| s-4075 s-6400 56200 s~ca00 S-a350} S-a500
Stalk
Torque 2.7 5.0 7.0 20 30 60 a0 1oo 200 325 350 450
b-in)
oe 0.30 0.58 0.79 2.26 3.39 6.78 s0.2 44.3 22.6 35.7 39.5 so.a
speed @
tepm) 6000 so00g Seco Sooo ao0o 4p00 3000 3000 3000 3000 2000 2000
a
poteyy 247 4-47 2.5 28 aa aa 67 oo S.8 G2 7.6 82
(n/a 0.43 0.13 0.28 0.28 0.50 0.50 0.76 o.6a o.66 0.70 9.86 9.92
a
ewekeoa) i6 46 24 24 60 &0 30 a2 ao 85 104 442
a
lottee) 7.3 26 6.6 4.3 20 0.6 0.9 o.49 ose o.c2 0.93 0.40
L a
(a 9.7 4.4 42.0 a4 9.0 aa sia aa 2.2 ae] as aca
J
tip-in-s4i |/0.00007] 0.00043] 0¢.00027/0.00072| 0.0022 o.0041/ 9.006 o.0a2 0.024 0.030 0.056 0.083
ikg-m2) .o00008 19. co0028/0.00003 6.00008 0.00025/9.09046/0.00068| 0.0023 0.0024 0.0034 0.0063 0.0094
saesoo — _ oe25 om-25 om-25 o50 ce-So ne-SO Oe-s00| OM-450 OM-4100 OM~250
pa-200 ov10 on-ao oxic ow-20 ceo o30 oso] — _ _ __ __
[1]
(2)
[3]
[4]
[5]
maximum continuous operating speed
peak amps of per phase sine wave
peak volts of line to jine sine wave
phase to phase
totally enclosed nonventilated
BRU-200/BRU-500 Brushless Drives instruction Manual

2.4 F-Series Motor Specifications (TENV) [5]
| Nedet F 4030 F-4050 F-4075 F-S100 F-sz00 F-£300
Stati
s
(tb- I?
C= as 69 93 13.0 19.8 27.8
at 61 a2 a5 i7S 245
@m
Kt 4.8 4.8 6.5 6.3 6.2 6.5
(iva
Clea) 0.54 0.54 0.79 o.71 0.70 6.79
ke ™) gg 5S ag & gs ag
O/irpa)
a)
cote 224 0-69 | 0,98 0.st 0.28 0.18
L #
cdo se 33 34 3a 1? oat
J
(lb-inea*?|| 0.009 0.019 0.029 0.057 0.095 O.144
tkg-m 27 0.001 0.00z7 0.0032 0.0084 0.0107 0.0162
{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 I-Series Motor Specifications (BRU-500 Only)
Specifications
i
Rotor
Cont.
30
Min.
Base
Max.
.
.
.
Model
|
Power
|
Rating
|
Speed Speed
Inert
a
teign
t
ra
r
dule
kW/HP
kW/HP
RPM
RPM
goer
t2|
Ke7tbs
Lb-in
I-5300
0.031/
TeA0,,
5°5/7-4
7.8710.0]
1500
|
6000
}
‘ogg
|
70/154
|
DH-100
I1-6690
0.073/
Teag,,
1714-7
|
18720
|
1800
sooo
|
Oe"
|
108/238
|
DM-150x
(1} totally enclosed air over (TEAO)
BRU-200/BAU-500 Brushless Drives Instruction Manual

Specifications
2.6 Encoder Specifications
Motor Type I-Series S-Series F-Series
Line Count 1000 [1] 2000 [1] 2000 [1]
Supply 5 ¥DC 5 VDC (190mA DC max} 5 VDC (245mA DC max)
Line Driver 26L531 26LS31
[1} standard line count
CAUTION
THE ENCODERS MOUNTED INSIDE THE S-SERIES AND F-SERIES
SYNCHRONOUS MOTORS ARE FACTORY ALIGNED AND MUST
NOT BE MOVED OR IMPROPER OPERATION MAY RESULT.
HOWEVER, THE ENCODERS MOUNTED ON THE I-SERIES
INDUCTION MOTORS MAY BE MECHANICALLY REALIGNED TO
ANY ARBITRARY POSITION IF DESIRED.
2.7 Transformer Specifications
BRU-500
-Rating (kVA) 3.0 6.0 12.0 18.0
Input 208/230 /240 /380/460 /480 VAC RMS (Three Phase)
Output 115/230 VAC RMS (Three Phase)
Ambient Temp. 32° -122° F (0° -50° C}
Weight 86 ibs 135 Ibs 200 Ibs 325 Ibs
(39 kg) (61 kg) (91 kg) (148 kg}
Refer to drawing 9101-0131 and drawing 9101-0132 in Section X for transformer outline drawings and load
regulation data.
BRU-200
Rating(kVA) 3.0
Input 220/230/240/440/460/480 VAC RMS (Singie Phase}
Output 115/230 VAC RMS (Single Phase)
Ambient Temp. 32° -122° F (0° -50° C}
Weight 62 Ibs (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

2.8 Maximum Power Losses
Model
DM-10
DM-20
DM-30
3 KVA Transformer (1 Phase)
DM-25
DM-50
DM-100
DM-150
DM-150X
PSM-50
PSM-125
3 kVA transformer (3 Phase}
6 kVA transformer (3 Phase)
12 kVA transformer (3 Phase)
18 kVA transformer (3 Phase)
specifications
Maximum Watts Loss
50 + dissipative shunt
100 + dissipative shunt
150 + dissipative shunt
350
120
180
275
300
110 + dissipative shunt
240 + dissipative shunt
350
600
950
1200
The maximum power losses are shown to help in sizing a NEMA 12 (or 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*(Q/A) + 1.1
where T is the temperature difference between inside air and outside ambient (° F), Q is heat generated in
enclosure (watts), and A is enclosure surface area (Ft). 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 (height) are in inches.
BRU-200/BRU-500 Brushless Drives Instruction Manual 9

installation
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 chemicais.
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 9101-0409 and 9101-0410 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 modules be located closest to the
power Supply module.
Drawing 9101-1300 shows the BRU-200 drive module dimensions including space requirements 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 (substitution not permitted) are provided with each drive module.
Selection of transformer, line fuses, and wire gauges is covered in drawing 9101-0411. The optional
auxiliary power supply wiring is covered in drawing 9101-0134.
10
BRU-200/BRU-500 Brushiess Drives instruction Manual

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
tumed 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, liné fuses, and wire gauges is covered in drawing 9161-1329,
3.3 Motor Mounting and Wiring
Motor outline drawings for the S-Series, F-Series, and !-Series motors are shown in drawings 9101-0129,
9101-0332, and 9101-0130 respectively.
Some motor mounting considerations are as follows:
1) Bo 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 100°C (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 flat surface. The same mounting restrictions apply
to the External Shunt as to the BRU-200.
Drawing 9101-1328 shows the Extemai 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