Gilderfluke & Co Br-EFB User manual

Br-EFB
Four Channel Electronic FeedBack Controller v3.1
An actuator is a mechanical device that moves something. It doesn't matter if the
actuator is powered by hydraulics or compressed air, or directly from an electric motor.
Analog closed loop control of actuators is used when you want to create truly lifelike
animatronic effects. The actuator can be commanded to move slowly or quickly, and
can stop repeatably at any point within its range of movement. If a force is applied to
try to move the actuator, it will fight to return to the original position.
The Br-EFB is used to close up to four Position Feedback loops for four
independent actuators. These can be used in animated shows, lighting, motion base
simulators, pneumatic and hydraulic systems, special effects, signs, fountains, and
more.
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 1 of 142

Safety Disclaimer: Any electronic or mechanical
system has a potential to fail. Certain applications using
Gilderfluke & Company equipment may involve
potential risks of death, personal injury, or severe
property, or environmental damage (“Critical
Application”). Gilderfluke & Company equipment is not
designed, intended, authorized, or warranted to be
suitable in life support applications, devices, or
systems, or other critical applications. Inclusion of
Gilderfluke & Company products in such applications is
understood to be fully at the risk of the customer. In
order to minimize risks associated with the customer's
applications, adequate design and operating
safeguards should be provided by the customer to
minimize inherent or procedural hazards.
Gilderfluke & Company assumes no liability for
applications assistance, customer produced design,
software performance, or infringement of patents or
copyrights. Nor does Gilderfluke & Company warrant or
represent that any license, either express, or implied, is
granted under any patent right, copyright, mask work
right, or other intellectual property right of Gilderfluke &
Company covering or relating to any combination,
machine, or process in which Gilderfluke & Company
products or services might be or are used.
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 2 of 142

................................................................................Br-EFB Overview!11
..........................................................................................Closing the Servo Loop!16
..............................................................................................................Compliance!19
.......................................................................Br-EFB Indicator LEDs!21
.........................................................................................'A' Trigger Input LED!21
.........................................................................................'B' Trigger Input LED!22
................................................................................................Error/Status LED!22
.............................................................................External Output Enable LED!24
....................................................................................................Heartbeat LED!24
.............................................................................................Ethernet '100' LED!24
..............................................................................Ethernet 'Link Activity' LED!24
..............................................................Indicator LEDs for each ServoLoop Axis!24
......................................................................................ServoLoop Error LEDs!25
...............................................................ServoLoop Position Feedback LEDs!25
.........................................................ServoLoop Compliance Feedback LEDs!25
..........................................................................ServoValve Output Indicators!26
............................................................................Br-EFB Connectors!27
.......................................................................................................Input Connector!27
............................................................................................'A' Trigger Input!28
............................................................................................'A' Trigger Input!28
............................................................................................'B' Trigger Input!28
............................................................................................'B' Trigger Input!28
......................................................................................Error/Status Output!29
......................................................................................Error/Status Output!29
................................................................................External Output Enable!29
................................................................................External Output Enable!29
.............................................................................................- 'Battery' Input!32
............................................................................................+ 'Battery' Input!32
..................................................................................Power Supply Ground!33
...................................................................Power Supply Positive (24vdc)!33
..............................................................................................DMX-512 Input!33
..............................................................................................DMX-512 'Thru'!33
.................................................................................................RS-422 Input!38
.................................................................................................RS-422 'Thru'!38
........................................................................................................Ethernet!40
........................................Power Supply 2.1mm Barrel connector (24vdc)!40
.............................................µSd/µSdHC/µSdXc Flash Memory Card Slot!41
........................................................................................................Mini USB!41
......................................................................................ServoLoop Error LEDs!41
......................................................Output Connectors for each ServoLoop Axis!42
............................................................................#1: Power Supply Ground!42
..............................................................#2: Negative (-) 10 Volt Reference!43
.......................................................................#3: Position FeedBack Input!43
.................................................................#4: Compliance FeedBack Input!46
...............................................................#5: Positive (+) 10 Volt Reference!46
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 3 of 142

............................................................................#6: 24 vdc Supply Output!47
...............................#7: Negative (-) ServoValve/Motor Controller Output!47
................................#8: Positive (+) ServoValve/Motor Controller Output!47
..................................................................Web-Based Configuration!51
...................................................Web-Based PID Configuration Tab!53
........................................................Minimum Scale (numeric value & slider)!54
........................................................Maximum Scale (numeric value & slider)!55
......Proportional (P) Gain (numeric value, slider & output voltage display)!55
Integral (I) Gain (numeric value, slider, checkbox & output voltage display)!56
Derivative (D) Gain (numeric value, slider, checkbox & output voltage display)!57
..................................................................Tightness (numeric value & slider)!57
Compliance Feedback Gain (numeric value, slider, checkbox & output voltage
...............................................................................................................................display)!58
........................Compliance Feedback Decay Rate (numeric value & slider)!58
..........................................................Jog (numeric value, slider & checkbox)!58
............................................Position Feedback Phase Reversed (checkbox)!58
........................................Compliance Feedback Input Reversed (checkbox)!58
..................................................Auto Jog While Setting Min/Max (checkbox)!59
......................................Position Feedback A/D Voltage Range (DropDown)!59
................................Compliance Feedback A/D Voltage Range (DropDown)!59
...................................................................................Polarity Wizard (Button)!59
...........................................................................................PID Wizard (Button)!59
......................................................................................................Valve Voltage!61
......................................................................................................Ultimate Gain!61
..................................................................................................Ultimate Period!61
..........................................................Web-Based Card Settings Tab!63
......................................................................................First DMX-512 Address!63
....................................................................................................Serial Address!64
........................................................................................Sequencer Enabled x!64
...................................................................................................DMX-512 mode!64
.............................................................DMX-512 Zero-Based or One-Based x!64
..................................................................................................EaseIn Speed x!65
..................................................................................Output to Test & Adjust x!67
...........................................................................................................Test One x!67
.............................................................................................................Test All x!68
.......................................................................................................Jog Output x!68
...................................................................................Set Power-On Defaults x!68
...........................................................................................................Use DHCP!69
.........................................................................................Restrict Subnet Only!69
..........................................................................................................IP Address!69
..............................................................................................................NetMask!69
..................................................................................................Gateway Server!69
..................................................................................JSON messages!71
.................................................Br-EFB Configuration (Text Menus)!79
......................................................................................First DMX-512 Address!81
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 4 of 142

....................................................................................................Serial Address!82
............................................................................................Sequencer Enabled!82
...................................................................................................DMX-512 mode!82
................................................................DMX-512 Zero-Based or One-Based!83
.....................................................................................................EaseIn Speed!83
.....................................................................................Output to Test & Adjust!85
.........................................................................................................Test Output!86
....................................................................................‘Jog’ Outputs to a Value!86
......................................................................................Set Power-On Defaults!86
...........................................Set Minimum, Maximum and ‘Jog’ using Keypad!87
.......................................................................................Set Analog Endpoints!90
.....................................................................................................................Next!90
.....................................................................................................................Last!91
...............................................................................................................More….!91
.................................................................................................................Info….!91
..................................................................................................Reload Defaults!95
............................................................................................................Play/Loop!95
......................................................................................................................Halt!95
...................................................................................................................Verify!95
......................................................................................................................eXit!96
..........................................Br-EFB PID Configuration (Text Menus)!97
......................................................................................................Axis Enabled!98
.........................................................................................proportional (P) gain!98
.............................................................................................set Integral (I) gain!99
.......................................................................................set Derivative (D) gain!99
..........................................................................................Limit Valve Voltage!100
.........................................................................................reverse Axis Output!100
........................................................................................compliance Settings!101
....................................................................................................Error Options!101
...............................................................................................A/D Input Range!101
..................................................................................PID Adjustment Wizards!101
...............................................................................................................More...!101
...................................................................................Output to Test & Adjust!101
.......................................................................................................Test Output!101
...................................................................................................................Next!101
...................................................................................................................Last!101
................................................................................................................Info….!101
................................................................................................Reload Defaults!101
..........................................................................................................Play/Loop!101
....................................................................................................................Halt!101
.................................................................................................................Verify!102
....................................................................................................................eXit!102
..................................................Br-EFB PID Wizards (Text Menus)!103
............................................................................................Set Input Voltages!104
.................................................................................................Polarity Wizard!104
........................................................................................................PID Wizard!104
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 5 of 142

..............................................................................Set Min/Max/Jog w/keypad!104
...............................................................................................................More...!104
...................................................................................Output to Test & Adjust!104
.......................................................................................................Test Output!105
...................................................................................................................Next!105
...................................................................................................................Last!105
................................................................................................................Info….!105
................................................................................................Reload Defaults!105
..........................................................................................................Play/Loop!105
....................................................................................................................Halt!105
.................................................................................................................Verify!105
....................................................................................................................eXit!105
.............................................Br-EFB Polarity Wizard (Text Menus)!107
.........................................................................................Run Polarity Wizard!110
...............................................................................................................More...!110
...................................................................................Output to Test & Adjust!110
.......................................................................................................Test Output!110
...................................................................................................................Next!110
...................................................................................................................Last!110
................................................................................................................Info….!110
................................................................................................Reload Defaults!111
..........................................................................................................Play/Loop!111
....................................................................................................................Halt!111
.................................................................................................................Verify!111
....................................................................................................................eXit!111
....................................................Br-EFB PID Wizard (Text Menus)!113
.....................................................................................................'P' Gain only!115
.....................................................................................................'P' & 'I' Gains!115
..............................................................................................'P', 'I' & 'D' Gains!116
.........................................................................................Increase 'Tightness'!116
...........................................................................................Reduce 'Tightness'!116
................................................................................................Run PID Wizard!116
...............................................................................................................More...!116
...................................................................................Output to Test & Adjust!116
.......................................................................................................Test Output!116
...................................................................................................................Next!116
...................................................................................................................Last!116
................................................................................................................Info….!116
................................................................................................Reload Defaults!116
..........................................................................................................Play/Loop!116
....................................................................................................................Halt!116
.................................................................................................................Verify!116
....................................................................................................................eXit!116
...................................Br-EFB Compliance Settings (Text Menus)!117
...........................................................................Compliance Feedback Gain!118
..................................................................................Compliance Decay Rate!118
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 6 of 142

..........................................................Compliance Feedback Input Reversed!118
.................................................................................Compliance Input Range!118
...............................................................................................................More...!118
...................................................................................Output to Test & Adjust!118
.......................................................................................................Test Output!118
...................................................................................................................Next!118
...................................................................................................................Last!118
................................................................................................................Info….!118
................................................................................................Reload Defaults!119
..........................................................................................................Play/Loop!119
....................................................................................................................Halt!119
.................................................................................................................Verify!119
....................................................................................................................eXit!119
.............................Br-EFB Following Error Settings (Text Menus)!120
..............................................................................Following Error Threshold!121
...........................................................................................Soft Error Timeout!121
..........................................................................................Hard Error Timeout!122
...............................................................................................................More...!122
...................................................................................Output to Test & Adjust!122
.......................................................................................................Test Output!122
...................................................................................................................Next!122
...................................................................................................................Last!122
................................................................................................................Info….!122
................................................................................................Reload Defaults!122
..........................................................................................................Play/Loop!122
....................................................................................................................Halt!122
.................................................................................................................Verify!122
....................................................................................................................eXit!122
..............................................Br-EFB Network Config (Text Menu)!123
..................................................................................................DHCP enabled!124
.......................................................................................Restrict Subnet Only!124
........................................................................................................IP Address!124
............................................................................................................NetMask!124
................................................................................................Gateway Server!124
.......................................................................................................Time Server!124
...................................................................................Output to Test & Adjust!124
.......................................................................................................Test Output!124
...............................................................................................................More...!124
...................................................................................................................Next!124
...................................................................................................................Last!124
................................................................................................................Info….!124
................................................................................................Reload Defaults!124
..........................................................................................................Play/Loop!124
....................................................................................................................Halt!124
.................................................................................................................Verify!125
....................................................................................................................eXit!125
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 7 of 142

........................................Optically Isolated Trigger Input Actions!127
............................................................................................................not used!128
........................................................................................................Start Show!128
........................................................................................................Stop Show!128
.......................................................................................................Stop At End!128
......................................................................................................Pause Show!128
.................................................................................................Continue Show!129
.....................................................................................................E-stop Show!129
......................................................................................................Clear E-stop!129
.......................................................................................Sequential From List!130
...........................................................................................Random From List!130
...................................................................................................Reshuffle List!131
.....................................................................................................Analog Limit!131
..........................................................................................................Binary Bit!132
..................................................Ethernet & Serial Port Commands!133
............................................................................................Echo Commands:!134
.......................................................................................................Card Reset:!134
......................................................................................................Card Status:!135
.............................................................................................Start Commands:!136
.............................................................................................Stop Commands:!136
............................................................................................Loop Commands:!137
.................................................................................Stop at End Commands:!137
................................................................................Select Show Commands:!137
................................................................................Show Pause Commands:!138
.....................................................Br-EFB Dimensions & Mounting!139
.........................................................!!!! Br-EFB Firmware Updates!141
.........................................HEXadecimal to Decimal to Percentage!142
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 8 of 142

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Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 9 of 142

Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 10 of 142
A note about this manual:
This manual covers the specifics of the Br-EFB. To
program the Br-EFB you will also want to refer to the
PC•MACs manual sections that cover the PC•MACs
software.
The Br-EFB is typically programmed in ‘Software-only’
or ‘Hardwareless RealTime’ mode. If you are using the
USB-DMX for programming your Br-EFB through the
DMX-512 inputs, please refer to the PC•MACs ‘Unlimited’
mode.
The full PC•MACs manual can be downloaded from our
web site at:
http://www.gilderfluke.com

Br-EFB Overview
The Br-EFB is effectively the combination of a DAC-Quad and analog PID-quad
board. Since it is an all-digital board, there are no potentiometers to adjust, and the
PID loop is much more 'intelligent'. It is able to adjust itself, sense error conditions and
compensate for changing loads.
Like most other GilderGear, the Br-EFB can be run as a stand-alone controller, or
networked together with other GilderGear and third party gear as either a DMX-512
'Master' to control hundreds of other actuators, lighting and effects, or as a DMX-512
'slave' to be among the controlled.
The Br-EFB has separate terminals for a full 512 channel universe of DMX-512 in
and 'thru' for daisy changing multiple Br-EFBs and other gear together using standard
CAT5 (or better) ethernet cables. The pinout of these connectors follows the USITT
standard. As with all GilderGear, checksums can be embedded in the DMX-512 data
to keep the Br-EFB, (or the gear that it is controlling through the DMX-512 output),
from updating on any DMX-512 packets that contain corrupted data.
For storing shows, the Br-EFB uses any micro Sd, micro SdHC or micro SdXC
flash cards. These can potentially hold years worth of shows!
Shows can be started using the two 'trigger' inputs, the USB port, the ethernet port,
or the RS-422 serial port. Shows can also be set to start playing when the Br-EFB is
powered up.
The Br-EFB keeps log and configuration files on the µSd card, so even if you don't
need to store show date, you should always have a µSd card inserted into the Br-EFB.
If you ever need to replace a Br-EFB with a new one, transferring the µSd card from
the old unit to the new one will transfer all the shows and settings to the new Br-EFB.
No additional configuration or adjustments should be needed.
For triggering shows and other actions, there are two optically isolated
non-polarized 'trigger' inputs imaginatively labeled 'A' and 'B'. These will accept any
DC voltage between 5 vdc and 24 vdc. Because they are non-polarized, you can't wire
them backwards. Either way you apply the voltage, they will accept it. What you want
these inputs to do is configured when you are saving the AutoDownload file that holds
the show data. Different actions can be configured for the 'closing' edge (when a
voltage is applied to the trigger input) or the 'opening' edge (when voltage stops
flowing through the trigger input).
There is also third optically isolated 'External Output Enable' input. Until 5 vdc to 24
vdc is applied to this terminal, all four servo loops are disabled, and the 'valve' outputs
are physically connected through electromechanical relays to the Br-EFB's 'battery'
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 11 of 142

terminals. If desired, a small voltage applied to the 'battery' terminals from an
uninterruptible power supply can be used to bias the ServoValves/Motor Controllers
(or VFDs) towards the 'home' positions. This allows the Br-EFB to safely return a
motion base or other device to the load/unload position, even in a complete power
failure. The 'Enable' input can also trigger a show, E-Stop, or anything else that the
normal trigger inputs can do. This allows the Br-EFBs to call up a video or audio cue,
ramp up the lights, or whatever you want it to do. In many applications, the 'Enable'
input can be wired right into the E-Stop safety loop. Any 'opening' in the E-Stop loop
(an E-Stop switch being hit, a wire break, etc.) will send the actuators for 'home, ramp
u the lights, and play the appropriate Audio/Video files.
For each of the four ServoLoops, there is:
•One sixteen bit resolution +/-10vdc analog output for connecting the
ServoValves/Motor Controllers These are updated at over 100 times each
second.
•One sixteen bit resolution Analog input for the actuator position feedback.
These are sampled at approximately 100,000 times each second.
•One sixteen bit resolution Analog input for an optional Compliance
Feedback sensor Also sampled at approximately 100,000 times each
second.
•One ground connection to supply power or a 'ground' reference to the
ServoValves/Motor Controllers and sensors (if needed)
•One 24 vdc connection (PTC fused for 1.1 amp) to supply power to the
ServoValves/Motor Controllers and sensors (if needed)
•One +10 vdc reference for use with potentiometer position feedback
sensors. The potentiometer can be referenced either from the -10 vdc and
the +10 vdc reference for a +/-10 vdc swing on the wiper (preferred), or
between ground and the +10 vdc reference for a 0 to 10 vdc swing on the
wiper.
•One -10 vdc reference for use with potentiometer position feedback
sensors.
Both analog inputs can be individually set to accept +/10 volts, 0-10 volts, +/-5 volts
or 0-5 volts. This can be set in the configuration to match whatever voltages your
Position Feedback and Compliance Feedback sensors will be outputting. The analog
inputs use sixteen bit resolution analog to digital converters (ADCs), and are
oversampled at 100,000Hz to reduce noise in the Position Feedback signals.
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 12 of 142

To talk to a local or remote computer, you can use the Rs-422 serial port, mini USB
port or Ethernet port.
The Rs-422 serial port has both a 'input' and 'thru' ports, to allow multiple Rs-422
port devices to be easily daisy chained together into a simple serial network using
simple Rj-12 cables. Each individual device on the
network is given a unique eight bit address, so
you can have up to 256 devices on each
network. This Rs-422 port is completely
compatible with the Rs-422 ports found on the
Br-Brain4, Br-ANA, Br-ZBR and other
GilderGear.
The mini USB port can be used to plug a
computer into the Br-EFB. If the computer
has the appropriate drivers installed, its
operating system will open the USB port
and begin communicating with it. The
Br-EFB will then appear as a 'COM' port to
the PC, and can be accessed using GilderTerm or any
other serial terminal software.
!!!! The ethernet port can be used to communicate with the Br-EFB
using simple !!!! formatted text data, or by using the built-in web server and just about
any web browser on your PC, tablet or smartphone.
The Br-EFBs are designed to be used as stand-alone show controllers, as a
‘master’ sending data to other devices that act as ‘slaves’ on a DMX-512 network, or
as ‘slaves’ themselves, receiving DMX-512 data from a ‘master’ elsewhere on the
DMX-512 network:
1) Br-EFB running standalone or acting as a ‘Master’: In this mode of
operation, data for the outputs is stored in the standard micro Sd, SdHC or
SdXc flash cards as Gilderfluke & Co. AutoDownload files.
When being running as a standalone controller or as a ‘master’, an
Br-EFB acts just like any other Gilderfluke & Co. Brick, playing animation
data from the micro Sd card. The Br-EFB can be set to start and play a
show at power up, or only play when triggered to do so. The start trigger
can come through the two optically isolated trigger inputs, the Rs-422
serial port, the mini USB port, or the Ethernet port. The Br-EFB then uses
the show data stored in the Flash Memory to update its outputs and the
DMX-512 network at the appropriate frame rate.
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 13 of 142

!Multiple Br-EFBs (and other GilderGear) can be triggered
simultaneously, but this is not generally recommended as a way to
synchronize multiple units.
The far better way of
synchronizing is by sending
data stored on the
designated ‘master’ to all
the ‘slaves’ attached to a
DMX-512 network.
2) Br-EFB as a ‘Slave’: In this
mode the Br-EFB receives
data from and external
source and uses this data
to update its outputs. Data
can come from:
a) RealTime serial updates
f r o m a P c • M A C s
programming system
through the serial port.
Up to sixteen eight-bit
wide channels of
animation control data can be received through the serial port at 9600
baud. The Br-EFB can be addressed to use any address from 1 to 16
for RealTime serial data.
b) DMX-512 data from a Pc•MACs programming system (or any other
source of DMX-512). Up to 512 eight-bit wide channels of animation
control data can be received through the DMX-512 port. The Br-EFB
can be addressed to use any DMX-512 address from 1-512. The
DMX-512 input allows the Br-EFB to be used as a permanent ‘slave’ as
a part of a larger Control System. If the incoming DMX-512 contains
GilderChecksums, the Br-EFB will automatically update only on valid
data packets.
The animation sequence which is to be used on the Br-EFB is generated on a
PC•MACs Animation Control System. During programming, the DMX-512 or serial port
RealTime updates can be used so that you can see the animation sequence as it is
programmed. Once programming is completed and your show(s) are saved to disk,
the data is downloaded to the µSd/µSdHC/µSdXc flash card onboard the Br-EFB. It is
generally much faster and easier to save the completed shows’ AutoDownload file to
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 14 of 142

your computer’s hard drive, then drag-n-drop the AutoDownload file onto the
µSd/µSdHC/µSdXc flash card which is then plugged into the Br-EFB. You may choose
to also include the .SET, .SHO, .STE and other files on the flash card as well, but the
only file the Br-EFB actually reads is the AutoDownload (.A00) file.
The Br-EFB supports position resolutions commands of eight, twelve, sixteen,
twenty-four or thirty-two bits of resolution. Internally, the ADCs and DACs in the
Br-EFB use 16 bits of resolution, so going beyond sixteen bits of resolution in your
show data can be done, but it won't actually benefit the resolution of the movement.
!!!! The analog and PCM outputs of the Br-EFB are oversampled for ultra-smooth
outputs, typically to ??? times the current frame rate. This means that even with eight
bit resolution data arriving at 30 FPS, the outputs will have four sub-frame outputs at
16 bit resolution at 120 Hz between each full frame of data that arrives.
All 512 channels of data are transmitted through the DMX-512 output on an
Br-EFB. The DMX-512 output can be used to control other GilderGear, light dimmers,
automated spotlights, color changers, fog and wind machines, or any other pieces of
equipment which will accept standard DMX-512. If there are less than 512 channels of
data in the shows, channels past the last channel are sent as ‘zeros’.
If you are transmitting DMX-512 data with GilderChecksums, you will want to avoid
addressing dimmers and other devices to the same addresses that are used for the
checksums (257, 258, 511 and 512). If you must use the addresses occupied by one
pair of checksums, the other can still be used. It is best to reuse the lower pair so that
you still retain protection across the whole universe. The lower pair of checksums will
not protect against data errors in DMX-512 channels 257 through 512, whereas the
upper checksums will protect the entire universe from data errors.
The Br-EFB can be mounted on standard 2-¾” Augat snap track, on DIN rails
(using a pair of the DIN-Adapt blocks), using screws through the provided mounting
holes, or simply velcro’d to whatever they are controlling. Rack mounting is normally
accomplished using a DIN rail mounted to a 2U (3.5”) tall ‘top hat’ plate, and then
using the DIN-Adapt blocks on the backs of the units.
The power requirements for Br-EFBs is 24 VDC. This is needed to allow some
‘head room’ for the analog circuitry to output the 0-10 volt levels. The actual current
requirements are determined by the loads attached to the unit (up to 50 ma. per
output). The Br-EFB itself draws just xx ma..
Customized front panel artwork is available on all GilderGear, including the Br-EFB.
These can be custom branded, or labeled for specific installation names. Please
contact the Gilderfluke & Company factory for details on generating custom Br-EFB
labels.
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 15 of 142

Closing the Servo Loop
Closed loop analog control of an actuator requires:
•An 'Electronic FeedBack Controller’ (EFB) is used for closing a ServoLoop.
The Br-EFB will simultaneously close four ServoLoops.
•An analog ServoValve must be used for pneumatic or hydraulic actuators.
For electronic actuators, a Brushless DC (BLDC) driver (for small three
phase DC motors) or Variable Frequency Drive (VFD) (for larger 3 phase AC
motors) is used in place of the ServoValve. In either case, it must be
capable of bidirectional control of the actuator/motor. The most common
command signal for these is +/-10 VDC. The positive or negative polarity
controls the direction or the movement, and the further away from zero, the
more the ServoValve/Motor Controller opens.
•A Position Feedback sensor. This can be a simple potentiometer or a more
complex electronic device like (the unfortunately named) 'Sick' sensors. The
position sensor can be built into the actuator, or mounted on its outside.
The EFB controller’s main job is to compare the requested actuator position (from
an external show control
system, or from the
AutoDownload file on the
Br-EFB's µSd flash card)
with the actual position of the
actuator (as measured by
the position sensor). The
EFB Controller will then
open or close the
ServoValve/Motor Controller
a little or a lot (as needed) to
send the actuator towards
the requested position.
One of the unique features
of the Br-EFB is that it can
a d j u s t i t s e l f i n m a n y
applications. Once it has
done the initial adjustments
for an actuator, the Br-EFB
can divide the stroke of the
actuator into many small segments, and then continuously adjust the settings for each
ServoValve
(+/- 10
vdc Input)
Actuator
(Pneumatic or Hydraulic Cylinder)
Electronic
FeedBack
Controller
(EFB)
Position Sensor
'Position'
Command
+/- 10vdc
Command to
ServoValve
'Current'
Position
Pressure
In
Exhaust
Out
RetractExtend
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 16 of 142

of these segments individually. This allows the Br-EFB to control uneven loads, or
unbalanced loads that go over fulcrum. Even if the load changes over time (the
actuator bore gets smoother, the hydraulic fluid gets thinner as it gets hotter, or the
motion base is loaded with a bunch of 300 pound football players), the Br-EFB can
compensate for this.
The Br-EFB can be set up
over ethernet using its built in
web server and just about any
browser on any tablet,
smartphone or computer. You
can also use its textual menu
a n d G i l d e r Te r m , e i t h e r
through an TCP connection
over ethernet, or through the
networkable Rs-422 serial
port.
You can configure the
Br-EFB using the PID Setup
Wizard or manually. The first
thing you need to tell the
Br-EFB is the range of voltage
expected on the position and
Compliance Feedback inputs
for the axis. Set these to
match the expected outputs
from your position and Compliance Feedback sensors. If you are using
potentiometers, you will probably be using the Br-EFB's +/10 vdc reference outputs,
and will set the inputs to match.
The next step is to tell the Br-EFB where the ends of the actuator's travel are
located. If the actuator can safely be moved to both its mechanical stops, then the
Br-EFB can find the endpoints for you. The Br-EFB will then back off slightly to set the
normal range of movement to just short of the ends of the actuator. Otherwise, you
can use the web menu to ‘Jog’ the actuator to where you want to place each end of
the actuator's stroke, and then lock them in. Once the endpoints have been set, the
Br-EFB will do its best to keep the actuator within this range of movement.
As you are setting the endpoints, the Br-EFB is detecting the 'phase' of the actuator
and Position Feedback hardware, and automatically correcting for any phase-flipped
wires or hoses.
VFD
or
BLDC
Motor Driver
Actuator
(Linear or Rotary Electric Motor)
Electronic
FeedBack
Controller
(EFB)
Position Sensor
+/- 10vdc
Command to
Motor Drive
Motor
Power
'Position'
Command 'Current'
Position
RetractExtend
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 17 of 142

At this point, you can manually set the 'Positional' ('P'), Integral ('I') and 'Derivative
(D)' ('D') gains for the axis, or let the Br-EFB do this for you.
If you opt for the automatic tuning, the Br-EFB will move the actuator to roughly
mid-stroke, and perform a series of short movements at gradually increasing speeds.
If it was successful, the Br-EFB will set the P, I and D to the optimal settings for the
actuator. Since you don't always want the axis too stiff, a slider lets you select
between a soft and hard tune for the actuator.
If the Br-EFB is unsuccessful in automatically setting the PID, you will need to
manually adjust these settings as needed.
The next step is to enable the continuous automatic tuning, if desired. This also
uses the setting for the tuning 'tightness', so it doesn't over tune the actuator over
time.
If Compliance Feedback is to be used, it is enabled and adjusted 'to taste'. Each
axis has a 'Gain' and 'Decay' setting. These set how much of an effect the Compliance
Feedback has on the actuator, and how long this effect lasts.
The plumbing for a closed loop actuator is not complicated. Air or hydraulic
pressure comes into the ServoValve and two hoses connect the ServoValve to the
actuator. The position feedback and command input go into the EFB controller. After
comparing the Command and Actuator positions, the EFB controller sends the
command voltages that are used to open and close the ServoValve as needed
(typically +/-10 vdc).
The speed of an electric actuator is set by the voltage for the actuator's motor (if the
actuator runs from DC current), or frequency of the current (if the actuator runs from
AC current).
A Brushless DC (BLDC) controller or Variable Frequency Drive (VFD) can be used
to control the speed and direction of motors by controlling the frequency of the current
the motor receives. BLDC motors are typically used to control motors from a DC
power source (they are what make electric cars go), while VFDs are used to run
motors from an AC 'mains' source (they are what make elevators go up and down).
To control an electric actuator, the ServoValve is simply replaced by a VFD or
BLDC controller. that accepts the +/-10 vdc as the speed and direction command.
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 18 of 142

Compliance
Compliance Feedback is a technique that was first proposed in several scientific
papers as a way to make pneumatic actuators 'stiffer' (more like hydraulic actuators),
and to make hydraulic actuators 'spongier' (more like pneumatic actuators).
It was first seen in experimental animatronics that were built for Disney by the late
Dr. Stephen Jacobsen of The University of Utah and Sarcos. These later evolved into
the S-100 series of animatronics at Disney.
The Gilderfluke & Co. Br-EFB controller has been designed with Compliance
Feedback inputs available on all four of its axis.
Compliance Feedback has the unusual effect of making an analog movement both
'softer' and 'stiffer' at the same time.
To accomplish these two seemingly contradictory effects, a compliant actuator
needs a strain gauge or differential pressure sensor to 'feel' the force being applied by
the actuator.
A strain gauge works best, but must be built into the figure. A differential pressure
sensor will have a slight 'lag',
but is far less expensive and
is easily mounted on or near
the ServoValve.
Other than the addition of a
differential pressure sensor or
strain gauge, a compliant
actuator is plumbed just like
any other closed-loop
actuator.
Even if it is strong enough
to throw you across the room,
as you push on a compliant
actuator, the force on the
cylinder will be sensed by the
differential pressure sensor or
s t r a i n g a u g e . T h e E F B
controller will open the
ServoValve/Motor Controller
to move the actuator out of
your way. This makes it seem like the movement is 'softer', but the effect is only
Optional
'Compliance'
Strain
Gauge
Actuator
(Pneumatic or Hydraulic Cylinder)
ServoValve
(+/- 10
vdc Input)
Actuator
(Pneumatic or Hydraulic Cylinder)
Electronic
FeedBack
Controller
(EFB)
Position Sensor
'Position'
Command
+/- 10vdc
Command to
ServoValve
'Current'
Position
Pressure
In
Exhaust
Out
RetractExtend
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 19 of 142

temporary. If you continue holding the actuator in a displaced position, it will soon
begin to fight you to move the actuator back to the original position using all its
strength.
If any actuator in a compliant figure is moved, the other actuators will feel the
changes in their loads and
move in sympathy. This
makes for a much more
'lifelike' animatronic.
If you tell a compliant
actuator to start moving
sharply, the acceleration
inertia of the actuator will be
s e n s e d , a n d t h e E F B
controller will open the
ServoValve/Motor Controller
more than just the positional
error would have caused.
This accelerates the actuator
more quickly.
Conversely, when the
actuator is stopped abruptly,
the deceleration inertia is
sensed, and this can cause
t h e S e r v o Va l v e / M o t o r
Controller to close, or even open the ServoValve/Motor Controller in the reverse
direction to provide active braking to the actuator.
The net result is that the actuator will move when you push on it, making it seem
'softer', but can accelerate and decelerate more quickly than a non-compliant actuator
making it seem 'stiffer'.
Optional
'Compliance'
Differential
Pressure Sensor
ServoValve
(+/- 10
vdc Input)
Actuator
(Pneumatic or Hydraulic Cylinder)
Electronic
FeedBack
Controller
(EFB)
Position Sensor
'Position'
Command
+/- 10vdc
Command to
ServoValve
'Current'
Position
Pressure
In
Exhaust
Out
RetractExtend
Gilderfluke & Co.• 205 South Flower Street • Burbank, California 91502 • 818/840-9484 • 800/776-5972 • fax [phone]
Br-EFB Manual / May 22, 2018 3:28 PM / page 20 of 142