Faulhaber 1525 BRC Series, Technical Manual

Page 1: ...WE CREATE MOTION Technical Manual 22xx BX4 S SC 32xx BX4 SC 32xx BX4 SCDC 26xx B SC 1525 BRC 1935 BRC 3153 BRC 2214 BXT H SC 3216 BXT H SC 4221 BXT H SC EN ...

Page 2: ...aber GmbH Co KG cannot accept any liability for any errors in this document or for the consequences of such errors Equally no liability can be accepted for direct or consequential damages resulting from improper use of the equipment The relevant regulations regarding safety engineering and interference suppression as well as the requirements specified in this document are to be noted and followed ...

Page 3: ...2 2 Electrical connection of motor 18 4 2 2 1 EMC compliant installation 18 4 2 2 2 EMC suppressor circuit 18 4 2 2 3 Pin assignment 19 4 2 2 4 Connection examples 22 5 Description of functions 24 5 1 Operating modes 24 5 1 1 Speed controlled operation 24 5 1 1 1 BL motors with digital Hall sensors 24 5 1 1 2 BL motors with analogue Hall sensors 25 5 1 1 3 BL motors without Hall sensors BRC motors...

Page 4: ...less mode only 35 5 4 8 Delayed Current Error only error output 35 5 5 Protective functions 36 5 5 1 I2 t current limitation 36 5 5 2 Overtemperature shutdown 37 5 6 Voltage output at motor 37 6 Commissioning 38 7 Maintenance 40 7 1 Maintenance tasks 40 7 2 Troubleshooting 40 8 Accessories 41 9 Warranty 42 ...

Page 5: ...ssociated documents For certain actions during commissioning and operation of FAULHABER products additional information from the following manuals is useful 1 3 Using this document Read the document carefully before undertaking configuration in particular chapter Safety Retain the document throughout the entire working life of the product Keep the document accessible to the operating and if necess...

Page 6: ...or avoidance Pre requirement for a requested action 1 First step for a requested action Result of a step 2 Second step of a requested action Result of an action Request for a single step action Abbreviation Meaning BRC Brushless DC motor with integrated Electronics EMF Back induced electromotive force EMC Electromagnetic compatibility ESD Electrostatic discharge PWM Pulse Width Modulation SC Speed...

Page 7: ... the manufacturer for information about individual use under special envi ronmental conditions 2 2 Safety instructions NOTICE Electrostatic discharges can damage the electronics Wear conductive work clothes Wear an earthed wristband NOTICE Penetration of foreign objects can damage the electronics Do not open the housing NOTICE Connection and disconnection of cables while the supply voltage is stil...

Page 8: ...served Machinery Directive 2006 42 EC Because of their small size no serious threats to life or physical condition can normally be expected from electric miniature drives Therefore the Machinery Directive does not apply to our products The products described here are not incomplete machines Therefore installation instructions are not normally issued by FAULHABER Low Voltage Directive 2014 35 EU Th...

Page 9: ...ted by means of digital option ally analogue Hall sensors or sensorless by means of the induced countervoltage EMF of the motors model series BRC The resulting lower speed limits are 1000 min 1 sensorless 200 min 1 digital Hall and 50 min 1 analogue Hall Depending on the model series FAULHABER Speed Control Systems SCS can be adapted to the application via the FAULHABER Motion Manager software fro...

Page 10: ...or family Motor nominal voltage 12 V Motor nominal voltage 24 V Shaft diameter 3 mm Shaft diameter 5 mm Motor length 32 mm Motor length 42 mm Motor length 50 mm Motor length 68 mm Motor diameter 22 mm Motor diameter 32 mm SC SCDC BX4 BX4S 12 24 S G 22 32 32 42 50 68 Speed Controller Brushless flat DC micromotor Motor nominal voltage 6 V Motor nominal voltage 12 V Shaft diameter 1 5 mm Motor length...

Page 11: ... diameter 4 mm Motor length 25 mm Motor length 35 mm Motor length 53 mm BRC BRC 6 9 12 15 24 U S K 25 35 53 Motor diameter 15 mm Motor diameter 19 mm Motor diameter 31 mm 15 19 31 SC BX T H 012 024 S W 22 32 14 16 21 BXT H SC G 42 Speed Controller Motor family 14 pin External rotor technology with housing Motor 12 V nominal voltage Motor 24 V nominal voltage Shaft diameter 3 mm Shaft diameter 4 mm...

Page 12: ...0 60 3242G012BX4 SCDC d Digital Hall 400 12 000 c 6 5 30 6 5 30 39 3242G024BX4 SCDC d Digital Hall 400 11 200 6 5 30 6 5 30 45 3268G024BX4 SC Digital Hall 400 6 500 6 5 30 6 5 30 99 Analogue Hall 50 6 500 6 5 30 6 5 30 99 3268G024BX4 SCDC d Digital Hall 400 7 000 6 5 30 6 5 30 60 1525U009BRC Sensorless 1 000 25 000 4 18 1 7 18 1 9 1525U012BRC Sensorless 1 000 25 000 4 18 1 7 18 1 9 1525U015BRC Sen...

Page 13: ...000 6 5 30 6 5 30 92 a The speed range depends on the maximum motor supply voltage b At metal flange c The drive must be reconfigured in order to reach the maximum speed d Option of analogue Hall sensors is not available in this version e Integrated gearhead for details see the product data sheet Motor series Sensors Speed range a Power supply of elec tronics motor V DC Rated torque mNm b ...

Page 14: ...ice in the immediate proximity of the motor Ensure that adequate heat dissipation is provided NOTICE Installation and connection of the motor when the power supply is applied can damage the device Prior to all aspects of installation and connection work on the motor switch off the power supply NOTICE The motor can be damaged if mounted incorrectly Observe the maximum screw in depth of the fastenin...

Page 15: ...tach parts to the motor shaft Tab 2 Attachment specifications Information on the used flange can be found in the product data sheet Motor series Screw type Thread depth mm Max tightening torque Ncm Radial motor load max N 22xx BX4 S SC M2 3 0 50 30 32xx BX4 SC SCDC M3 4 0 120 60 2622 B SC a a Motors of model series 2610 B SC are mounted at fastening points outside the motor diameter using a quad r...

Page 16: ...tions Connect the connections as per the pin assignment see chap 4 2 2 3 p 19 NOTICE Extreme static or dynamic loads on the ribbon cable can cause the cable to be damaged Make sure that the ribbon cable is not subjected to abrasion crushing or excessively tight bending radii during installation and operation With frequent bending the bending radius must not be less than 10 mm The possible number o...

Page 17: ...us tensile load 11 N Bending radius with one off installation 1 2 mm 1525 BRC 1935 BRC 1 00 AWG28 Tensile load 20 N Continuous tensile load 11 N Bending radius with one off installation 1 2 mm 3153 BRC 1 27 AWG26 Tensile load 20 N Continuous tensile load 17 N Bending radius with one off installation 1 2 mm 2214 BXT H SC 1 27 AWG28 Tensile load 30 N Continuous tensile load 17 N Bending radius with ...

Page 18: ...ed directly at the unit with two windings through a suitable ferrite sleeve e g Würth Elektronik No 74270090 4 2 2 2 EMC suppressor circuit Suppressor circuit 1 Fig 7 EMC suppressor circuit with ceramic capacitors If a ceramic capacitor C1 is used in the PWMnsoll operating mode To avoid faults use a signal source with a low internal resistance To update the firmware using the Motion Manager softwa...

Page 19: ... Electronics supply 2 Umot Power supply of the motor 3 GND Common ground 4 Unsoll Control voltage for the set speed see chap 5 2 p 28 5 DIR Switching input for the rotation direction of the motor 6 FG Digital output with open collector and integrated pull up resistor 22 kΩ The digital output can be configured for various tasks see chap 5 3 p 31 Wire Designation Value 1 Up Electronics supply 5 28 V...

Page 20: ...supply 6 5 30 V DC 3 GND Ground 4 Unsoll Analogue input Input voltage Uin 0 10 V Uin 10 V Up speed set value not defined Input resistance Rin 8 9 kΩ Speed set value pro 1 V 1 000 min 1 Uin 0 15 V motor stops Uin 0 3 V motor runs 5 DIR Digital input Rotation direction input To ground or U 0 5 V anticlockwise U 3 V clockwise Input resistance Rin 10 kΩ 6 FG Digital output Frequency output Max Up Imax...

Page 21: ...t Frequency output Max Up Imax 15 mA Open collector with 22 kΩ pull up resistor 6 lines per revolution Wire Designation Value 1 Up Electronics supply 1525 BRC 4 18 V DC 1935 BRC 4 18 V DC 3153 BRC 5 30 V DC 2 Umot Coil supply 1525 BRC 1 7 18 V DC 1935 BRC 1 7 18 V DC 3153 BRC 0 30 V DC 3 GND Ground 4 Unsoll Analogue input Input voltage Uin 0 10 V Uin 10 V Up speed set value not defined Input resis...

Page 22: ...1 S Uin 0 15 V motor stops Uin 0 3 V motor runs 5 DIR Digital input Rotation direction input To ground or U 0 5 V anticlockwise U 3 V clockwise Input resistance Rin 10 kΩ 6 FG Digital output Frequency output Max Up Imax 15 mA Open collector with 22 kΩ pull up resistor 21 lines per revolution Wire Designation Value 1 Up Electronics supply 6 5 30 V DC 2 Umot Coil supply 6 5 30 V DC 3 GND Ground 4 Un...

Page 23: ...where Unsoll 10 V If the digital output is configured as the frequency output see chap 5 3 p 31 the speed signal can be measured at the digital output Motor clockwise SCDC Fig 10 Clockwise rotating motor Mot is connected to the positive pole Mot is connected to the negative pole The motor rotates clockwise at a load dependent speed Motor anticlockwise SCDC Fig 11 Anticlockwise rotating motor Mot i...

Page 24: ...the digital Hall sensors The actual value for speed is determined using the time interval between the edges of the Hall sensor signals DIR Rotationaldirectioninput Evaluation rotational direction Unsoll nsoll 0 10VDC Setpointinput Digitaloutput FG 22 kΩ Electronicssupply Up Motorsupply Umot GND MOSFET Power output stage Protectionfunction Overtemperature Microcontroller PIvelocity controller Speed...

Page 25: ...tion via PWM signal at speed set value input Digital output Frequency output The number of lines per revolution which is output at the fre quency output can be set Possible values are 2 and 6 lines per rev olution Fault output see chap 5 3 p 31 Operating mode Speed controlled Voltage controller 2 quadrant operation with brake func tion The speed is reduced by short circuiting the motor Brake funct...

Page 26: ...ion Set value specification Analogue Digital output Frequency output Operating mode Speed controlled Speed filter Active Designation Explanation Set value specification The following set value specifications can be set see chap 5 2 p 28 Fixed speed mode Speed set value specification via analogue signal Speed set value specification via PWM signal at speed set value input Digital output Frequency o...

Page 27: ... 3Phase PWM block commutator BL Motor PhaseA PhaseB PhaseC Iist RM Motor model kE Depending on the motor stable speed control is possible in this configuration from approx 1 000 min 1 Designation Explanation Motor start The motor start uses algorithms which also enable the motor to start from stationary when the position of the rotor is unknown As a result when the motor starts it can briefly less...

Page 28: ...rated at a certain speed In this case the set speed to be set is fixed using a parameter see chap 5 4 p 32 The following settings for the speed set value input Unsoll are possible Quick stop input low level Motor stop with Unsoll 0 15 V Motor stop with open connection Motor start with Unsoll 0 3 V 0 5 V with BL motors in sensorless operation Quick stop input inverted high level Motor start with Un...

Page 29: ...tion of 10 V corresponds to the value specified in the parameter nsetMax A linear conversion is performed between 0 V and 10 V Speed controlled operation nsoll nsetMax Unsoll 10 V Voltage controller U Umot Unsoll 10 V Depending on the motor type and the applied voltage the set value specified in nset Max cannot be reached In this case the motor rotates at the maximum speed which can be reached at ...

Page 30: ...an be configured as switching levels Tab 13 TTL and PLC level values DIR Rotationaldirectioninput Evaluation rotational direction Unsoll nsoll Setpointinput Digitaloutput FG 22 kΩ Electronicssupply Up Motorsupply Umot GND MOSFET Power output stage Protectionfunction Overtemperature Microcontroller PIvelocity controller Speed calculation Armature position calculation t I tcurrent limitation Ua 3Pha...

Page 31: ...mine the actual motor speed In this exam ple a signal contains 6 lines per motor revolution Fig 17 Signal structure of frequency output T Pulse duration Fig 18 Connection of an additional pull up resistor 1 Not available for BRC motors In order to increase the edge steepness at the digital output an additional external pull up resistor can be connected Observe the maximum load capacity of the digi...

Page 32: ...Value for the briefly permitted maximum current Motor specific mA Motor continuous current Icont Value for the continuous current to which the motor is limited Motor specific mA Motor series Motor continuous current Icont a Peak current Imax a Unit 2232S012BX4 S SC 1 000 2000 mA 2232S024BX4 S SC 500 1 000 mA 2250 BX4 S SCC 900 1800 mA 3242G012BX4 SC 2000 4000 mA 3242G024BX4 SC 1 000 2000 mA 3242G0...

Page 33: ...eter can be adapted using the FAULHABER Motion Manager The specified values apply in the case of 22 C ambient temperature and the nominal voltage for motor and electronics b Parameters can only be changed at the factory Motor series Motor continuous current Icont a Peak current Imax a Unit Parameter Meaning Maximum value Unit Fixed speed NsetFix Speed set value in fixed speed mode 65 535 rpm Param...

Page 34: ... set value input Unsoll Motor specific min 1 Motor series Sensors Maximum speed value nsetMax a a Delivery state The speed range depends on the maximum motor supply voltage Unit 2232 BX4 S SC Digital Hall Analogue Hall 20000 20000 min 1 2250 BX4S SC b b Option of analogue Hall sensors is not available in this version Digital Hall 20000 min 1 2250 BX4 SC Digital Hall Analogue Hall 10000 20000 min 1...

Page 35: ... is used even if other parameters or speed set value specifications would result in a lower speed 5 4 8 Delayed Current Error only error output This parameter is only effective if the digital output has been set as a fault output see chap 5 3 p 31 Activation of the output may be delayed in this case The output is not activated until the time preset by DCE has expired even if the current is already...

Page 36: ...e Continuous current Icont The current is limited to the continuous current if the thermal model calculates a critical temperature Functionality of the I2 t current limitation The functionality of I2 t current limitation is explained below with the aid of an example Fig 19 Example of I2 t current limitation Area I When the motor is started the peak current is preset as the set value at the current...

Page 37: ...tage output at motor The power stage of a motor with Speed Controller uses pulse width modulation PWM In the case of a fixed PWM frequency the duty cycle between the switch on time and switch off time is set according to the controller output value Since in the case of pulse width modulation the inductance of the motor acts as a current filter a high PWM frequency is selected 96 kHz and 24 kHz wit...

Page 38: ...actory The controller can optionally be optimised for specific applications In this case the digital controller operates at a sampling rate of 500 μs Controller optimisation performed when commissioning the motor is described below Motor is mounted as per the specifications see chap 4 p 14 Motor is electrically connected as per the specifications see chap 4 2 2 p 18 Connected mechanical components...

Page 39: ...0 7000 05061 2nd edition 31 03 20207000 05061 Commissioning 39 6 Reduce the controller gain until the system is stable again 7 Repeat steps 2 to 6 for the proportional integral component VI The motor is ready for operation ...

Page 40: ...The motor is generally maintenance free Where the device is mounted in a cabinet depending on the deposition of dust the air filter should be regularly checked and cleaned if necessary 7 2 Troubleshooting If unexpected malfunctions occur during operation according to the intended use please contact your support partner ...

Page 41: ...tact adapter 6501 00112 Programming adapter USB 6501 00096 Details on configuration can be found in the Motion Manager manual see chap 1 2 p 5 Details on the connection sequence can be found in the product data sheet of the pro gramming adapter Information on other accessories can be found in the main catalogue Programming adapter Customer application and power source Contact adapter Drive with Sp...

Page 42: ...Faulhaber GmbH Co KG are produced using the most modern production methods and are subject to strict quality inspections All sales and deliv eries are performed exclusively on the basis of our General Conditions of Sale and Delivery which can be viewed on the FAULHABER home page www faulhaber com gtc and down loaded from it ...

Page 43: ...edition 31 03 2020 Dr Fritz Faulhaber GmbH Co KG DR FRITZ FAULHABER GMBH CO KG Antriebssysteme Daimlerstraße 23 25 71101 Schönaich Germany Tel 49 0 7031 638 0 Fax 49 0 7031 638 100 info faulhaber de www faulhaber com ...