Bravo drive
Contents
1. pam pa E aw die me ee FY x duoa H iaaa zg D ct i CA i ee a ToT wa W er unn Wad vl N GE anaes vim Ae W S k It EE Een ES a ir mano d PE Ga van ane O tno uk JP Ap 7 MiniBravo Service Manual 312. The drive has the internal zero signal connected with the negative power consequently Don t use auto transformers The factory reccomends using transformers with the secondary winding that must be delta triangle connected VOLTAGE The primary voltage depends on the available net voltage The secondary voltage will be calculated according to the motor s characteristics and according to the voltage drive range The value will be V1 ac Vmotor 0 9 x 1 36 9 Service Manual MiniBravo Installation The factory suggests keeping a margin by choosing AC voltage to avoid too high voltage during the deceleration phases of the motor this value is 60 VDC 44 VAC Max value is 80Vdc and minimum value is 22 Vdc The power rating of the transformer is calculated in accordance with the total power SUM of all single motors used P VA Power absorbed servomotor 1 power abs servomotor 2 etc Notice lf multiaxis application is required the transformer power rating may be reduced by 30 respecting the original equation REF the filter capacitor the factory reccomends one with a working voltage of at least 100 Vdc The appropriate value may be find with the follow equation C mF P VA trasfo x 2000 V2 V2 DC voltage on the terminals capacitor without load The capacitor serves to filter the voltage from the bridge and recover the energy during the motors deceleration phases Service Manual MiniBravo 10 In
3. dynamic constant CKR and RKV must be inserted on the personalization socket PI loop gain S7 Normally open If closed enable the armature feedback See chapter 6 6 Service Manual MiniBravo 6 Adjustments 2 3 Potentiometer adjustment ACC U The solder bridges S2 S4 allow ACC insertion of the acc dec function VEL ramp With this potentiometer we ou can adjust the slope of the ramp in KV acceleration and deceleration DER Turning the potentiometer clockwise cw increases the ramp time from 0 1 to 1 Sec with 10 V reference It is also possible to increase more i this time by opening solder bridge ars ps S3 and inserting resistance RP 2 on the socket See chapter ADJUSTMENT VEL Speed potentiometer Turn the potentiometer clockwise cw to increase the maximum speed and anti clockwise ccw to reduce the maximum speed The range of the adjustment is 20 BIL Offset adjustment Adjust this potentiometer to cancel any offset in the external speed ref signal Max ref compensation 200mV KV With this adjustment we can improve the dynamic behaviour of the servomotor With a clockwise turn cw we increase the gain of the PI speed stage therefore improving the response DER Turn the potentiometer clocwise cw to increase the derivative effect reducing the amount of overshoot in the system response 7 Service Manual MiniBravo Diagnostics 3 1 LED indi
4. screen must be connected to 0 S of the drive with only one cable That cable connects the tacho screen to the isolated bar in the electrical box Service Manual MiniBravo 12 Installation Connections continued B This drawing shows an example with an application to connect the differential speed ref from CNC The connections are the same as explained in A C Applying a resistive load a current limitation comes from the drive when contact 1 is closed If we insert a potentiometer with a value of 470 Kohm connected as rheostat the current may be reduced from 95 to zero lt 29 oro Kee ee eene DDD 24 ext g CND RELE Rx L 470K 13 Service Manual MiniBravo Installation Power connection D The outputs M and M may be connected directly to the motor terminals When a motor has an inductance value less than 0 7 0 8 mH a choke is required connect in series so the form factor is improved This avoids overheating the servomotor Service Manual MiniBravo 14 Installation 4 3 Preliminary checks Check that all of the terminals are properly fixed in according with the motor polarity and tacho polarity so the motor runs clockwise cw with positive speed reference Check that the correct val
5. short circuit between the motor terminals or the motor winding is connected to ground Switch off the system and check by instrument the insulation 4 During the motor s deceleration phase the green OK LED switch goes off The voltage has exceeded the max value accepted Check the value of the filter capacitor See the chapter on power supply 5 During normal operation the S T red LED is on and the motor stops Enviroment temperature to high more than 40 C 0 F Ventilate if necessary 25 Service Manual MiniBravo Options 8 1 Options available External choke When a motor has an inductance value less than 0 7 0 8 mH it is necessary to use an external choke connected in series Thereby improving the form factor and avoiding overheating the motor N B The two cables between the drive and the choke are a source of noise consequently they should be kept as short as possible DESCRIPTION Encoder feedback board Single phase bridge 35A 600V Filter capacitor 10000mF 100V Filter capacitor 4700mF 100V etc Service Manual MiniBravo 26 Options and accessories 8 2 Encoder feedback option The encoder feedback board 5 002 0 is an option of the MiniBravo drive This card allows you to adjust the motor speed using a signal coming from an encoder with two channels This solution saves the use of a tachogenerator using the same signal requested for the position control The perform
6. The MiniBravo amplifier series is distributed with the CE mark because they are in accordance with the European Directives on EMC and Low Voltage CE WARNING ELECTRICAL AND CONTROL EQUIPMENT CAN BE DANGEROUS IF HANDLED IMPROPERLY This manual describes the mechanical and electrical characterists of the MiniBravo series It is important that the installation procedures are only performed by qualified personnel in accordance with local safety guidelines Whoever installs the equipment must follow all of the technical instructions printed in this manual For more information please contact Global Motion T echnologies technical department All rights reserved Reproduction in whole or in part is prohibited without prior written consent of the copyright owner All specifications are subject to change without prior notice Service Manual MiniBravo Ver MB gb 05 00 Index 1 Description 1 1 Introduction 1 2 Technical features 1 3 Inputs and outputs 1 4 Drive dimensions 2 Adjustments 2 1 Personalizations and settings 2 2 Solder bridges 2 3 Potentiometer adjustments 3 Diagnostic 3 1 L E D indicators 4 Installation 4 1 Power supply rating 4 2 Connections 4 3 Preliminary checks 5 Commissioning 5 1 Initial start up 6 Setting up the drive 6 1 Speed adjustment with tacho feedback 6 2 Nominal current adjustment 6 3 Peak current adjustment 6 4 Offset adjustment 6 5 Ramp time adjustment 6 6 Adjustment wi
7. anceof the drive at low speeds are improved with the high encoder resolution It is reccomended that you use an encoder with resolution of at least 500 imp rev An auxiliary power supply 5 V or 12 V is avalaible to supply the encoder Don t exceed the load declared If the encoder s absorption is unknown please check it by a milliamperometer connected in series to Vs If the value is higher please use an external power supply 27 Service Manual MiniBravo Options and accessories To insert the encoder board into the MiniBravo follow these procedures Take off the cover and remove the R screw Insert the S stand off in the R hole Mount the encoder card 5 002 0 inserting the pin strip into the MiniBravo Now replace the R screw and affix the card If not specified the MiniBravo with encoder feedback is supplied adjusted to 25Khz Tecnical specification Encoder inputs Push Pull Line driver Open C Power supply levels From OV to 5 min OV to 24V max Max frequency 200 Khz Encoder power supply S2 Close Vs 5V Max 85 mA S2 Open Vs 12V Max 100 mA Operating temperature 0 40C Terminals description Description Pin out Encoder power supply 5 12V Output GND Power supply Output Input channel A encoder Input Input channel B encoder Input Solder bridge description Code Description Standard Insert internal res pull up Open Si 2 Select value Power supply Close 8 Insert internal res pull u
8. cators U 8 Four LEDs are available onthe drive OK jai and they signify the following IN e L1 GREEN OK Normally ON ST S signifying proper operation of the OC ja drive When the LED is OFF it indicates that at least one of the drive protection H functions is active 1 3 Le Ee L2 RED IN Normally OFF it is lit when it exceeds the programmed value Reversible alarm L3 RED ST Normally OFF it represents overheating of the heatsink drive This fault provokes the activation and memorization of the alarm To reset it is necessary that you turn off the power supply wait until the heatsink temperature is lower and then re start the power supply L4 RED OC Normally OFF May come ON because of a short circuit between motor terminals or come to ground It can t be reset and the fault provokes the memorization of the alarm Switch off the system eliminate the cause and then re start the power supply Service Manual MiniBravo 8 Installation 4 1 Power supply rating WARNING Use the following scheme and equation shown below to calculate the power supply rating The drive doesn t need auxiliary voltage al of the voltages requested come from an internal flyback A single or three phase transformer may be able to supply one or more drives Fl F2 AT Ra E ch Ke RS I l pi O SR fe RETE AC A Transformer A sch
9. ents are 20 6 2 Nominal current adjustment The drive is pre set for nominal sized current RIN free To reduce this value in accordance with the servomotor s characteristics it is necessary to mount a resistance RIN in the socket see fig 1 A table with the correspondence current resistor is reported below current express in A 18 82 47 33 22 18 12 1 Of Service Manual MiniBravo 18 Seiting up the drive 6 3 Peak current adjustment To reduce the value of peak current it s necessary to mount RIP on the socket see fig 1 located inside of the drive Below is a table with the proper values current express in A 14 135 13 46 45 41 39 37 35 34 31 26 111 107 97 93 89 84 8 75 6 HE op 18 174 155 15 44 137 13 121 10 BIL The drive is provided with the offset adjustment made by tachogenerator feedback If any further adjustment is required please use the Bil potentiometer The compensation is 200mV in respect to the input reference With zero input reference adjust the potentiometer until the motor is perfectly still 19 Service Manual MiniBravo Seiting up the drive 6 5 Ramp time adjustment This function is enabled by solder bridges S2 S4 closed It allows adjustment of the ramp slope during both acceleration and deceleration Adjusting the ACC potentiomenter located in front of the drive clockwise cw increases the ramp time between 0 1 and 1S It c
10. he opposite direction of the expected one reverse the motor and tachogenerator connections or reverse the speed reference connections Service Manual MiniBravo 16 Commissioning 5 Apply the load to the motor s shaft and insert the space loop on the C N C If the system s behaviour is the same as before and the servo error alarm doesn t appear the system has been properly regulated 6 Now leave the system powered up in typical working conditions Check that no protection occurs red LEDs all OFF and the green drive LED is on 6 1 Speed adjustment with tacho generator feedback The drives are provided with the RDT resistance mounted on board The drive is adjusted for 3000 rpm with a tachometer costant 10v 1000 rpm referred to 10V reference If you desire to change this resistor just open the cover of the drive then change the value of the resistor To calculate it please use the following equation RDT Kohm Kdtxnx9 Za 1000 x Vref 17 Service Manual MiniBravo Seiting up the drive Where Ratis the value expressed in Kohm with a power rating of 1 8 or 1 4w Kat is the tachogenerator costant n is the max speed express ed in RPM Vref is the max voltage reference expressed in Volts When the RDT resistor is mounted adjust the fine speed by using the VEL potentiometer located in front of the drive Clockwise Increases the speed CounterClockwise Decreases the speed The range adjustm
11. l Features The nominal and peak current can be adjusted by a resistor located on the socket The drive dimensions are 134 5 x 81 x 27 5mm 3 19 x 5 29 x 1 08 Listed below are the four sizes of the MiniBravo product line The operating temperature is from 0 to 40 C 32 to 104 F and no ventilating system is required as long as the spacing between the drives allow for adequate air flow Size Nominal A Peak A 1 2 1 2 2 5 5 2 5 5 6 12 6 12 10 20 10 20 1 3 Inputs and Outputs The Following are descriptions of the output drive connector DriveOK NC open collector max current 100mA Demand current Common zero signal Auxiliary output voltage 10 volts 5 mA max Auxiliary output voltage 10 volts 5 mA max Enable 10 30 volt drive enabled Input speed reference Non inverting input NO OO P OM 3 Service Manual MiniBravo Description 10 11 13 14 Input speed reference inverting input Tacho input Tacho input AT Power supply input positive power supply AT Power supply input negative power supply M Positive motor terminal M Negative motor terminal 1 4 Drive dimensions 1 08 134 50 5 29 27 50 E Peere EAEREERAERIEECE 134 50 Service Manual MiniBravo 4 Adjustments 2 1 Personalizations and set
12. mounted on the socket pin 3 22 to compensate for the voltage drop due to the motor s internal resistance To calculate it use this equation geg onm on et Co Ri WHERE n max speed expressed in rpm Ri Total motor resistance with brushes lpk Peak current size of the drive Ke Sevomotor BEMF at 1000 rpm Vref Max voltage reference Example Drive 10 20 A Ri 2 5 ohm RCA kohm 9 5 x 4000 x DO 200 Kohm 10 x 20x 2 5 Use a resistor of 56 Kohm or the higher value If after this procedure the motor is unstable increase the value by using the next higher commercial value avalaible Service Manual MiniBravo 22 Seiting up the drive 6 7 Dynamic costant adjustment Usually these calibrationsare made by the factory and don t need adjusting Only re tuning by KV and DER potentiometer is required If high inertia loads are present ratio 3 1 between load and motor it is necessary to modify the proportional gain by KV potentiometer and increase the value of derivative by DER potentiometer The adjustment procedure must take place with the load connected to the motor Connect a function generator with square wave 0 5 Hz 1V to the input speed reference terminals Connect the probe of the memory oscilloscope channel A to the tachogenerator signal The ground of the probe must be connected to the GND of the drive Adjust counter clockwise ccw the DER potentiometer Be su
13. orresponds to 10V reference See note 1 D S3 S2 S4 FUNCTION RANGE NOTE gt dh Fanpdisabled 0 sec Standard solder bridges Fn emble 01 1 sec Adjustable by ACC pot O Rap emble RP2 res Adjustable by ACC pot Itis also possible to modify the range of the ramp opening solder bridge S3 and mounting a resistor in the socket between pin 9 and 16 Rp2 res The proper value is reported on the table below See note 2 820K 0 2 2 6s 0 3 3 2s Service Manual MiniBravo 20 Seiting up the drive 6 6 Armature feedback adjustment Armature feedback mode may be used as speed feedback when a tachogenerator is not fitted to the motor Speed control is then less precise the regulation range is 1 20 and below this value the torque is reduced This funciton will be enabled by solder bridge closed JP7and mounting in the socket RA and RCA resistors RA resistor It will be mounted on the socket pin 2 23 to adapt the system to the voltage motor costant To calculate it use this equation D n ohm 166 x Vref E 1 4 Vref WHERE E_nx Ke 1000 Ke Servomotor BEMF at 1000 rpm Vref Max voltage reference n max speed express in rpm Example Servomotor with Ke 20 n 3000 RPM Vref 10 E _ 3000 x 20 _ 60 1000 RA kohm 166 x 10 36 Kohm 60 1 4 x10 Use the nearest commercial value 33 Kohm 21 Service Manual MiniBravo Seiting up the drive RCA resistor It will be
14. p Open Service Manual MiniBravo 28 Options and accessories Encoder adjustment The R10 resistor allows adjusting the speed with 10V of reference to the preferred frequency R10 810000 Where Fenc is Fenc Imp g x Rpm Fenc 60 Example N encoder rev 500 RPM 3000 R10 810000 32 4Kohm Willbe use 33Kohm or 25000 27Kohm Connections The system show in FIG 2 is a typical connection with a push pull or open collector encoder The power supply is provided onboard by the same card If a Line driver encoder is used connect to input channels only CHA and CHB positive i R10 EE T 5 0000000000 FIG 2 aps H THe 0000 D 7 29 Service Manual MiniBravo Options and accessories Below is an example with push pull or open collector encoder Fig 3 The encoder receives the power supply from an external source connecting the GND of the source with GND of the board If a Line driver encoder is used connect to input channel only CHA and CHB positive I R10 0000000000 FIG 3 KL D KL Ee ap DEER C p 00 H ENCODER DOOD LN ext GND ext Service Manual MiniBravo 30 Block diagram 8 3 Block diagram
15. re that the load s motion doesn t create a safety risk Apply power to the drive and start it The load will begin to move alternatively if possible increase the generator amplitude up to 2V Check the signals in the oscilloscope the waveforms should be as shown on the right 23 Service Manual MiniBravo gt gt Caution Don t exaggerate with the gain it unnecessary motor heating Segnale di velocit Segnale di velocit Segnale di velocit Segnale visualizzabile tra iltest point m corrente motore e il segnale dl GND el can cause Setting up the drive Insufficient proportional gain Increase the gain turning clokwise cw using KV potentiometer until achiving a situation as shown on the left To reduce the overshoot adjust clockwise cw using Der potentiometer until achieving a situation as shown on the left KV DER It s possible to increase the velocity loop derivative constant by inserting a capacitor CDER on the personalization adjustment See chapter 2 1 Service Manual MiniBravo 24 Fault finding 7 1 Troubleshooting 1 Applying power supply the green OK LED is unlit Power supply voltage is out of range Check the voltage value by instrument 2 Green OK LED on with drive on and motor not moving Check the input signal 3 When the drive is turned on the Green OK LED goes off and the red O C LED comes on Look for a
16. stallation Power supply rating continued A fuse should be fitted into each of the transformer s primary and secondary windings F1 and F2 These fuses may be replaced with a magneto termic switch with the same value The F1 fuse mounted on the primary protects the transformer This fuse must be the slow type The F2 fuse mounted on the secondary also protects the transformer and that fuse must be the slow type Fl F2 o mej RETE AC i l e F 1 P VA trasnf x 1 1 V primary ac 1 2 2A 2 5 5 5A 6 12 10A 10 20 20A 11 Service Manual MiniBravo Installation 4 2 Connections Below is information about appropriate wiring thereby improving noise reduction and safety Always use shielded cables to connect the ref signals and the tacho signal Signal cables and power cables must be segregated and wired through different trunking Reference the section of the cable the factory suggests 1 5 mm square up to size 6 12 for power cables 2 5 mm square up to size 10 20 for power cables Connections example RW eege e ge bet D 2 Seee i S Cc SESFT ESTs Ee SES e VC veL 10K A This drawing shows an example of connecting the speed reference using the internal voltage of the drive The speed potentiometer must have a value between 5k and 47 kOhm The tacho
17. th armature feedback 6 7 Dynamic costant adjustment 7 Troubleshooting 8 Options 8 1 Available options 8 2 Encoder feedback 8 3 Block Diagram 1 Service Manual Description Ronni NOW 8 9 12 15 16 17 18 19 19 20 21 23 2 26 27 31 MiniBravo Description 1 1 Introduction The MiniBravo is a very small sized bi directional drive with four quadrant function The output power stage mosfet is controlled using the PWM technique with 20 Khz modulation frequency This drive is designed for driving small Dc brushed servomotors up to 2 Nm where dynamic performance and fast response is required The speed feedback may be through tachogenerator ar mature feedback or encoder option For its supply a unique Dc source with a wide range is required If a drive module is replaced it is important to verify that the new drive module is calibrated as the one removed Itis also possible adapt the dynamyic costant in according with the adjustment requested To use the various options avalaible on drive we must open or close the solder bridges located upon the drive Four leds on the drive describe the status of the drive 1 2 Technical Features The MiniBravo is a drive with a wide range of power supply It needs a unique Dc source from 22 to 80 Vdc witha differential input reference The enable is provided by Dc voltage between 10 Vdc 30Vdc Service Manual MiniBravo 2 Description Technica
18. ting WARNING After switching off to do the adjustments please wait for about 30 sec before working inside the drive If the drive isn t adjusted with the proper servomotor follow these procedures Allof the personalizations are located inside of the MiniBravo To enter to the adjustment components and the solder bridges unscrew A and remove the cover B See fig 1 A o0o000000j000 0o0000000 5 Service Manual MiniBravo Adjustments All of the adjustments are located in the area behind the potentiometers It s there that a socket containing all of the adjustment components is located The socket is made by a double row of components with pitch 7 62mm 0 3 resistors with 9 9 ways and 3 3 ways for components with pitch 5 08 mm 0 2 capacitors The resistors may be 1 4W Pin 1 24 RDT Pin 223 RA Pin 322 RCA Pin 421 RIN Pin 5 20 RIP Pin 619 RKV Pin 748 GAIN Pin 8 17 RP1 Pin 9 146 RP2 Pin 10 15 pitch5 08 CKV Pin 11 14 pitch5 08 CDER Pin 1243 pitch5 08 CDER 2 2 Solder bridges S1 Normally open If closed the activation of IN protection inhibits the output of the drive s OK transistor When this situation occurs the green OK LED is OFF S2 S4 Normally opens See chapter 6 5 Ramp time adjustement S3 Normally closed See chapter 6 5 Ramp time adjustement S5 S6 Normally closed If open the
19. ues of components have been used Also check that the components are correctly fitted From tachogenerator feedback from armature feedback from encoder feedback or in current mode 15 Service Manual MiniBravo Commissioning 5 1 Initial start up 1 First itis important that the motor s shaft is free from the load and be ready to stop the main power supply quickly if necessary It is also important that the motor is fixed to a proper stand Please ensure that the ref signal is zero 0 2 Apply power to the drive In normal situations after a delay of about 1 second the green OK LED will come on The motor must be still If the LED doesn t come on please check the proper value of the power supply with a multimeter WARNING If the motor is driven by C N C use the ref in manual mode with the servo error disabled Space loop disabled 3 Enable the drive PWM ON active A good rule is to provide the enable after the power supply Check that the motor is stationary or turns slowly due to a signal offset this means that the tacho polarity is correct If the motor rotates in an opposite direction to the expected one switch off and reverse the motor and tachogenerator connections WARNING After switching off wait about 15 seconds before re applying power to the drive in order to avoid problems 4 Increase the speed reference up to one 1 volt and check the sense of the motor s rotation If the motor rotates in t
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