Bonfiglioli BTD/BCR Servo Motor System Integration and Interface Configuration Guide

PTC interface: PTC signals occupy Pin 2 (+) and Pin 6 (-) of the signal connector. Mandatory requirement: The PTC signal line must be connected to the temperature monitoring circuit of the driver and set as a fault shutdown response to ensure safe shutdown of the motor before the temperature reaches the F-class insulation limit (155 ° C).

Feedback system configuration: Parser vs. Encoder

The choice of feedback system directly affects the control accuracy and stability of the system.

1. Standard configuration: Resolver

The standard 2-pole rotary transformer for BTD/BCR has extremely high environmental tolerance (-55 ° C~+155 ° C), strong resistance to vibration and pollution, and is the first choice for harsh industrial environments.

Accuracy index: Absolute accuracy ± 4 ′ (arc minutes), repeatability accuracy 1 ′, able to meet the majority of speed control and positioning requirements.

Integration points: The Resolver interface on the driver side (such as the EMRES-03 module of the ACTION Cube) provides excitation signals (7Vrms, 5kHz) and receives sine and cosine feedback. When wiring, attention should be paid to the polarity of the Sin/Cos channel, as reversing the polarity can cause the motor to trip.

2. Optional configuration: Absolute value encoder

For high-precision positioning (such as machine tools and robots), Heidenhain (S1-S3 incremental, D1-D4 EnDat absolute values) or Sick Stegmann (H1-H8 Hiperface absolute values) encoders can be used.

Integrated value: The absolute value encoder can still remember its position after power failure, eliminating the need for zeroing operations and improving equipment efficiency and safety.

Interface difference: Absolute value encoders require bidirectional data communication through EnDat or Hiperface protocols, which means there are more signal cables and a dedicated interface module (such as EM-ENC-ABS) needs to be matched.

Cable selection and wiring specifications

The reliability of servo systems largely depends on the quality of cables and wiring methods. BTD/BCR provides pre assembled Desina standard cables, significantly reducing the risk of on-site cable production.

1. Power cables and signal cables

Color distinction: The power cable is orange (PUR outer skin), and the signal cable is green for easy on-site identification and to prevent misconnection.

Shielding requirements: Signal cables must be shielded with tinned copper braided mesh (coverage>85%) and must be grounded in a 360 ° circular manner, meaning that the shielding layers at both ends of the cable (motor end and driver end) must be extensively grounded, rather than relying solely on a single wire.

Bending radius: When fixed installation, the bending radius should be ≥ 7 times the outer diameter; When using mobile drag chains, the outer diameter should be ≥ 12 times and the maximum acceleration should not exceed 4 m/s ².

2. Selection matching table

Select the corresponding pre installed cable length based on the motor model (standard offers 3m, 5m, 10m):

Resolver signal cable: model 8RTCxx25 (xx represents length), with a 12 core circular connector on the motor end and a SUB-D9 connector or loose wire on the driver end.

Power cable: model 42MBCxxyy (xx represents length, yy represents wire diameter), motor end is an 8-core circular connector, and driver end is a loose wire (needs to be crimped and connected to the main circuit terminal of the driver).

Maintain the integration and debugging of the brake system

For applications with vertical axis or power-off holding requirements, the optional 24V DC holding brake is a safety critical component.

1. Hardware integration

Wiring: The brake power cord is integrated inside the power connector. A 24V DC controllable power supply must be output by the driver to drive.

Control logic: The driver controls the release and engagement of the brake through internal parameters. The standard logic is: after the motor is powered on to establish torque, the brake is released; When the driver shuts down the output or detects a fault, the brake immediately applies.

2. Timing parameters

The manual provides brake action time parameters, which are crucial for programming control logic:

T_BrC: The time from disconnecting the brake voltage to establishing stable braking torque (used for emergency stop delay).

T_BrS: The time from restoring the brake voltage to reducing the braking torque to 10% (used for starting acceleration delay).

Correctly setting the brake control parameters of the driver can avoid rolling or brake impact.

Key points of electromagnetic compatibility (EMC) integration

The BTD/BCR motor itself complies with CE and UL standards, but the EMC compliance of the system depends on the overall installation.

The motor power cable must be physically isolated from the signal cable (with a minimum distance of 20-30cm) to avoid parallel wiring.

The PE grounding on the driver side must use star grounding to ensure a low impedance circuit for high-frequency noise.

The motor casing must be reliably grounded through a PE wire to release bearing current and common mode interference.