SAXophone Installation Guide - · PDF fileElmo SAXophone Installation Guide SAXUGEN0402 2-1 Chapter 2: Introduction The Saxophone system includes the Saxophone servo amplifier and

SAXophone Installation Guide

April 2002

Elmo Motion Control http://www.elmomc.com

Important Notice This guide is delivered subject to the following conditions and restrictions:

This guide contains proprietary information belonging to Elmo Motion Control Ltd. Such information is supplied solely for the purpose of assisting users of the Saxophone servo amplifier.

The text and graphics included in this manual are for the purpose of illustration and reference only. The specifications on which they are based are subject to change without notice.

Information in this document is subject to change without notice. Corporate and individual names and data used in examples herein are fictitious unless otherwise noted.

Doc. no. SAXUGEN0402 Copyright 2002

Elmo Motion Control Ltd. All rights reserved.

The Elmo Motion Control warranty for this product covers only the elimination of problems due to manufacturing defects that result in impaired function. Specifically excluded from this warranty is the elimination of problems caused by abuse, damage, neglect, overloading, wrongful operation and unauthorized manipulations of the product. This product warranty is for a period of 12 months from the time of operational startup but no longer than 18 months from shipment from the manufacturing plant. Damage claims that exceed the warranty obligation – including consequential damages – will be rejected in all cases. If any term or condition in this warranty is at variance or inconsistent with any provision or condition (whether general or special) contained in or referred to in the Terms of Conditions of Sale outlined at the back of Elmo’s Standard Acknowledgement form, then the latter shall prevail and be effective.

Microsoft and Windows are registered trademarks of Microsoft Corporation. All other product and company names mentioned in this manual maybe trademarks of their respective owners.

Elmo Motion Control Ltd. 64 Gisin St., P.O. Box 463 Petach Tikva 49103 Israel Tel: +972 3 929-2300 Fax: +972 3 929-2322

Elmo Motional Control Inc. 900(H) River St., Kennedy Industrial Park Windsor, CT 06095 USA Tel: +1 860 683-0095 Fax: +1 860 683-0036

Elmo Motion Control GmbH Steinbeisstrasse 41 D-78056 Villingen-Schwenningen Germany +49 07720 8577-60 +49 07720 8577-70

Contents

Chapter 1: Safety Information............................................................................................... 1-1 1.1 Amplifier Compliance ................................................................................................... 1-1 1.2 Safety Precautions.......................................................................................................... 1-1 1.3 Power Precautions ......................................................................................................... 1-2

Chapter 2: Introduction .......................................................................................................... 2-1 2.1 System Description ........................................................................................................ 2-1 2.2 System Architecture....................................................................................................... 2-2 2.3 How to Use this Guide .................................................................................................. 2-3

Chapter 3: Installation ............................................................................................................ 3-1 3.1 Unpacking the System Components............................................................................ 3-1 3.2 Mounting the Saxophone .............................................................................................. 3-2

3.2.1 Mounting Directly onto Wall......................................................................... 3-2 3.2.2 Mounting on a DIN Rail................................................................................. 3-3

3.3 Connecting the Cables................................................................................................... 3-4 3.3.1 Wiring the Saxophone .................................................................................... 3-4 3.3.2 Connecting the Power Cables........................................................................ 3-5 3.3.3 Connecting the Motor Cables ........................................................................ 3-7

3.4 Powering Up ................................................................................................................ 3-10 3.5 Initializing the System................................................................................................. 3-10

Chapter 4: Status Indications................................................................................................. 4-1

Appendix A: Pin Assignments ............................................................................................. A-1 A.1 Auxiliary Power Connector ......................................................................................... A-1 A.2 Committed I/O Connector .......................................................................................... A-1 A.3 General I/O Connector ................................................................................................ A-2 A.4 Feedback A – Encoder Option ..................................................................................... A-3 A.5 Feedback A – Resolver Option .................................................................................... A-4 A.6 Analog I/O Connector ................................................................................................. A-5 A.7 Com1 .............................................................................................................................. A-6 A.8 Com2 .............................................................................................................................. A-7 A.9 Feedback B..................................................................................................................... A-7

Appendix B: Technical Specifications .................................................................................B-1 B.1 Power Ratings ................................................................................................................B-1

B.1.1 1x230 VAC or 3x230 VAC Power Ratings ....................................................B-1 B.1.2 3x400 VAC Power Ratings .............................................................................B-1 B.1.3 Rated Specifications........................................................................................B-2 B.1.4 Auxiliary Power Supply.................................................................................B-2 B.1.5 Analog Input and Output ..............................................................................B-2 B.1.6 Feedback Supply Voltage..............................................................................B-3

B.2 Control Specifications....................................................................................................B-3 B.3 Feedback Options ..........................................................................................................B-4 B.4 Digital Input Interface ...................................................................................................B-5 B.5 Digital Output Interface ................................................................................................B-6 B.6 Fault Output ...................................................................................................................B-7 B.7 Single-Phase Operation .................................................................................................B-7

Elmo SAXophone Installation Guide SAXUGEN0402

B.8 Mechanical Specifications .............................................................................................B-8 B.9 Recommended Wire Cross-sections.............................................................................B-8 B.10 Environmental Conditions............................................................................................B-8 B.11 Resolver ..........................................................................................................................B-9 B.12 Compliance Standards ..................................................................................................B-9

B.12.1 Quality Assurance ..........................................................................................B-9 B.12.2 Design ..............................................................................................................B-9 B.12.3 Safety................................................................................................................B-9 B.12.4 EMC................................................................................................................B-10 B.12.5 Workmanship................................................................................................B-10 B.12.6 PCB.................................................................................................................B-10 B.12.7 Packing...........................................................................................................B-10

B.13 Dimensional Drawings................................................................................................B-11 B.13.1 General Dimensions .....................................................................................B-11 B.13.2 Mounting Dimensions..................................................................................B-12

Appendix C: Supplemental Configuration Schematics ................................................... C-1 C.1 CANopen Configuration.............................................................................................. C-1 C.2 Auxiliary Encoder Configurations.............................................................................. C-2

Index...........................................................................................................................................I-1

Elmo SAXophone Installation Guide Contents SAXUGEN0402

ii

Chapter 1: Safety Information

In order to achieve the optimum, safe operation of the Saxophone servo amplifier, it is imperative that you implement the safety procedures included in this installation guide. This information is provided to protect you and to keep your work area safe when operating the Saxophone and its accompanying equipment. Read this chapter carefully before you begin the installation process.

1.1 Amplifier Compliance

The end product used with the Saxophone must comply with the European Safety of Machinery Directive 89/392/EEC safety requirements, and with the most recent versions of the EN60204-1 and EN292-2 standards.

The Saxophone conforms to the following industry safety standards:

Item Safety Standard

Power conversion equipment Recognized UL508c

Insulation coordination, including clearance and creepage distances of electrical equipment

In compliance with UL840

Safety of information technology equipment, including electrical business equipment


Low Voltage Directive, 73/23/EEC In compliance with EN60204-1

1.2 Safety Precautions

Follow these safety guidelines when installing the Saxophone servo amplifier:

Power connection during operations: Disconnect the Saxophone servo amplifier from its power source during all operations, such as installation, adjustment maintenance and repair.

Qualified personnel: Ensure that only qualified personnel carry out any operation relating to the Saxophone servo amplifier.

Live servo operations: Perform operations when the amplifier is disconnected from the power source. Only qualified personnel who are fully aware of the dangers of performing operations connected to the power source should carry out these operations.

Components: Only certified Elmo representatives may replace damaged Saxophone servo amplifier components.

Elmo Saxophone Installation Guide SAXUGEN0402

1-1

Elmo SAXophone Installation Guide Safety Information SAXUGEN0402

1-2

1.3 Power Precautions

Observe the following safety precautions when connecting the Saxophone servo amplifier to a power supply or during power-up.

Power supply: The maximum AC/DC power supply connected to the instrument must comply with the parameters outlined in this guide.

Grounding: The Saxophone servo amplifier contains grounding conduits for electric current protection. Any disruption to these conduits may cause the instrument to become hot (live) and dangerous.

Powering up: Before switching the Saxophone on, verify that all safety precautions have been observed and that the installation procedures in this manual have been followed.

The Saxophone SAX-xx/400 series is designed to operate only from a 3-phase voltage source. The Saxophone SAX-xx/230 series is designed to operate from a 1- or 3-phase voltage source. It can be connected directly to the line voltage. An isolation transformer is not needed.


2-1

Chapter 2: Introduction

The Saxophone system includes the Saxophone servo amplifier and the Composer software, which run in conjunction with your permanent-magnet synchronous motor. The servo amplifier connects easily to your motor. You use the Composer software to set the various servo and motor parameters that meet your specific configuration.

The Composer software is Windows-based and provides a plug-and-run tool that enables users to quickly and simply set up the communication and the servo system. Refer to the Composer Software Manual for more information.

This installation guide describes the Saxophone system and the steps for its setup, installation and powering up. Following these guidelines ensures maximum functionality of the Saxophone system.

2.1 System Description

The Saxophone system is designed for use with high-performance automated machinery. The Saxophone series of servo amplifiers has been developed for permanent magnet synchronous motors and incorporates digital velocity loop, a digital current loop and sinusoidal commutation.

The Saxophone's basic configuration is a trimmerless velocity servo amplifier. All adjustments to the velocity, current and commutation functions are made via the serial or field bus (CANopen option) communication line, using a PC.

Independent control of the magnetic flux and the torque-generating current component in motors is provided by sinusoidal control with phase advance algorithms. This is particularly significant for permanent magnet synchronous motors and brushless motors used in high-performance drives.

The Saxophone series' power source is a three-phase 400 VAC or one- or three-phase 230 VAC line. The control and auxiliary supplies are derived from a 24V AC or DC supply that is isolated from the AC power bus. This allows a safe and economical "power backup" feature that is essential for positioning systems.

The Saxophone series meets UL508C and the relevant CE regulations.

Elmo SAXophone Installation Guide Introduction SAXUGEN0402

2-2

2.2 System Architecture

CANopen

(option)Interface

Analog command

Aux. EncoderInterface

Aux.Encoder

RS232

Main EncoderInterface

ResolverInterface(option)

Dadicated I/O:Enable/DisableLimit SwitchesAbort Fault

MCU+

I/O

Motor

Feedback

RS485Interface(Option) AC1

AC2

AC3

M1

M3

M2

Main Power:3x400 AC3x230AC

Aux. Power:24VDC

or24VAC

Bridge Commands(6 x PWM)

Status Lines

Current FeedbackPhase - M1Phase - M3

InternalPowerSupply

PowerStage

Encoder output

+5v, 15v, 24v

PE

General I/O

Circuitbreaker

Contactor

PE

Figure 2-1: Saxophone Architecture Block Diagram

For three-phase supply voltage:

The circuit breaker current rating should be between 150% to 200% of the amplifier current.

The circuit breaker voltage rating should be 460 VAC.

The contactor should be up to 150% of the amplifier current.

For single-phase supply voltage:

The circuit breaker current rating should be between 200% to 300% of the amplifier current.

The circuit breaker voltage rating should be 460 VAC.

The contactor should be up to 200% of the amplifier current.

Elmo SAXophone Installation Guide Introduction SAXUGEN0402

2-3

2.3 How to Use this Guide

In order to install and operate your Elmo Saxophone servo amplifier, you will use this manual in conjunction with a set of Elmo documentation. Installation is your first step; after carefully reading the safety instructions in the first chapter, the following chapters provide you with installation instructions as follows:

Chapter 3, Installation, provides step-by-step instructions for unpacking, mounting, connecting and powering up the Saxophone.

Chapter 4, Status Indications, lists the different symbols shown on the Saxophone display.

Appendix A, Pin Assignments, gives the pin-out information you need when preparing the Saxophone cables.

Appendix B, Technical Specifications, lists all the amplifier ratings and specifications.

Appendix C, Supplemental Configuration Schematics, are additional diagrams to assist with CANopen and encoder configurations.

Upon completing the instructions in this guide, your Saxophone servo amplifier should be successful mounted and installed. From this stage, you need to consult higher-level Elmo documentation in order to set up and fine-tune the system for optimal operation. The following figure describes the accompanying documentation that you will require.

Programming

Setup

Installation Hardware installation guides

Composer software manual (doc. no. COMSFEN0202)

Command reference manual

Implementing Motion Control with Elmo Products

Figure 2-2: Elmo Documentation Hierarchy


3-1

Chapter 3: Installation

Before configuring and operating the Saxophone, you need to perform a number of procedures to guarantee the best working conditions for the amplifier.

This chapter describes how to fully install the Saxophone: from unpacking it and verifying its type designation, through wiring and mounting it, and then connecting it to the required power.

There are five main steps in the Saxophone installation:

1. Unpacking and checking the system components

2. Mounting the Saxophone

3. Connecting the power cables and motor cables

4. Powering up

5. Performing initial setup and initialization

3.1 Unpacking the System Components

Before you begin working with the Saxophone system, verify that you have all of its components, as follows:

The Saxophone servo amplifier

The Composer software and software manual

Optional mounting clips

The Saxophone is shipped in a cardboard box with Styrofoam protection.

To unpack the Saxophone:

1. Carefully remove the servo amplifier from the box and the Styrofoam.

2. Check the amplifier to ensure that there is no visible damage to the instrument.

3. To ensure that the Saxophone you have unpacked is the appropriate type for your requirements, locate the part number sticker on the side of the Saxophone:

Elmo SAXophone Installation Guide Installation SAXUGEN0402

3-2

The P/N number at the top gives the type designation as follows:

4. Verify that the Saxophone type is the one that you ordered, and ensure that the voltage meets your specific requirements.

3.2 Mounting the Saxophone

The Saxophone has been designed for two standard mounting options: Attaching directly to the wall with screws Mounting on a DIN rail

With either type of mounting, be sure to leave about 10 cm (4 in) above and below the instrument for heat dissipation.

3.2.1 Mounting Directly onto Wall

The vertical mounting strip at the back of the Saxophone enables you to screw the amplifier directly into a wall.

To mount the Saxophone with the mounting strip:

1. On the back of the amplifier, push the mounting strip up until it clicks and locks. The top lip (with the hole) should be exposed.

Figure 3-1: Extending the Mounting Strip Figure 3-2: Mounting Strip Fully Extended


3-3

2. Mount the Saxophone vertically onto the wall with two screws, one through the top hole of the mounting strip and one at the bottom.

3.2.2 Mounting on a DIN Rail

At the top rear of the Saxophone, a horizontal groove lets you quickly and easily snap the Saxophone onto a DIN rail in your work area

To mount the Saxophone on a DIN rail:

1. Be sure that the vertical mounting strip (with the hole at the top) is pressed down fully and does not protrude from the top of the instrument.

Figure 3-3: Mounting Strip Pressed Down

2. Tilt the Saxophone back towards the top part of the DIN rail.

Figure 3-4: Attaching Top Part of Mounting Groove to DIN Rail


3-4

3. Press the Saxophone down to a vertical position until it clicks onto the DIN rail.

Figure 3-5: Saxophone Mounted on DIN Rail

3.3 Connecting the Cables

3.3.1 Wiring the Saxophone

Once the Saxophone is mounted, you are ready to wire the device. Proper wiring, grounding and shielding are essential for ensuring peak servo operation and performance.

Follow these instructions to ensure safe and proper wiring:

Keep the motor wires as far as possible from the signal level wiring (such as for feedback and control).

If additional inductors (chokes) are required, keep the wires between them and the amplifier as short as possible.

Minimize lead lengths as much as is practical. Although the amplifier is protected against long (inductive) supply wires, the leads should be as short as possible. If the cable length exceeds 10 m (35 ft), consult Elmo for further instructions.

Use twisted pairs and shielded wires whenever possible. Avoid running them in close proximity to power leads or other sources of EMI noise.

Tie grounded components together at a single point (star connection). Then tie this point with a single conductor to an earth ground point.

After completing the wiring, carefully inspect all wires to ensure tightness, good solder joints and general safety.


3-5

3.3.2 Connecting the Power Cables

Access the power terminal connections on the Saxophone servo amplifier by removing the front safety cover located at the bottom of the front panel of the unit, as shown below:

Figure 3-6: Removable Bottom Saxophone Panel

After removing the safety cover, the power terminal connections are visible, as follows:

1 2

6 7 8 93 4 5

Connector No. Signal Function

1 24V AC/DC auxiliary power

2 24V AC/DC auxiliary power

3 M1 Motor phase U

4 M2 Motor phase V

5 M3 Motor phase W

6 PE Protective earth

7 AC1 Main voltage phase 1



Figure 3-7: Saxophone Power Cable Connectors


3-6

Before connecting cables to the power terminal, it is important to organize your cables to simplify the connection process. Refer to Appendix A, Pin Assignments, for more information about the cables required for connection to the Saxophone.

The power connections are as follows:

Auxiliary power supply: Supplies power to the Saxophone logic board. The required voltage is 24V AC/DC.

Motor supply: Supplies power for the motor output.

Motor

M1

M2

M3

A

B

C

Chassis

PE

SAXOPHONE

Figure 3-8: Saxophone – Motor Power Connections

Power supply: Supplies power to the Saxophone.

To connect the power cables:

1. On the open section at the bottom of the Saxophone front panel, connect the

auxiliary power supply to the J2-Aux Power points.

Note: The DC cables (plus and minus) can be placed in either connector.

2. Connect the motor power cables to the J1-Power M1, M2 and M3 points. Ground the motor to the PE point. Refer to the data sheet of your motor to determine which cables are for the motor and which is for grounding.

3. Connect the 3-phase power supply to the J1-Power AC1, AC2 and AC3 points. Also, be sure to ground the power supply to the PE point.


3-7

Note: You may connect the motor power cables in any order and the Composer software will automatically configure the system. For more information about configuration, refer to the Composer Software Manual.

4. Reattach the safety panel to cover the motor and power connectors.

3.3.3 Connecting the Motor Cables

The Saxophone servo amplifier has a front panel that provides easy-to-use connections for all required cables. These connections are through 9-pin, 15-pin or 25-pin D-type ports; they support several types of configurations and interfaces.

Figure 3-9: Saxophone Front Panel

The following cables must be connected:

Main feedback cable

Communication cable

I/O cables

Refer also to Appendix A, Pin Assignments.


3-8

3.3.3.1 Main Feedback Cable The main feedback cable is used to transfer feedback information from the motor to the Saxophone. You should select this cable according to the feedback type of your motor: either Encoder or Resolver. Consult your motor documentation for more information. Refer to Appendix A for more information about this cable.

To connect the main feedback cable, insert the main feedback cable from the motor into the Feedback A port on the Saxophone servo amplifier, using a 15-pin, D-type female connector.

3.3.3.2 Communication Cable The communication cable is used to transfer configuration information from the PC to the Saxophone.

The communication interface may differ according to the user’s hardware. The Saxophone can communicate using the following options (explained fully in Appendix A):

RS-232: Connects to the Com1 port of the Saxophone. This is the most common option.

RS-485: Connects to the Com1 port of the Saxophone.

CANopen: Connects to the Com2 port of the Saxophone (field bus). Also requires an RS-232 cable.

Note: Ensure that each servo drive is allocated a unique ID. Otherwise, the CANopen network may hang.

In order to benefit from CANopen communication and the CiA DS-301 CANopen standard, the user must have a good understanding of the basic programming and timing issues of a CANopen network.

To connect the communication cable:

For an RS-232 connection, insert the communication cable from the serial port of the PC (Com1 or Com2) into the Com1 port on the Saxophone servo amplifier, using a 9-pin, D-type female connector.

For CANopen communication, connect a communication cable from the CANopen network to Com2 of the Saxophone servo amplifier.


3-9

Figure 3-10: Saxophone with Connected Communication and Feedback Cables

3.3.3.3 I/O Cables The following table lists the I/O cables that you should connect according to your specific requirements:

Cable Description

General Uncommitted digital IO

Type Plus: 2 input/output

Type Plus Plus: 6 digital input/output

Analog 2 analog input

1 analog output

Committed 4 dedicated input

1 dedicated output

3.4 Powering Up

After the Saxophone has been mounted, check that the cables are intact. The Saxophone servo amplifier is then ready to be powered up.

To power up the system, switch on the main and auxiliary power supplies. A d appears on the front panel display. The Saxophone is powered up and functional. For more information about the display, refer to Chapter 4, Status Indications.

3.5 Initializing the System

After the Saxophone has been connected and mounted, the system must be set up and initialized. This is accomplished using the Composer, Elmo’s proprietary Windows-based software application. Install the application and then perform setup and initialization according to the directions in the Composer Software Manual.


3-10


4-1

Chapter 4: Status Indications

The following table lists the symbols shown on the Saxophone display.

Symbol Status Action

Disable Bridge is disabled (all switches are off), no fault.

Enable All OK, amplifier is ready.

Under Voltage Bus voltage is too low.

Over Voltage Bus voltage is too high.

SVP Internal power supply problem.

Shunt The shunt is operating.

Short Phases are shorted to each other or to the ground.

Ishort = 3 × Ipeak

Temperature Amplifier temperature is too high.

Feedback Feedback loss.

FLS Forward switch is active according to the defined

logic (IL[3]).

RLS Reverse switch is active according to the defined logic (IL[4]).

FLS&RLS Both switches are active.

Over Speed Speed exceeded high or low limitation (HL[2], LL[2]).

IC Continuous current limit is active.

Over Current Current exceeded peak current limitation.

Undeclared Fault

Fault not declared on LED; may be detected with MF command.

Appendix A: Pin Assignments The following connectors are used in the Saxophone installation:

Type Used For Remarks

7-pin terminal Main power Mains, motor power

2-pin terminal Auxiliary power Logic power supply

9-pin D-type male Committed I/O Enable, Abort, Limits

25-pin D-type female General I/O Programmable I/O

15-pin D-type female Feedback A Encoder option

15-pin D-type female Feedback A Resolver option

9-pin D-type female Analog I/O

9-pin D-type female Com1 RS-232 or RS-485 interface

9-pin D-type male Com2 CAN interface

15-pin D-type male Feedback B Auxiliary encoder, encoder output

A.1 Auxiliary Power Connector

Pin # Signal Function

1 APS1 (24 V) Auxiliary power supply 24 VDC/VAC

2 APS2 (24 V) Auxiliary power supply 24 VDC/VAC

A.2 Committed I/O Connector


1 FLS Forward limit switch

2 RLS Reverse limit switch

3 LSRET Limit switch return

4 ENABLE Amplifier enable (disabling resets any protective latch)

5 ENRET Amplifier enable return

6 STOP Applying power will stop the motor at maximum deceleration

7 STRET Stop return

8 FAULT Fault relay

9 FAULT Fault relay


A-1

A.3 General I/O Connector

Pin # Signal Function Remarks

1 IN1 Programmable input 1

2 IN2 Programmable input 2

3 IN3 Programmable input 3 Sax-PP only

4 IN4 Programmable input 4 Sax-PP only

5 IN5 Programmable input 5: Event capture input Main Home input

Sax-PP only

6 IN6 Programmable input 6 Event capture input Auxiliary Home input

Sax-PP only

7 NA

8 OUT1 Programmable output 1

9 OUT2 Programmable output 2

10 OUT3 Programmable output 3 SAX-PP only




14 INRET1 Programmable input return 1

15 INRET2 Programmable input return 2

16 INRET3 Programmable input return 3 SAX-PP only

17 INRET4 Programmable input return 4 SAX-PP only

18 HOMERET Home return 1 SAX-PP only

19 AHOMERET Auxiliary home return 1 SAX-PP only

20 OUTRET1 Programmable output return 1

21 OUTRET2 Programmable output return 2

22 OUTRET3 Programmable output return 3 SAX-PP only




Elmo SAXophone Installation Guide Pin Assignments SAXUGEN0402

A-2


A-3

A.4 Feedback A – Encoder Option


1 HC Hall sensor C input

2 HA Hall sensor A input

3 SUPRET Hall sensor/Encoder supply voltage return

4 +5V Hall sensor/Encoder +5V supply voltage

5 CHA- Channel A complement

6 CHA Channel A

7 INDEX- Index complement

8 INDEX Index

9 SUPRET Supply return

10 HB Hall sensor B input


12 +15V Hall sensor +15V supply voltage


14 CHB- Channel B complement

15 CHB Channel B

The following diagram illustrates the Hall sensor/encoder sensor pin assignment:

15 Pin FemaleConnector

Hall C

Hall A

Hall / Encoder Supply Voltage Return

Encoder / Hall +5v Supply

CHA-

CHA

Index -

Index

Hall Sensor B Input

Hall +15v Supply ( if required)

CHB -

CHB

Encoder/ Hall Sensor

SAX - FEEDBACK A MOTOR

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

HC

HA

SUPRET

+5v

CHA-

CHA

INDEX-

INDEX

SUPRET

HB

SUPRET

+15v

SUPRET

CHB-

CHB

Figure A-1: Hall/Encoder Sensor Pin Assignment


A-4

A.5 Feedback A – Resolver Option


6 R1 Resolver reference output R1

7 S2 Resolver cosine input S2

8 S1 Resolver sine input S1

9 S3 Resolver sine input S3

11 SCREEN Cable shield should be connected to this terminal

3,13 SUPRET Supply return

14 R2 Resolver reference output R2

15 S4 Resolver cosine input S4

The following diagram illustrates resolver connections:

Sine S1

Sine S3

Reference R1

Reference R2

Cosine S2

Cosine S4

6

7

8

9

3

11

13

14

15

R1

S2S1

S3

SCREEN

SUPRET

R2

S4

D Type 15 Pin FemaleConnector

Resolver

SAX - FEEDBACK A(RESOLVER OPTION)

Motor

SUPRET

Figure A-2: Resolver Connections


A-5

A.6 Analog I/O Connector


1 ANLIN1+ Analog input 1

2 ANLIN1- Analog input 1

3 ANLRET Analog ground

4 ANLIN2+ Analog input 2

5 ANLIN2- Analog input 2

6 GND Common circuit

7 ANLOUT Analog output

8 ANLRET Analog ground

9 GND Common circuit

The following diagram illustrates an analog input with a single-ended source configuration:

+

-

20K

4.99

K

20K

ANLIN1+ 1

3ANLRET

2

RETURN

+

-

Single-EndedSource SAX

ANLIN1-

+

-

20K

4.99

K

20K

4

5ANLIN2-

ANLIN2+

Figure A-3: Analog Input with Single-ended Source

Note: It is recommended that you connect the ANLRET line to GND, even when the analog interface is not used.


A-6

A.7 Com1

Pin # Signal RS-232 Function RS-485 Function

1 – –

2 Tx Transmit –

3 Rx Receive –

4 – –

5 COMRET Communication return Communication return

6 TR+ – TR+

7 TR- – TR-

8 – –

9 – –

The following diagrams illustrate the two COM1 connection options.

D-Type9 pin

Female

Figure A-4: RS-232 Connections

D-Type

Figure A-5: RS-485 Connections


A-7

Note: When the RS-485 option is used, a standard RS-232 cable may damage the RS-485 transceiver, because the RS-232 control signals conflict with the RS-485 input. In this case, a three-wire cable is required, as shown in the diagram above.

A.8 Com2 (SAX Plus and SAX Plus Plus)


1 –

2 CAN_L CAN_L bus line (dominant low)

3 CAN_GND CANopen ground

4 –

5 CAN_SHLD CANopen shield

6 CAN_GND CANopen ground

7 CAN_H CAN_H bus line (dominant high)

8 –

9 (CAN_V+) Optional CANopen external positive power

A.9 Feedback B


1 INDEX Auxiliary index high input

2 CHB Auxiliary channel B high input

3 CHA Auxiliary channel A high input

4 +5V Encoder supply voltage


6 CHAO Channel A output

7 CHBO Channel B output

8 INDEXO Index output

9 INDEX- Auxiliary index low input

10 CHB- Auxiliary channel B low input

11 CHA- Auxiliary channel A low input

12 SUPRET Encoder supply voltage return

13 CHAO- Channel A complement output

14 CHBO- Channel B complement output

15 INDEXO- Index complement output

Appendix B: Technical Specifications

B.1 Power Ratings

B.1.1 1x230 VAC or 3x230 VAC Power Ratings

Specifications SAX-8/230

Phase RMS continuous current 8.5 A

Phase RMS peak current 17 A

Nominal operating voltage 1x230 VAC or 3x230VAC

DC bus over-voltage protection 390 V

DC bus under-voltage protection 78 V

Shunt current 8.0 V

B.1.2 3x400 VAC Power Ratings

Specifications SAX-4/400 SAX-8/400 SAX-10/400 SAX-14/400

Phase RMS continuous current 4.5 A 8.5 A 10.5 A 14.0 A

Phase RMS peak current 9.0 A 17.0 A 21.0 A 28.0 A

Nominal operating voltage 3x400 VAC 3x400 VAC 3x400 VAC 3x400 VAC

DC bus over-voltage protection 765 V 765 V 765 V 765 V

DC bus under-voltage protection 153 V 153 V 153 V 153 V

Shunt current 7.0 A 7.0 A 14.0 A 14.0 A

The power rating is defined for 10 KHz switching frequency on the motor’s winding. The default is 18 KHz.


B-1

B.1.3 Rated Specifications

Rated Specifications SAX-xx/230 SAX-xx/400

Rated supply voltage 3 x 240 VAC max 10% 3 x 460 VAC max

Pulse power of ballast circuit 1.5/3 KW 5/10 KW

Continuous power of ballast circuit

80/160 W 80/160 W

Switch-off threshold at over voltage

390 VDC 765 VDC

In-rush current limit <85 A <140 A

Efficiency @ rated power >95 % >97 %

B.1.4 Auxiliary Power Supply

Auxiliary power supply An AC or a DC source.

AC voltage input 18 VAC< VIN(AC) < 28 VAC

DC voltage input 18 VDC < VIN(DC) < 40 VDC

Power rating of the source 40 VA

Input frequency 45 Hz < f IN < 500 Hz

B.1.5 Analog Input and Output

Analog input - differential mode voltage

+ 20V maximum

Analog input - common mode voltage

+ 10V maximum

Input resistance 5 KΩ

Analog output voltage + 10 V maximum (10 KΩ impedance)

Analog output accuracy + 3%

Elmo SAXophone Installation Guide Technical Specifications SAXUGEN0402

B-2

B.1.6 Feedback Supply Voltage

Encoder supply voltage 5V +5%

Hall effect supply voltage 5V or 15V +5%

Encoder supply current (pin 4 of feedback A and B)

300 mA maximum (total for both outputs)

Hall effect supply current 50 mA maximum

B.2 Control Specifications

Feature Description

Velocity loop bandwidth x4 current loop

Current control Digital Sinusoidal with vector control Programmable PI control filter based

on a pair of PI controls of AC current signals and constant power at high speed

Current loop bandwidth Approximately 1.2 KHz

Current loop step response (including settling time)

300 - 400 µs

Current rise time 150 - 200 µs

Current rise delay time The time it takes from applying the command until the current starts to rise. This delay is due to the digital processing (100 - 200 µs).

Resolution of current loop 12 bits

Resolution of analog input command 12-bit inputs

Commutation feedback options Digital Hall effects and incremental encoder Resolver Incremental encoder only Pulse/direction

Velocity control Digital Programmable PID and FFW control

filter Sampling rate x4 current loop sample

time


B-3

Feature Description

Velocity and position feedback options

Resolver Incremental encoder Digital Hall effect (velocity only)

Note: With all feedback options, 1/T with automatic modes switching will be activated (gap, frequency and derivative).

Velocity command options Analog Internally calculated by either jogging

or step

Note: All software-calculated profiles support on-the-fly changes.

PWM switching frequency Factory default 18 KHz on the motor

Reduction for dissipation (30%) Can be reduced to half without reducing bandwidth

Switching method Advanced unipolar PWM

Control inputs PLC level only

B.3 Feedback Options

Feature Description

Type of encoder Differential Quadrature

Interface RS-422

Input resistance 300 Ω

Maximum incremental encoder frequency

Maximum absolute: 2 MHz single; 8 MHz quadrature

Input voltage range for the encoder

Maximum common mode: ±7V Maximum differential mode: ±7V


B-4


B-5

B.4 Digital Input Interface

Feature Description

Type of input Optically isolated Single ended

Input current Rin

VVinIin 5.6−=

* Iin = 2.2mA @ Vin = 12V

Minimum input current @ Vi=24V Iin = 7mA

High level input voltage 12V < Vin < 30V

Low level input voltage 0V < Vin < 7V

Min pulse width (IN1 - IN4) 1 msec

Execution time (all inputs) 500µs < T ≤ 2ms

High speed input capture minus pulse width capture on input transition (IN5 - IN6)

20µs < T ≤ 50µs

The following diagram shows a digital input schematic for the Saxophone series of servo amplifiers:

GroupCommon

In(i)

Rin=2.49KVz=5.1v

V =1.5vF

Figure B-1: Saxophone Digital Input


B-6

B.5 Digital Output Interface

Feature Description

Type of output Optically isolated

Maximum supply output (Vcc) 30V

Maximum output current Io (max) (Vout = Low)

TTL level: IOL < 2mA, VOL < 0.8 PLC level: IOL ≅ 10mA, VOL < 3v

VOL @ maximum output voltage (low level)

TTL level: Vcc = 5v, Vout = 0.8v PLC level: Vcc = 24v, Vout = 3v

Minimum RL

(max)O

OLCCL

IVVR −

≥

Executable time Up to 2 msec

The following diagram shows a digital output schematic for the Saxophone series of servo amplifiers:

Rout=25.5Ω

33v

RL

Vcc

Output(i)

Vout

Output(i)

SAX

Figure B-2: Saxophone Digital Output


B-7

B.6 Fault Output

The following table lists specifications for the fault output switches, to be used if a hardware failure occurs.

Amp Status Relay Contact Status

No fault Close

Fault Open

Switching current 0.25A maximum

Switching voltage 40v AC/DC

The following diagram describes the relay connection:

FAULT

8

9

RELAYN.O.

Figure B-3: Saxophone Relay Connection

B.7 Single-Phase Operation

When operating with a single-phase supply (SAX-xx/230 only), the voltage drop must be considered. Voltage drop can be calculated using the following equation:

Vout (Max Phase to phase) = 0.85*[ Vsupply (AC) - Vdrop]

Vdrop ACRMS

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

1 2 3 4 5 6 7 8 9 10 11

Motor's phase current RMS

Vdrop ACRMS

Figure B-4: Single-phase Voltage Drop Concept


B-8

B.8 Mechanical Specifications

Mounting Method Bookshelf

Overall dimensions 247 x 188 x 92 mm (9.72 x 7.4 x 3.6 in)

Weight SAX-5/400: 2.7 kg (6 lb)

B.9 Recommended Wire Cross-sections

Model AC Input Motor Auxiliary

SAX-3/230 1.5 mm2 16 AWG 1.5 mm2 16 AWG 0.5-1 mm2 18-22 AWG







B.10 Environmental Conditions

Feature Description

Operating ambient temperature Figure B-5

Storage temperature -20 to +85° C (-4 to +185° F)

Humidity 90% maximum non-condensing

Maximum operation altitude above sea level

2000 m (about 6000 ft)

Protection level IP20

The following graph shows the Saxophone operating ambient temperature at nominal operating voltage:

Ic

0.6 Ic

6045t 0

C

I (RMS)

Figure B-5: Operating Ambient Temperature at Nominal Operating Voltage

B.11 Resolver

The optional resolver feedback processor is set for the following type of resolver.

Reference voltage 7 V RMS

Frequency 5.0 or 10 KHz software selectable

Maximum load current 70mA RMS

Transformation ratio 0.5

R/D resolution 12-bit

Maximum velocity 8,000 RPM

Encoder outputs 1024 pulse per revolution resolution Differential outputs CHA, CHB An index with the complementary signals RS-422: 20 mA load maximum.

B.12 Compliance Standards

B.12.1 Quality Assurance

ISO9001

B.12.2 Design

Reliability prediction of electronic equipment (rating, de-rating, stress, etc.)

MIL-HDBK- 217F

Printed wiring for electronic equipment (clearance, creepage, spacing, conductors sizing, etc.)

IPC-D-275 IPC-SM-782 IPC-CM-770 UL508c UL840

Type testing In compliance with VDE0160 -7

B.12.3 Safety

Power conversion equipment Recognized UL508c

Insulation coordination, including clearance and creepage distances of electrical equipment


Safety of information technology equipment, including electrical business equipment


Low voltage directive, 73/23/EEC In compliance with EN60204-1


B-9

B.12.4 EMC

Electromagnetic compatibility (EMC) In compliance with IEC 1800-3, Part 3: 1996 (Adjustable speed electrical power-drive systems - EMC products standard, including specific test methods)

B.12.5 Workmanship

Acceptability of electronic assemblies In compliance with IPC-A-610, level 2

B.12.6 PCB

Acceptability of printed circuit boards

In compliance with IPC-A-600, level 2

B.12.7 Packing

Protection of electrostatic sensitive devices

In compliance with EN100015


B-10


B-11

B.13 Dimensional Drawings

B.13.1 General Dimensions

Rear View Front View

Side View


B-12

B.13.2 Mounting Dimensions

Rear View


C-1

Appendix C: Supplemental Configuration Schematics

C.1 CANopen Configuration (SAX Plus and SAX Plus Plus)

The following schematic shows the pinout for CANopen communication using Com2.

CANTransceiver

CAN - Interface

7

2

3

CANH

COMRETCANL

CAN Host

SAX P1

OpticallyIsolated

CANTransceiver

CAN - Interface

7

2

3

OpticallyIsolated

CANTransceiver

CAN - Interface

7

2

3

OpticallyIsolated

SAX P2

SAX Pn

6

6

6

Figure C-1: Saxophone Configuration with CANopen Communication

Elmo SAXophone Installation Guide Supplemental Configuration Schematics SAXUGEN0402

C-2

C.2 Auxiliary Encoder Configurations

CHA

CHB

INDEX

INDEX-

CHA-

SlaveDriver

MasterDriver

SAX - Plus Plus

Feedback A

MasterAxis

SlaveAxis

CONNECTORFEEDBACK B

CHB-

CONNECTORFEEDBACK B

6

13

14

15

7

8

CHAO

CHBO

INDEXO

INDEXO-

CHAO-

CHBO-

Feedback A3

11

10

9

2

1

SUPRET

Figure C-2: Master-Slave Configuration for Auxiliary Encoder

3 CHA

2 CHB

10 CHB-

1 INDEX

9 INDEX-

Motor

11 CHA-

Aux. EncoderIndependent

Encoder

SAX - Plus Plus

IsolatedEncoderPowerSupply

+5v Supply

5v RET

FEEDBACK

Figure C-3: Independent Configuration for Auxiliary Encoder

Index

A Amplifier compliance · 1-1 Analog I/O connector · A-5 Analog input and output · B-2 Auxiliary encoder configurations · C-2 Auxiliary power connector · A-1 Auxiliary power supply · 3-6, B-2

C Cables

CANopen · 3-8 Communication · 3-8 I/O · 3-9 Main feedback · 3-8 Motor · 3-7 Power · 3-5 RS-232 · 3-8 RS-485 · 3-8

Cabling · 3-4 CANopen

Cable · 3-8 Configuration · C-1

Com1 connector · A-6 Com2 connector · A-7 Communication cables · 3-8

CANopen · 3-8 RS-232 · 3-8 RS-485 · 3-8

Compliance standards · B-9 Composer · 3-10 Connecting

Motor cables · 3-7 Power cables · 3-5

Control specifications · B-3

D Digital input interface · B-5 Digital output interface · B-6 DIN rail mounting · 3-3 Display panel · 4-1

E Encoder connections · A-3 Environmental conditions · B-8

F Fault output · B-7 Feedback A - encoder · A-3 Feedback A - resolver · A-4 Feedback B · A-7 Feedback options · B-4

G General I/O connector · A-2 Grounding · 1-2

I I/O cables · 3-9 Initializing the Saxophone · 3-10 Installing the Saxophone · 3-1

L Live servo operations · 1-1

M Main feedback cable · 3-8 Mechanical specifications · B-8 Mounting the Saxophone · 3-2

Directly on wall · 3-2 On DIN rail · 3-3

P Pin assignments · A-1

Analog I/O connector · A-5 Auxiliary power connector · A-1 CANopen · C-1 Com1 · A-6 Com2 · A-7 Committed I/O connector · A-1 Feedback A - encoder · A-3 Feedback A - resolver · A-4 Feedback B · A-7 General I/O connector · A-2

Power Disconnecting · 1-1 Grounding · 1-2 Precautions · 1-2 Source · 2-1 Supply · 1-2


I-1

Power ratings · B-1 Power supply · 3-6 Powering up the Saxophone · 1-2, 3-10

R Rated specifications · B-2 Replacing components · 1-1 Resolver · B-9

Connections · A-4 Specifications · B-9

RS-232 cable · 3-8 RS-485 cable · 3-8

S Safety

Amplifier compliance · 1-1 Compliance standards · B-9 Disconnecting power · 1-1 Live servo operations · 1-1 Precautions · 1-1, 1-2 Replacing components · 1-1

Saxophone Cables · 3-7 Display · 4-1 Initializing · 3-10 Installation · 3-1 Mounting

Directly on wall · 3-2 On DIN rail · 3-3

System architecture · 2-2 System description · 2-1 Technical specifications · B-1 Type designation number · 3-1 Wiring · 3-4

Single-phase Operation · B-7 Voltage · 2-2

Specifications 1x230 VAC power ratings · B-1 3x230 VAC power ratings · B-1 3x400 VAC power ratings · B-1 Analog input and output · B-2 Auxiliary power supply · B-2 Control · B-3 Digital input interface · B-5 Digital output interface · B-6 Environment · B-8 Fault output · B-7 Feedback options · B-4 Mechanical · B-8 Rated · B-2 Resolver · B-9 Supply voltage · B-3

Status indications · 4-1 Supply voltage · B-3 System architecture · 2-2

T Technical specifications · B-1 Three -phase voltage · 2-2 Type designation number · 3-1

U Unpacking the Saxophone · 3-1

V Voltage

Single-phase · 2-2 Three-phase · 2-2

W Wire cross-sections · B-8 Wiring the Saxophone · 3-4

Elmo SAXophone Installation Guide Index SAXUGEN0402

I-2

Documents

SAXophone Installation Guide - · PDF fileElmo SAXophone Installation Guide SAXUGEN0402 2-1 Chapter 2: Introduction The Saxophone system includes the Saxophone servo amplifier and