Elmo 95VDC manual

Duo Integrated Solution Installation Guide June 2007 (Ver. 1.0)[...]

Notice This guide is delive red subject to the following condi tions and restri ctions:  This guide con tains prop rietary inf ormation be longing to Elm o Motion Co ntrol Ltd. Such informati on is supp lied solely fo r the pu rpose of assisting users of th e Duo in its installation.  The text and graphic s included in this manual are for the[...]

Contents Chapter 1: S afety Informati on .......................................................................................... 1-1 1.1 Warning s ............................................................................................................. 1-2 1.2 Cautions .........................................................................[...]

3.11.2 Digit al Output ....................................................................................................... 3- 29 3.11.3 Analog Input ......................................................................................................... 3-29 3.12 Communic ations .................................................................[...]

B.5 I/O (CBL-H DRIO-001) ....................................................................................... B-5 B.6 Communication Cables ...................................................................................... B-6 B.6.1 RS-232 Option (C BL-RJ4523 21) ............................................................................. B-[...]

Duo Installation Guide MAN-DUOIG (Ver. 1.0) 1-1 Chapter 1: Safety Information In order t o achie ve the o ptimum, saf e oper ation of th e Duo, i t is imper ative th at you implement th e safety procedures in cluded in this installation guide. This informa tion is provided to protect you and to keep your work area safe when operating the Duo and ac[...]

1.1 Warnings To avoid el ectric arcing and haz ards to personne l or electrical dama ge, never connect/ disconnect any plug or cable from the ser vo drive whil e the power source is on. Power cables can carry a high vo ltage, even when th e motor is not in motion. Dis connect the Du o from all voltag e sources before it is ope ned for servicing. Th[...]

1.3 Directives and Standards The Duo conforms to the followin g industry safety standards: Safety Standard Item In complianc e with UL508 c Power Conversi on Equipment In complianc e with UL840 Insulatio n Coordina tion, Inclu ding Clear ance and Creepage Distances of Electri cal Equipment In complianc e with UL60950-1 (formerly UL1950) Safet y of [...]

Duo Installation Guide Introduction MAN-DUOIG (Ver. 1.0) 2-1 Chapter 2: Introduction This installa tion guide desc ribes the Duo and the steps fo r its wiring, installa tion and power-up. Fo llowing these guid elines ensures maximu m functionality of the prod uct and the system to which it is conne cted. 2.1 Product Description The Duo series of se[...]

Duo Installation Guide Introduction MAN-DUOIG (Ver. 1.0) 2-2 2.2 Product Features 2.2.1 Current Control  Fully digital  Sinusoidal commutation wi th vect or control or trapezoidal co mmutation with encoder an d/or digital Hall sen sors  12-bit current loop res olution  Automatic gain s cheduling, t o compensate for variations i n the DC[...]

Duo Installation Guide Introduction MAN-DUOIG (Ver. 1.0) 2-3 • Interpolat ed Anal og Sine/Cos ine Encod er – up t o 250 KH z (analog signal) Internal Interpolation - up to x4096 Automatic Correction of am plitude mism atch, phase mismatch, signals o ffset Auxiliary emulated, unbuffered , single-ended, encoder output • Resolver Programmable 10[...]

Duo Installation Guide Introduction MAN-DUOIG (Ver. 1.0) 2-4 Figure 2-1: Elmo Digital Servo Drive Do cumentation Hie rarchy As depicted in the previou s figure, this installa tion guide is an integral pa rt of the Duo documentation set, comprising:  The Duo Installa tion Guide contai ns information about how to use th e Duo and Cable Kit  The[...]

Duo User Guide 3-1 Chapter 3: Installation 3.1 Site Requirements You can guarantee the safe operati on of the Duo by ensuring that it is installed in an appro priate en vironmen t. Feature Value Ambient oper ating temperat ure 0 ° to 40 ° C (32 ° to 104 ° F) Maximum operating altitude 10,000m (30,000 ft) Maximum rela tive humidity 90% non-cond [...]

The part number at the t op gives the type designation as f ollows: DUO- A XX A XX/YYY ZZ Ax is 1 V er sio n : Blank = Standard A = A dvanced Ax is 2 V e r s io n : Blank = Standard A = Advanced Axis 1 Continuous Curr ent( Am ps) Axis 2 Continuous Curr ent( Am ps) Axis 1 Feedbacks: E- Incr emental Encoder and/or Hall s R- Res ol ve r I- Int erpolat[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-3 3.4 Connecting the Cables 3.4.1 Wiring the Duo Once the Duo is mou nted, you are ready to wire the de vice. Proper wiring, grou nding and shielding are esse ntial for ensuring safe, immu ne a nd optim al servo p erform ance of th e Duo. Follow these instructions to ensure safe a nd proper wirin g  Use twis[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-4 Type Function Connector Location Main Feedback Feedback I/O I/O Auxiliary Feedback Auxiliary Feedback Table 3-2: Co nnectors on the “F ront” of the Duo Type Function Connector Location CANopen CANopen IN CANopen CANopen OUT RS232 RS232-1 RS232-2 Table 3-3: Co nnectors on the “Top ” of the Duo Auxiliar[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-5 3.5 Duo Connectors type Type On Board Connector Qty Conn. 1 Main Power Phoenix 5-pin H e a d e r P/N:MSTBA 2.5HC/5-G Motor Power 2 P h o e ni x 4 - p i n Header P/N:MSTBA 2.5/4G-5.08 Main Feedback 2 12-pin Molex Header P/N:90130-3 212 I/O 2 14-pin Molex Header P/N:90130-3 214 2 Auxiliary Feedback 16-pin Molex[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-6 3.6 Hardware Requirements The compon ents that y ou will ne ed to install your Duo are: Described in section Cable Drawing Qty Conn. Component Mating Connector Function VL, VP+, PR , PR, PE Phoenix 5-pin P l u g P/N:MSTBT 2.5HC/5-ST Main Power 1 Plug PE VL Motor Power 2 Phoenix 4-pin P l u g P/N:MSTBT 2 .5/4-[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-7 3.7 Duo Block Diagram Figure 3-2: Duo Bloc k Diag ram[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-8 3.8 The Main Power and Motor Power Connectors Pi n Function Cable Pin Positions P E Protective earth Power P R Power return Power P R Aux. Supply Input Return Auxiliary VP+ Pos. Power input Power VL Aux. Supply Input Auxiliary AC Motor Cable DC Motor Cable M3 Motor phase Motor Motor M2 Motor phase Motor Motor[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-9 3.8.2 Connecting Main Power Connect the DC power supply cable to the VP+ and PR terminals of the Main po wer connecto r. Notes for connecti ng the DC po wer supply:  The source of the 0 ~ 95 VDC Power Supply mu st be isolated.  For the gre atest immunity, it is hig hly recommended t o use twisted and sh[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-10 3.8.3 Low power Auxiliary Supply (optional) Notes for 12 ~ 95 VDC Auxiliary Supply connections:  The source of the 12 ~ 95 VDC Auxilia ry Supply must be isolated f rom the Main. the  For safety reasons , connect the return (common) of Auxiliar y Supply so urce to the closest ground near the Auxilia ry [...]

Figure 3-6: Shared Supply Connectio n Diagram Duo User Guide MAN-DUOUG (Ver. 1.0) 3-11[...]

3.9 Main Feedback The Main Feedback port is used to transfer Feed back dat a from the m otor to th e drive. The Duo accepts the following as a Main Feedback mechanism:  Incrementa l encoder only  Incremental en coder with digital hal l sensors  Digital hall se nsors only  Incrementa l analog (sine/ cosine) encoder (option)  Resolver [...]

Figure 3-7: Main Feedback- In cremental En coder With Digi tal Halls Sen sors Connecti on Diagram Figure 3-8: Main Feedback- Incremental En coder Only Connection Diagram Duo User Guide MAN-DUOUG (Ver. 1.0) 3-13[...]

Figure 3-9: Main Feedback – Interpolated Analog Encod er Connection Diagram Figure 3-10 : Main Feed back– R esolver Conn ection Diagram Duo User Guide MAN-DUOUG (Ver. 1.0) 3-14[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-15 Figure 3-11 : Main Feed back – Tachom eter Feedba ck with Digit al Hall Sensor Connection Diagram for Brushless Motors Figure 3-12 : Main Feed back – Tachom eter Feedba ck Connectio n Diagram for B rush Motors[...]

Figure 3-13 : Main Feed back – Po tentiometer Feedback with Digital Hall Sensor Connection Diagram for Brushless Motors Figure 3-14 : Main Feed back – Potentiometer Feedback Connection Diag ram for Bru sh Motors and Voice Coils Duo User Guide MAN-DUOUG (Ver. 1.0) 3-16[...]

3.10 Auxiliary Feedback (bi-directional) When using one of the A uxiliary Fee dback opt ions, the relevant f unction ality of t he Auxili ary Feedback's p orts are s oftware sele cted for that op tion. Refer to the S implIQ Comman d Referenc e Manual for d etailed inf ormation about Auxiliary Feedback setup. The Auxiliary Feedback connecto r h[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-18 3.10.1 Main and Auxiliary Feedback Combinations The Main Feedback is always used in motion control devices whereas Auxili ary Feedback is often, bu t not always used. The Auxiliar y Feedback connec tor has two po rts (B1 and B2). When used in comb ination with Main Feedback, the Auxil iary Feedback can be se[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-19 Auxiliary Feedback: Input Main Feedback YA[4] = 2 (Auxiliary Feedback: input) YA[4] = 0 (Auxiliary Feedback: input) Incrementa l Encoder Input Interpolated Analog (Sin/Cos) Encoder Input Resolver Input Potentiometer Tachometer Input Mai n Feedback: Increm ental Encoder or Anal og Encoder or Resolver or Tacho[...]

3.10.2 Auxiliary Feedback – Emulated, Differential Buffered Encoder Output Option (YA[4]=4) The Auxiliary Feedback's B2 port can provide emulated en coder signals to other controllers or dr ives. Thi s option can be used when:  A Resolver or Analog Encoder is used as a Main Feedb ack device .  The Whistle is used as a current ampl ifie[...]

Figure 3-15: Emulated Encoder Outputs of the Resolver or Analog Encoder - Connection Diagram Duo User Guide MAN-DUOUG (Ver. 1.0) 3-21[...]

3.10.3 Auxiliary Feedback - Differential Encoder Input Option (YA[4]=2) The Whistle can be used as a slave by receivin g the position data (o n Port B1) of the master encoder in Follower or ECAM m ode. In this m ode Port B2 pr ovides differential buffered Auxiliary outputs of B1 for the next slave a xis in Foll ower or ECAM mo de. Below are the s i[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-23 Figure 3-6: Differential Auxiliary Input Option - Block Diagram[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-24 Figure 3-16: Differential Auxiliary Input Option on Auxi liary Feedback - Connection Diagra m[...]

3.10.4 Auxiliary Feedback – Differential Pulse-and-Direction Input Option (YA[4]=0) This mode is use d for input of differential pu lse-and-direction position commands on Port B1. In this mode Port B2 provides differential buffered pulse -and-direction outputs of B1 for another axis. Below are the s ignals on the Au xiliary Feedback ports when se[...]

Figure 3-17: Pulse-and-Direction Input Op tion on Auxi liary Feedback - Connection Diagram Duo User Guide MAN-DUOUG (Ver. 1.0) 3-26[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-27 3.11 I/O Each Whistl e on the Duo has 6 digital inputs, 2 digit al outputs and a single analog input. The I/O port has a 14-pin M olex Heade r plug with the following pin-outs. Pin Signal F un ct io n 1 OUT1 Programmable Digita l output 1 2 OUTRET1 Programmable Digital outpu t 1 return 3 OUT2 Programmable Di[...]

3.11.1 Digital Input The Default Digital I nput level Signal is set to 24v (PLC). Note: 5v is also available (TTL ). Figure 3-18: Digital Input Conn ection Diagram Duo User Guide MAN-DUOUG (Ver. 1.0) 3-28[...]

3.11.2 Digital Output Figure 3-19: Digital Output Conn ection Diagram 3.11.3 Analog Input Figure 3-20: Analog Input wi th Single-ended Source Duo User Guide MAN-DUOUG (Ver. 1.0) 3-29[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-30 3.12 Communications The communication cables use an 8-pin RJ-45 pl ug that connect t o the RS 232 and CAN open ports on the Du o. The communicatio n interface ma y differ according to the us er’s hardware. The Duo can communic ate using the fo llowing option s: 1. RS232, full duplex 2. CANopen RS232 commun[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-31 Figure 3-21: RS232 Connection Diagram 3.12.2 CANopen Communication Notes for connecti ng the CANop en communication cabl e:  Use 26 or 28 AWG twisted pair shie lded cables. For best results, the shield should have alum inum foil and be covere d by copper braid with a drain wire  Connec t the shield to [...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-32 Figure 3 -22: CANopen Network Conn ection Diagram Caution: When installing CAN open communications, ensure that each servo drive is allocated a unique ID . Otherwise, t he CANopen network may hang.[...]

Duo User Guide MAN-DUOUG (Ver. 1.0) 3-33 3.13 Powering Up After the cables have be en conn ected to their devices, the Du o is ready t o be powered up. Caution: Before apply ing power, ensure th at the DC supp ly is within the specified range and that the proper plus-mi nus connecti ons are in order. 3.14 Initializing the System After the Duo ha s [...]

Appendix A: Technical Specifications A.1 Features • Operating power o DC po wer su ppl y: 12 - 95 VDC source • DC BUS o DC power supply • Control supply o A separate DC power supply 12 - 95 VDC serves as both the auxiliary supply and the backup supply (Option) • Operating modes o Current, velocity and po sition • Commutati on alter native[...]

• Event triggered prog ramming st ructure • Analog inputs o 1 differenti al inputs with 12-bit resolution • Enable input, limit swit ches and emergency st op handling • Smart multi- purpose inputs o Programmable as Enable, Forward an d Reverse Limit Switches, H ome, Capture • Uncommitted programmable inputs o 6 Inputs sh aring one single [...]

A.2 Built-In Protection • Softwa re erro r handli ng o Software-based • Status repor ting o Available for a large numb er of fault conditi ons • Protecti on agai nst: o Short ci rcuit betwee n motor power outp uts o Short circu it betwee n each motor powe r output and DC bu s return o Failure of internal power supply o Heatsink ov er-temperat[...]

Duo Installation Guide MAN-DUOIG (Ver. 1.0) A-4 A.3 Duo Dimensions[...]

Duo Installation Guide MAN-DUOIG (Ver. 1.0) A-5 A.4 Power Ratings Feature Unit 1/60 2.5/60 5/60 10/60 15/60 1/100 2.5/100 5/10 0 10/100 15/100 M i ni mu m s u p pl y v ol t a g e VD C 8.5 12 Nominal supply voltage V DC 4 8 8 5 Maximum supply voltage V D C 59 9 5 Max. output power from the drive without heat sink W 50 120 240 480 720 75 180 400 800 [...]

A.5 Control Specifications A.5.1 Current Loop Feature Detail s Controller type Vector, digit al Current sampling time 70 - 100 μ sec Current loop bandwidth 1400 - 2500 Hz Compen sation fo r bus volta ge variations Gain scheduling Motor types  AC brushless (sin usoidal)  DC brushl ess (trape zoidal)  DC brush  Linear b rushless moto r C[...]

A.5.2 Velocity Loop Feature Detail s Controller type PI Speed sampling time 140 - 200 μ sec ( x2 current loop sample ti me) Velocity loop band width Velocity control  Fully digital  Programmable PI and FFW control filters  On-the -fly ga in schedul ing  Automatic, manual and advanced manual tuning Velocity and po sition feedbac k optio[...]

Duo Installation Guide MAN-DUOIG (Ver. 1.0) A-8 A.6 Feedbacks A.6.1 Incremental Encoder Feature Detail s Encoder form at  A, B and Inde x  Differential  Quadratu re Interface: RS-422 Input resistance: Differentia l: 120 Ω Maximum increment al encoder frequency: Maximum absolute: 5 MHz single, 20 MHz quadrature Minimu m quadra ture inpu t [...]

A.6.3 Digital Halls Feature Detail s Halls inputs  HA, HB, HC.  Single end ed inputs  Built in hysteresis for noise immunity. Input volt age Nominal op erating rang e: 0V < V In_Hall < 5V Maximum absolute: -1V < V In_Hall < 15V High level input v oltage: V InHigh > 2.5V Low level input volt age: V InLow < 1V Input current[...]

A.6.5 Resolver Feature Detail s Resolver format  Sine/Cosine  Differential Input resistance Differential 2.49 K Ω Resolution Programmable: 10 ~ 15 bits Maximum electrical frequency (RPS) 512 revolutio ns/sec Resolver transfer ratio 0.5 Reference frequency 1/Ts (Ts = sample time in seconds) Reference voltage Supplied by the Whistle Reference [...]

Duo Installation Guide MAN-DUOIG (Ver. 1.0) A-11 A.6.7 Potentiometer Feature Detail s Potentiometer F ormat Single-ended Operating Voltage Range 0 ~ 5V suppli ed by the W hist le Potentiometer Resistance 100 Ω ~ 1 K Ω … above this range, linearity is affected detrime ntally Input Resistance 100K Ω Resolution 14 Bit A.6.8 Auxiliary Feedback Por[...]

Duo Installation Guide MAN-DUOIG (Ver. 1.0) A-12 A.6.9 Auxiliary Feedback Port (input mode YA[4]= 2, 0) Feature Details Encoder input, pulse and direction input  A, B, Index  Differential Output current capability V In Low: 0V < V IL < 0.8V V In High: 2 V < V IH < 5V Maximum absolute voltage: 0 < V In < 5.5V Input current: ?[...]

Duo Installation Guide MAN-DUOIG (Ver. 1.0) A-13 A.7 I/Os A.7.1 Digital Input Interface – 6 Digital Inputs Feature Details Con nect or Locat ion Type of input  Optically isolated  All six inputs share one signal return line Input current for all inputs Iin = 6.5 mA @ Vin = 24 V Input voltage level 24 V Note: 5V level is also available Minim[...]

Duo Installation Guide MAN-DUOIG (Ver. 1.0) A-14 A.7.2 Digital Output Interface – 2 Digital Outputs Feature Details Con nect or Locat ion Type of output  Optical ly isolated  Open collec tor and op en emitter Maximum su pply output (Vcc) 30 V Max. output current Iout (max) (Vout = Low) Iout (max) ≤ 10 mA VOL at maximu m output voltage (lo[...]

A.8 Mechanical Specifications Feature Detail s Mounting The Duo designed for two standard mounting options:  “Wall Moun t” along the back (ca n also be mounted horizo ntally on a metal surface)  “Book Shelf ” along th e side Overall dimensions 150 X 105 X 25.4 (5 .9 X 4.13 X 1 in) Weight ~ 450 grams A.9 Environmental Conditions Featur[...]

A.10.2 Safety Specification Detail s Recogniz ed UL508c Power conversion equipment In complianc e with UL840 Insulation coord ination , includi ng clearan ce and creepag e distances of electric al equipment In complianc e with UL6095 0 Sa fety of in formation technolo gy equipme nt, including electri cal business equipment In complianc e with EN602[...]

Duo Installation Guide B-1 Appendix B: Cables (Optional) B.1 Cable Photos Main Feedback: CBL- HD RFB - 001 Auxiliary Feedback: CBL- HDRAUX -001 I/O: CBL- HDRI O-001 RS-232 Com.: CBL-RJ 452321 CAN Com.: CBL-RJ45CAN1[...]

B.2 Cable Kit The cables are all 2m in len gth. Each set contains the cab les listed below. Add itional cable kit and/or i ndividual cable s (in mul tiples of 10 ea ch) are availabl e from Elm o. Cable Application Cable Part. No. QTY Main Feedback CBL-HDRFB-001 2 Auxiliary Feedback CBL-HDRAUX-001 2 I/O CBL-HDRIO-001 2 RS-232 Communicati ons CBL-RJ4[...]

Duo Installation Guide MAN-DUO (Ver. 1.0) B-3 B.3 Main Feedback Cable (CBL-HDRFB-001) The Main Feedback cab le (CBL-HDRFB-001 ) is made of a 24-AWG shielded cable with a 12-pin Molex Hea der socket. It conn ects to the Main Feedback port on th e Duo. It is open on its other s ide so th at it can be connec ted to customer-speci fic motor con nector.[...]

Duo Installation Guide MAN-DUO (Ver. 1.0) B-4 B.4 Auxiliary Feedback (CBL-HDRAUX-001) The Auxiliary Feedback cable (CBL-HDRAUX-001) is made of a 24-AWG shielded cable with a 16-pin Molex Header socket. It conne cts to the Auxiliary Feedback port on the Duo. Pin No. Color Signal Pairs 1 Brown +5V 2 White COMRET pair 3 Cyan CHA 4 Orange CHA- pair 5 P[...]

Duo Installation Guide MAN-DUO (Ver. 1.0) B-5 B.5 I/O (CBL-HDRIO-001) The I/O cable (CBL- HDRIO-001) is m ade of a 24-AWG shield ed cable with a 14-pin Mol ex Header socket. It connects to th e I/O port on the Duo. Pin No. Color Signal Pairs 1 Orange OUT1 2 Cyan OUTRET1 pair 3 Black OUT2 4 Purple OUTRET2 pair 5 Brown IN1 6 White IN 2 pair 7 Green I[...]

Duo Installation Guide MAN-DUO (Ver. 1.0) B-6 B.6 Communication Cables The communicatio n cables use 26-AWG twi sted pair shielded cable. They are connecte d using an 8-pin RJ-45 pl ug. Elmo drives c an communi cate using the fo llowing opti ons:  RS-232 fu ll duplex  CANopen B.6.1 RS-232 Option (CBL-RJ452321) RJ45 Pin No. Color D-type Female[...]

Duo Installation Guide MAN-DUO (Ver. 1.0) B-7 B.6.2 CAN Open (CBL-RJ45CAN1) RJ45 Pin No. Color D-type Female Pin No. Signal Description 1 Green 7 CAN-H CAN_H bus line 2 Yellow 2 CAN_L CAN_L bus line 3 White 3 CAN_GND CAN ground 4 — — — — 5 — — — — 7 — — — — 8 — 1 — — — body Drain Wire body shield cable shield The shi[...]

Duo Installation Guide MAN-DUO (Ver. 1.0) B-8 B.7 Guidelines for Making Your Own Cables Proper wiring, grou nding and sh ielding are essential for ensuring safe, immun e and optimal servo performance of the Duo. If you do not plan to use ca bles provided by Elmo, follow the instructions belo w carefully. Follow these instructions to ensure safe a n[...]