Elmo ExtrIQ Dragonfly-Butterfly, BUT- X-YYY, DRA- X-YY User Manual

Dragonfly/Butterfly

Current Mode Servo Amplifiers for DC Brush and Brushless

Motors with Trapezoidal Commutation in

Extended Environmental Conditions

Installation Guide

April 2008 (Ver. 1.1)

www.elmomc.com

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 Dragonfly and Butterfly servo drives in their installation.

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.

Elmo Motion Control and the Elmo Motion Control logo are trademarks of Elmo Motion Control Ltd.

Information in this document is subject to change without notice.

Document No. MAN-DRBUIG

Copyright 2008

Elmo Motion Control Ltd.

All rights reserved.

Hornet/Bee Catalog Numbers:

BUT- X/YYY

DRA- X/YY

Continuous Current

Continuous Current

(Amps)

(Amps)

Maximum DC

Maximum DC

Operating Voltage

Operating Voltage

Related Products:

Evaluation Board Catalog Number

OCA-EVLBRD-1(available upon request)

Evaluation Board User Manual

MAN-EVLBRD-OCA(available on our web site)

Revision History:

Ver. 1.1

April 2008

Updated Power Ratings Table in Appendix

Ver. 1.0

June 2007

Initial release

(MAN-DRBUIG.PDF)

Elmo Motion Control Ltd.

Elmo Motion Control Inc.

Elmo Motion Control GmbH

64 Gisin St., P.O. Box 463

1 Park Drive, Suite 12

Steinkirchring 1

Petach Tikva 49103

Westford, MA 01886

D-78056,Villingen-Schwenningen

Israel

USA

Germany

Tel: [phone]

Tel: [phone]

Tel: [phone]

Fax: [phone]

Fax: [phone]

Fax: [phone]

[e-mail]

[e-mail]

[e-mail]

www.elmomc.com

	Dragonfly/Butterfly Installation Guide	i
	MAN-DRBUIG(Ver. 1.1)
	Contents

Chapter 1: Safety Information ...............................................................................................		1-1
1.1	Warnings....................................................................................................................	1-2
1.2	Cautions .....................................................................................................................	1-2
1.3	Directives and Standards .........................................................................................	1-3
1.4	CE Mark Conformance .............................................................................................	1-3
1.5	Warranty Information...............................................................................................	1-4

Chapter 2: Introduction...........................................................................................................		2-1
2.1	ExtrIQ Product Family..............................................................................................	2-1
2.2	Product Description ..................................................................................................	2-2
2.3	Highlights ..................................................................................................................	2-2
2.4	Fault Protection .........................................................................................................	2-3
2.5	How to Use this Guide .............................................................................................	2-3

Chapter 3: Installation ............................................................................................................			3-1
3.1	Before You Begin.......................................................................................................		3-1
	3.1.1	Site Requirements .............................................................................................	3-1
3.2	Unpacking the Amplifier..........................................................................................		3-1
3.3	Dimensions ................................................................................................................		3-2
	3.3.1	Butterfly Dimensions........................................................................................	3-2
	3.3.2	Dragonfly Dimensions .....................................................................................	3-3
3.4	Mounting ...................................................................................................................		3-3
	3.4.1	Butterfly..............................................................................................................	3-3
	3.4.2	Dragonfly ...........................................................................................................	3-3
3.5	Integrating the Dragonfly and Butterfly on a PCB ................................................		3-4
	3.5.1	Traces..................................................................................................................	3-4
	3.5.2	Grounds and Returns.......................................................................................	3-5
3.6	Pin Functions .............................................................................................................		3-6
	3.6.1	Pinouts................................................................................................................	3-6
	3.6.2	Connector J1 ......................................................................................................	3-7
3.7	Dragonfly/Butterfly Connection Diagram.............................................................		3-9
3.8	Evaluation Board and Cable Kit ..............................................................................		3-9
3.9	DC Power Supply....................................................................................................		3-10
3.10 Heat Dissipation......................................................................................................			3-12
	3.10.1	Butterfly............................................................................................................	3-12
		3.10.1.1 Thermal Data.........................................................................................	3-12
		3.10.1.2 Heat Dissipation Data...........................................................................	3-12
		3.10.1.3 How to Use the Charts .........................................................................	3-13
	3.10.2	Dragonfly .........................................................................................................	3-13

Chapter 4: Servo Control Operation .....................................................................................			4-1
4.1	Current Command Input .........................................................................................		4-1
4.2	External Current Limit - Continuous (ECLC) ........................................................		4-1
	4.2.1	External Voltage............................................................................................	4-1
	4.2.2	External Resistor ...............................................................................................	4-2
	4.2.3	External Current Limit - Peak (ECLP) ...........................................................	4-2

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	4.2.4	External Voltage	4-2
	4.2.5	External Resistor ...............................................................................................	4-3
	4.2.6	Latch Mode (LM) ..............................................................................................	4-3
4.3	Status Indications......................................................................................................		4-3
Appendix: Specifications ......................................................................................................			A-1
A.1	General Specifications..............................................................................................		A-1
	A.1.1	Butterfly.............................................................................................................	A-1
	A.1.2	Dragonfly ..........................................................................................................	A-2
A.2	Environmental Specifications .................................................................................		A-2
A.3	Standards Compliance.............................................................................................		A-3
	A.3.1	Quality Assurance ...........................................................................................	A-3
	A.3.2	Design................................................................................................................	A-3
	A.3.3	Safety .................................................................................................................	A-3
	A.3.4	EMC ...................................................................................................................	A-4
	A.3.5	Workmanship...................................................................................................	A-4
	A.3.6	PCB ....................................................................................................................	A-4
	A.3.7	Packing ..............................................................................................................	A-4
	A.3.8	WEEE* ...............................................................................................................	A-4
	A.3.9	RoHS..................................................................................................................	A-4

	Dragonfly/Butterfly Installation Guide	1-1
	MAN-DRBUIG(Ver. 1.1)

Chapter 1: Safety Information

In order to achieve the optimum, safe operation of the Dragonfly and Butterfly servoamplifiers, 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 Dragonfly and Butterfly and accompanying equipment.

Please read this chapter carefully before you begin the installation process.

Before you start, ensure that all system components are connected to earth ground. Electrical safety is provided through a low-resistanceearth connection.

Only qualified personnel may install, adjust, maintain and repair the servo drive. A “qualified person” has the knowledge and authorization to perform tasks such as transporting, assembling, installing, commissioning and operating motors.

The Dragonfly and Butterfly servo drive contain electrostatic-sensitivecomponents that can be damaged if handled incorrectly. To prevent any electrostatic damage, avoid contact with highly insulating materials, such as plastic film and synthetic fabrics. Place the product on a conductive surface and ground yourself in order to discharge any possible static electricitybuild-up.

To avoid any potential hazards that may cause severe personal injury or damage to the product during operation, keep all covers and cabinet doors shut.

The following safety symbols are used in this manual:

Warning:

This information is needed to avoid a safety hazard, which might cause bodily injury.

Caution:

This information is necessary for preventing damage to the product or to other equipment.

Note:

This is auxiliary information that ensures the correct operation of the equipment.

Dragonfly/Butterfly Installation Guide	Safety Information	1-2
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1.1Warnings

Cleaning after soldering

To avoid the damage of the product's acrylic coating the Dragonfly/Butterfly must not be cleaned after soldering by dissolving solvents and /or "water" cleaning process. For more details: http://www.elmomc.com/applications/article/Soldering-and- Cleaning_Application-Note.pdf

To avoid electric arcing and hazards to personnel and electrical contacts, never connect/disconnect the servo drive while the power source is on.

Power cables can carry a high voltage, even when the motor is not in motion. Disconnect the Dragonfly and Butterfly from all voltage sources before they are opened for servicing.

The Dragonfly and Butterfly servo drive contain grounding conduits for electric current protection. Any disruption to these conduits may cause the instrument to become hot (live) and dangerous.

After shutting off the power and removing the power source from your equipment, wait at least 1 minute before touching or disconnecting parts of the equipment that are normally loaded with electrical charges (such as capacitors or contacts). Measuring the electrical contact points with a meter, before touching the equipment, is recommended.

1.2Cautions

The Dragonfly and Butterfly servo drives contain hot surfaces and electrically-chargedcomponents during operation.

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

When connecting the Dragonfly and Butterfly to an approved 12 ~ 95 VDC auxiliary power supply, connect them through a line that is separated from hazardous live voltages using reinforced or double insulation in accordance with approved safety standards.

Before switching on the Dragonfly and Butterfly, verify that all safety precautions have been observed and that the installation procedures in this manual have been followed.

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1.3Directives and Standards

The Dragonfly and Butterfly conform to the following industry safety standards:

	Safety Standard	Item
	In compliance with MIL-STD-704	Aircraft, Electric Power Characteristics
	In compliance with MIL-STD-810	Environmental Engineering Considerations and
		Laboratory Tests
	In compliance with MIL-STD-1275	Characteristics of 28 Volt DC Electrical Systems in
		Military Vehicles
	In compliance with MIL-STD-461	Requirements for the Control of Electromagnetic
		Interference Characteristics of Subsystems and
		Equipment
	In compliance with MIL-HDBK-217	Reliability Prediction of Electronic Equipment
	In compliance with ISO-9001:2000	Quality Management
	In compliance with UL508c	Power Conversion Equipment
	In compliance with UL840	Insulation Coordination, Including Clearance and
		Creepage Distances of Electrical Equipment
	In compliance with UL60950-1	Safety of Information Technology Equipment,
	(formerly UL1950)	Including Electrical Business Equipment
	In compliance with EN60204-1	Low Voltage Directive, 73/23/EEC

The Dragonfly and Butterfly servo drives have been developed, produced, tested and documented in accordance with the relevant standards. Elmo Motion Control is not responsible for any deviation from the configuration and installation described in this documentation. Furthermore, Elmo is not responsible for the performance of new measurements or ensuring that regulatory requirements are met.

1.4CE Mark Conformance

The Dragonfly and Butterfly servo drives are intended for incorporation in a machine or end product. The actual end product must comply with all safety aspects of the relevant requirements of the European Safety of Machinery Directive 98/37/EC as amended, and with those of the most recent versions of standards EN60204-1andEN292-2at the least.

According to Annex III of Article 13 of Council Directive 93/68/EEC, amending Council Directive 73/23/EEC concerning electrical equipment designed for use within certain voltage limits, the Butterfly and Dragonfly meet the provisions outlined in Council Directive 73/23/EEC. The party responsible for ensuring that the equipment meets the limits required by EMC regulations is the manufacturer of the end product.

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1.5Warranty Information

The products covered in this manual are warranted to be free of defects in material and workmanship and conform to the specifications stated either within this document or in the product catalog description. All Elmo drives are warranted for a period of 12 months from the time of installation, or 18 months from time of shipment, whichever comes first. No other warranties, expressed or implied — and including a warranty of merchantability and fitness for a particular purpose — extend beyond this warranty.

Cymbal Installation Guide	Introduction	2-1
MAN-CYMIG(Ver. 1.1)

Chapter 2: Introduction

This Installation Guide is intended for design engineers who are integrating Elmo Motion Control Cymbal servo amplifiers into a machine.

2.1Product Description

The Cymbal series of servo amplifiers is designed to operate in the current mode controlling permanent-magnettrapezoidal brushless motor and DC brush motor.

The Cymbal exhibits “the highest density of power and intelligence” and can deliver up to 11.3 kW of continuous power or 13.6 k W of peak power in a most compact and efficient package.

The Cymbal operates from a DC power source in the range of 12 ~ 195 VDC.

The Power stage of the Cymbal is fully isolated from other sections of the Cymbal, such as the control stage and the heatsink. This contributes very significantly to the safety and the EMI immunity of the Cymbal. In addition it simplifies the requirements of the DC power supply used to power the DC bus of the Cymbal and allows also the operation with a non-isolatedDC power source.

The Cymbal incorporates full custom mixed analog/digital ICs and a hybrid power stage. The basic configuration is a current mode amplifier targeting the OEM market. As such, no trimmers are used in the basic version. In addition to its compliance with relevant MIL standards, the Cymbal amplifier also meets UL508c and the relevant CE regulations.

The Cymbal power stage is implemented on ceramic substrates. This design enables very high thermal conductivity, high current carrying capacity, improved EMC and good mechanical strength. The control section is implemented by dedicated custom ICs that contribute to enhanced performance and reliability.

2.2Standard Features

•Operates in current mode

•Internal DC-to-DCconverter, which allows for operation from a single supply

•Zero dead-band

•Excellent linearity

•One differential input

•Motor current monitor

•Current gain change for low inductance motors

•Remote current gain control

•Status indication and remote control functions by four open collector transistors

•External continuous and peak current-limitadjustments

•Package: plated-aluminumbase plate, plastic housing, UL94V0 recognized

•Ultra-lightweightof 700 grams (24.7 oz)

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MAN-CYMIG(Ver. 1.1)

2.3Fault Protection

Built-inprotection against possible fault conditions, including:

•Shorts between the outputs or between each output and the power input/return

•Over-heating

•Under/over voltage

•Failure of internal power supplies

•Latch mode for each protective feature

2.4How to Use this Guide

Installation is the first step in integrating and operating the Elmo Cymbal servo amplifiers. After carefully reading the safety instructions in the first chapter, the following chapters provide you with installation instructions as follows:

Chapter 3, Installation, providesstep-by-stepinstructions for unpacking, mounting and connecting the Cymbal.

Chapter 4, Servo Control Operation, explains how to control the operation of the servo amplifier.

The Appendix, Technical Specifications, lists all the drive ratings and specifications.