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

Dragonfly/Butterfly

Current Mode Servo Amplifiers for DC Br ush 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

Continuous Current

Operating Voltage

Related Products:

Evaluation Board Catalog Number
Evaluation Board User Manual

Revision History:

Ver. 1.1 April 2008 Updated Power Ratings Table in Appendix
Ver. 1.0 June 2007 Initial release

Elmo Motion Control Ltd.

64 Gisin St., P.O. Box 463
Petach Tikva 49103
Israel

Tel: [phone]
Fax: [phone]

[e-mail]

(Amps)

Maximum DC

Elmo Motion Control Inc.

1 Park Drive, Suite 12
Westford, MA 01886
USA

Tel: [phone]
Fax: [phone]

[e-mail]

DRA-

Continuous Cu rrent

(Amps)

Maximum DC

Operating Voltage

X/YY

OCA-EVLBRD-1 (available upon request)
MAN-EVLBRD-OCA (available on our web site)

(MAN-DRBUIG.PDF)

Elmo Motion Control GmbH

Steinkirchring 1
D-78056, Villingen-Schwenningen
Germany

Tel: [phone]
Fax: [phone]

[e-mail]

www.elmomc.com

Dragonfly/B utterfly Installation Guide

MAN-DRBUIG (Ver. 1.1)

i

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

Dragonfly/B utterfly Installation Guide Contents

MAN-DRBUIG (Ver. 1.1)

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

ii

Dragonfly/B utterfly Installation Guide

MAN-DRBUIG (Ver. 1.1)

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-resistance earth 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-sensitive components 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 electricity build-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/B utterfly Installation Guide Safety Information

MAN-DRBUIG (Ver. 1.1)

1.1 Warnings

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/applicat ions/ar ti cl e/Sol der ing-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.

1-2

The Dragonfly and Butterfly servo drive cont ain ground ing condui ts 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.

1.2 Cautions

The Dragonfly and Butterfly servo drives contain hot surfaces and
electrically-charged components 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.

Dragonfly/B utterfly Installation Guide Safety Information

MAN-DRBUIG (Ver. 1.1)

1.3 Directives and Standards

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

Safety Standard Item

1-3

In compliance with MIL-STD-704
In compliance with MIL-STD-810

Aircraft, Electric Power Characteristics
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
In compliance with ISO-9001:2000

Reliability Prediction of Electronic Equipment

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
(formerly UL1950)

Safety of Information Technology Equipment,
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 r esponsib le for t he perform ance of new
measurements or ensuring that regulatory requirements are met.

1.4 CE 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 EN60204-1 and EN292-2 at the least.

According to Annex III of Article 13 of Council Directive 93/68/EEC, amending Council
Directive 73/23/EEC concerning electrical equipment desi gned for use wit hin certai n
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 t he
limits required by EMC regulations is the manufacturer of the end product.

Dragonfly/B utterfly Installation Guide Safety Information

MAN-DRBUIG (Ver. 1.1)

1.5 Warranty 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.

1-4

Cymbal Installat ion Guide Introduction

MAN-CYMIG (Ver. 1.1)

Chapter 2: Introduction

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

2.1 Product Description

The Cymbal series of servo amplifiers is designed to operate in the current mode
controlling permanent-magnet trapezoidal 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.

2-1

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-isolated DC 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.

2.2 Standard Features

• Operates in current mode

• Internal DC-to-DC converter, 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-limit adjustments

• Package: plated-aluminum base plate, plastic housing, UL94V0 recognized

• Ultra-lightweight of 700 grams (24.7 oz)

Cymbal Installat ion Guide Introduction

MAN-CYMIG (Ver. 1.1)

2.3 Fault Protection

Built-in protection 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

2.4 How 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, provides step-by-step instructions for unpacking, mounting and

connecting the Cymbal.

2-2

Chapter 4, Servo Control Operation, explains how to control the operat ion of t he servo

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