Elmo Elmo Computer Drive Drum Digital Servo Drive, Elmo Computer Drive 1 User Manual

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Drum

Digital Servo Drive

Installation Guide

April 2008 (Ver. 1.0)

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 Drum servo drive in its 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-DRUIG

Copyright 2008

Elmo Motion Control Ltd.

All rights reserved

Drum Catalog

DRU- A XX/YYYR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Version :

 

 

 

 

 

 

 

 

 

 

 

Number:

 

 

 

 

 

 

Blank = Standard

 

 

 

 

 

 

A = Advanced

 

 

 

 

 

 

Continuous Current

 

 

 

 

 

Feedback:

 

(Amps)

 

 

 

 

 

 

 

 

 

Blank = Incremental

 

Maximum DC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Encoder

 

Operating Voltage

 

and/or Halls

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R = Resolver

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I = Interpolated

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Analog

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Encoder

 

 

 

 

 

 

 

 

 

 

 

 

 

 

T = Tachometer &

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Potentiometer

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Q = Absolute

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Encoder

Revision History:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Ver. 1.0 April 2008

Initial Release (MAN-DRUIG.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: +972 (3) 929-2300

Tel: +1 (978) 399-0034

Tel: +49 (0) 7720-8577 60

 

Fax: +972 (3) 929-2322

Fax: +1 (978) 399-0035

Fax: +49 (0) 7720-8577 70

www.elmomc.com

 

 

 

info-il@elmomc.com

info-us@elmomc.com

info-de@elmomc.com

 

 

 

 

 

Drum Installation Guide

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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 ........................................................................................

1-3

Chapter 2: Introduction....................................................................................................

2-1

2.1

Drive Description................................................................................................

2-1

2.2

Product Features .................................................................................................

2-1

 

2.2.1

Current Control ...........................................................................................

2-1

 

2.2.2

Velocity Control...........................................................................................

2-2

 

2.2.3

Position Control...........................................................................................

2-2

 

2.2.4

Communication Options............................................................................

2-2

 

2.2.5

Feedback Options........................................................................................

2-2

 

2.2.6

Fault Protection............................................................................................

2-3

2.3

System Architecture............................................................................................

2-3

2.4

How to Use this Guide .......................................................................................

2-4

Chapter 3: Installation......................................................................................................

3-1

3.1

Before You Begin.................................................................................................

3-1

 

3.1.1

Site Requirements........................................................................................

3-1

 

3.1.2

Hardware Requirements ............................................................................

3-1

3.2 Unpacking the Drive Components ...................................................................

3-3

3.3

Mounting the Drum............................................................................................

3-4

3.4

Connecting the Cables........................................................................................

3-5

 

3.4.1

Wiring the Drum .........................................................................................

3-5

 

3.4.2 Connecting the Power Cables....................................................................

3-8

 

 

3.4.2.1 Connecting the Motor Cable................................................................

3-10

 

 

3.4.2.2 Connecting the DC Power....................................................................

3-10

 

 

3.4.2.3 Connecting the Optional Back-upSupply Cable ...............................

3-13

 

3.4.3 Feedback Control and Communication Cable Assemblies .................

3-14

 

3.4.4 Main Feedback Cable (FEEDBACK A)...................................................

3-15

 

3.4.5 Main and Auxiliary Feedback Combinations .......................................

3-28

 

3.4.6 Auxiliary Feedback (FEEDBACK B).......................................................

3-29

 

 

3.4.6.1 Main Encoder Buffered Outputs or Emulated Encoder Outputs Option

 

 

on FEEDBACK B (YA[4]=4)...............................................................................

3-30

 

 

3.4.6.2 Differential Auxiliary Encoder Input Option on FEEDBACK B

 

 

(YA[4]=2) ........................................................................................................

3-32

 

 

3.4.6.3 Single-endedAuxiliary Input Option on FEEDBACK B (YA[4]=2).3-34

 

 

3.4.6.4 Pulse-and-DirectionInput Option on FEEDBACK B (YA[4]=0) ......

3-36

 

3.4.7

I/O Cables ..................................................................................................

3-40

 

 

3.4.7.1 General I/O Port (J3) ............................................................................

3-40

 

3.4.8

Communication Cables ............................................................................

3-42

 

 

3.4.8.1

RS-232Communication ........................................................................

3-42

 

 

3.4.8.2

CANopen Communication ..................................................................

3-43

3.5 DC Power Supply .............................................................................................

3-45

3.5.1 Powering Up ..............................................................................................

3-45

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3.5.2

Initializing the System

3-45

 

 

 

3.6

Heat Dissipation................................................................................................

3-46

 

 

3.6.1

Drum Thermal Data..................................................................................

3-46

 

 

3.6.2

Heat Dissipation Data...............................................................................

3-46

 

 

3.6.3

How to Use the Charts..............................................................................

3-48

 

Appendix: Drum Technical Specifications..................................................................

A-1

 

A.1

Features...............................................................................................................

A-1

 

 

A.1.1

Motion Control Modes ..............................................................................

A-1

 

 

A.1.2

Advanced Positioning Control Modes....................................................

A-1

 

 

A.1.3

Advanced Filters and Gain Scheduling...................................................

A-1

 

 

A.1.4

Fully Programmable ..................................................................................

A-1

 

 

A.1.5

Feedback Options.......................................................................................

A-1

 

 

A.1.6

Input/Output..............................................................................................

A-2

 

 

A.1.7

Built-InProtection ......................................................................................

A-2

 

 

A.1.8

Accessories ..................................................................................................

A-3

 

 

A.1.9

Automatic Procedures ...............................................................................

A-3

 

A.2

Dimensions .........................................................................................................

A-4

 

A.3

Power Ratings ....................................................................................................

A-5

 

A.4

Environmental Conditions................................................................................

A-5

 

 

A.4.1

Auxiliary Supply ........................................................................................

A-6

 

A.5

Control Specifications........................................................................................

A-6

 

 

A.5.1

Current Loop...............................................................................................

A-6

 

 

A.5.2

Velocity Loop..............................................................................................

A-7

 

 

A.5.3

Position Loop ..............................................................................................

A-7

 

A.6

Feedbacks............................................................................................................

A-8

 

 

A.6.1

Feedback Supply Voltage..........................................................................

A-8

 

 

A.6.2

Main Feedback Options.............................................................................

A-8

 

 

 

A.6.2.1 Incremental Encoder Input ...................................................................

A-8

 

 

 

A.6.2.2 Digital Halls............................................................................................

A-9

 

 

 

A.6.2.3 Interpolated Analog Encoder (Sine/Cosine).......................................

A-9

 

 

 

A.6.2.4 Resolver...................................................................................................

A-9

 

 

 

A.6.2.5 Tachometer*..........................................................................................

A-10

 

 

 

A.6.2.6 Potentiometer .......................................................................................

A-11

 

 

 

A.6.2.7 Absolute Encoder.................................................................................

A-11

 

 

 

A.6.2.8 Encoder Outputs ..................................................................................

A-11

 

 

A.6.3

Auxiliary Port............................................................................................

A-12

 

A.7

 

I/Os .........................................................................................................

A-13

 

 

A.7.1

Digital Input Interfaces............................................................................

A-14

 

 

A.7.2

Digital Output Interface ..........................................................................

A-15

 

 

A.7.3

Analog Input .............................................................................................

A-15

 

A.8

Communications ..............................................................................................

A-16

 

A.9

Pulse Width Modulation (PWM)....................................................................

A-16

 

A.10 Standards Compliance..............................................................................

A-16

 

 

A.10.1 Quality Assurance....................................................................................

A-16

 

 

A.10.2 Design ........................................................................................................

A-16

 

 

A.10.3 Safety..........................................................................................................

A-17

 

 

A.10.4 EMC............................................................................................................

A-17

 

 

A.10.5 Workmanship ...........................................................................................

A-17

 

 

A.10.6 PCB .............................................................................................................

A-17

 

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A.10.7 Packing

.......................................................................................................A-18

 

A.10.8 WEEE*........................................................................................................

A-18

 

A.10.9 RoHS...........................................................................................................

A-18

 

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Chapter 1: Safety Information

In order to achieve the optimum, safe operation of the Drum servo drives, 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 Drum as well as the 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 Drum servo drives 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.

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Safety Information

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1.1Warnings

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 Drum from all voltage sources before it is opened for servicing.

The Drum servo drives 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 Drum 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 Drum to an approved 12~195 VDC auxiliary power supply, connect it 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 Drum, verify that all safety precautions have been observed and that the installation procedures in this manual have been followed.

Drum Installation Guide

Safety Information

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1.3Directives and Standards

The Drum conforms to the following industry safety standards:

Safety Standard

Item

 

 

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 Drum 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 Drum 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 Drum 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.

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.

Drum Installation Guide

Introduction

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Chapter 2: Introduction

This installation guide describes the Drum servo drives and the steps for its wiring, installation and power-up.Following these guidelines ensures maximum functionality of the drive and the system to which it is connected.

2.1Drive Description

The Drum series are highly resilient digital servo drives designed to deliver “the highest density of power and intelligence”. The Drum delivers up to 9.6 kW of continuous power or11.2 kW of peak power in a compact package.

The digital drives are based on Elmo’s advanced SimplIQ motion control technology. They operate from a DC power source in current, velocity, position and advanced position modes, in conjunction with apermanent-magnetsynchronous brushless motor, DC brush motor, linear motor or voice coil. They are designed for use with any type of sinusoidal and trapezoidal commutation, with vector control. The Drum can operate as astand-alonedevice or as part of amulti-axissystem in a distributed configuration on areal-timenetwork.

The drives are easily set up and tuned using Elmo’s Composer software tools. ThisWindows-basedapplication enables users to quickly and simply configure the servo drive for optimal use with their motor. The Drum, as part of theSimplIQ product line, are fully programmable with ElmoMetronome motion control language.

Power to the drives is provided by a 12 ~ 195 VDC isolated DC power source (not included with the Drum). The power stage is fully isolated from the control stage. A “smart” control-supplyalgorithm enables the Drum to operate with only one power supply with no need for an auxiliary power supply for the logic.

If back-upfunctionality is required for storing control parameters in case ofpower-loss,an external 12 ~ 195 VDC isolated supply should be connected (via the CAN connector on the Drum) providing maximum flexibility and backup functionality when needed.

Note: Thisback-upfunctionality can operate from any voltage source within the

12 ~ 195 VDC range. This is much more flexible than to be restricted by only using a standard 24 VDC power supply.

If back-uppower is not needed, then the main power supply will also power the control/logic supply. In this way there is no need for a separate control/logic supply.

2.2Product Features

2.2.1Current Control

Fully digital

Sinusoidal commutation with vector control or trapezoidal commutation with encoder and/or digital Hall sensors

12-bitcurrent loop resolution

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Automatic gain scheduling, to compensate for variations in the DC bus power supply

2.2.2Velocity Control

Fully digital

Programmable PI and FFW (feed forward) control filters

Sample rate two times current loop sample time

“On-the-fly”gain scheduling

Automatic, manual and advanced manual tuning and determination of optimal gain and phase margins

2.2.3Position Control

Programmable PIP control filter

Programmable notch and low-passfilters

Position follower mode for monitoring the motion of the slave axis relative to a master axis, via an auxiliary encoder input

Pulse-and-directioninputs

Sample time: four times that of current loop

Fast event capturing inputs

PT and PVT motion modes

Position-basedandtime-basedECAM mode that supports anon-linearfollower mode, in which the motor tracks the master motion using an ECAM table stored in flash memory

Dual (position/velocity) loop

Fast output compare (OC)

2.2.4Communication Options

Drum users can use two communication options:

RS-232serial communication

CANopen for fast communication in a multi-axisdistributed environment

2.2.5Feedback Options

Incremental Encoder – up to 20 Mega-Counts(5Mega-Pulse)per second

Digital Halls – up to 2 kHz

Incremental Encoder with Digital Halls for commutation – up to 20 MegaCounts per second for encoder

Interpolated Analog Sine/Cosine Encoder – up to 250 kHz (analog signal)

Internal Interpolation - up to x4096

Automatic Correction of amplitude mismatch, phase mismatch, signals offset

Auxiliary emulated, unbuffered, single-ended,encoder output

Resolver

Programmable 10~15 bit resolution Up to 512 revolutions per second (RPS)

Auxiliary emulated, unbuffered, single-ended,encoder output

Tachometer, Potentiometer