Ocarina/Castanet
Analog Servo Drives
Installation Guide
April 2008- Ver. 1.2
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 Ocarina
and Castanet 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-OCSIG
Copyright 2008
Elmo Motion Control Ltd.
All rights reserved.
Ocarina/Castanet Catalog Number:
OCA- X/YYY
Continuous Current
(Amp s)
Maximum DC
Operating Voltage
Related Products:
Evaluation Board Catalog Number
Evaluation Board User Manual
Revision History:
Ver. 1.2 April 2008 Updated Power Ratings Table in Appendix
Ver. 1.1 April 2007 Added section in Ch.4 about connecting to DC motors (MAN-OCSIG.PDF)
Ver. 1.0 June 2006 Initial (MAN-OCSIG.PDF)
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
info-il@elmomc.com
Elmo Motion Control Inc.
1 Park Drive, Suite 12
Westford, MA 01886
USA
Tel: +1 (978) 399-0034
Fax: +1 (978) 399-0035
info-us@elmomc.com
CAS- X/YY
Continuous Current
(Amps)
Maximum DC
Operating Voltage
OCA-EVLBRD-1 (available upon request)
MAN-EVLBRD-OCA (available on our web site)
Elmo Motion Control GmbH
Steinkirchring 1
D-78056, Villingen-Schwenningen
Germany
Tel: +49 (0) 7720-85 77 60
Fax: +49 (0) 7720-85 77 70
info-de@elmomc.com
www.elmomc.com
Ocarina/Castanet Installation Guide
MAN-OCSIG (Ver. 1.2)
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...............................................................................................1-3
Chapter 2: Introduction...........................................................................................................2-1
2.1 Product Description..................................................................................................2-1
2.2 Highlights..................................................................................................................2-1
2.3 Fault Protection.........................................................................................................2-2
2.4 How to Use this Guide.............................................................................................2-2
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 Ocarina Dimensions......................................................................................... 3-2
3.3.2 Castanet Dimensions........................................................................................3-2
3.4 Mounting...................................................................................................................3-3
3.4.1 Ocarina...............................................................................................................3-3
3.4.2 Castanet..............................................................................................................3-3
3.5 Integrating the Ocarina and Castanet on a PCB.................................................... 3-4
3.5.1 Traces..................................................................................................................3-4
3.5.2 Grounds and Returns.......................................................................................3-4
3.6 Pin Functions.............................................................................................................3-5
3.6.1 Pinouts................................................................................................................3-5
3.6.2 Connector J1 ......................................................................................................3-6
3.7 Ocarina/Castanet Connection Diagram.................................................................3-8
3.8 Main Power and Motor Power................................................................................ 3-9
3.9 Evaluation Board and Cable Kit..............................................................................3-9
3.10 DC Power Supply....................................................................................................3-10
3.11 Heat Dissipation......................................................................................................3-12
3.11.1 Ocarina.............................................................................................................3-12
3.11.1.1 Thermal Data.........................................................................................3-12
3.11.1.2 Heat Dissipation Data...........................................................................3-12
3.11.1.3 How to Use the Charts.........................................................................3-13
3.11.2 Castanet............................................................................................................3-13
Chapter 4: Servo Control Operation.....................................................................................4-1
4.1 Ocarina/Castanet Connected to DC Motors..........................................................4-1
4.2 Current Command Input .........................................................................................4-1
4.3 External Current Limit - Continuous (ECLC)........................................................4-1
4.3.1 External Voltage................................................................................................4-1
Ocarina/Castanet Installation Guide Contents
MAN-OCSIG (Ver. 1.2)
4.3.2 External Resistor...............................................................................................4-2
4.3.3 External Current Limit - Peak (ECLP)...........................................................4-2
4.3.4 External Voltage................................................................................................ 4-2
4.3.5 External Resistor...............................................................................................4-3
4.3.6 Latch Mode (LM).............................................................................................. 4-3
4.4 Status Indications ......................................................................................................4-3
Appendix: Specifications ......................................................................................................A-1
A.1 General Specifications..............................................................................................A-1
A.1.1 Ocarina..............................................................................................................A-1
A.1.2 Castanet.............................................................................................................A-2
A.2 Standards Compliance.............................................................................................A-3
A.2.1 Quality Assurance...........................................................................................A-3
A.2.2 Design................................................................................................................A-3
A.2.3 Safety.................................................................................................................A-3
A.2.4 EMC...................................................................................................................A-4
A.2.5 Workmanship...................................................................................................A-4
A.2.6 PCB ....................................................................................................................A-4
A.2.7 Packing..............................................................................................................A-4
ii
Ocarina/Castanet Installation Guide
MAN-OCSIG (Ver. 1.2)
1-1
Chapter 1: Safety Information
In order to achieve the optimum, safe operation of the Ocarina and Castanet 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 Ocarina and Castanet 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 Ocarina and Castanet servo drives 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.
Ocarina/Castanet Installation Guide Safety Information
MAN-OCSIG (Ver. 1.2)
1.1 Warnings
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 Ocarina and Castanet from all voltage sources
before they are opened for servicing.
The Ocarina and Castanet servo drives contains 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.
1-2
Cleaning after soldering
To avoid the damage of the product's acrylic coating the Flute mus t not be
cleaned after soldering by dissolving solvents and /or "water" cleaning
process. For more details:
www.elmomc.com/applications/article/Soldering-andCleaning_Application-Note.pdf
1.2 Cautions
The Ocarina and Castanet 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 Ocarina and Castanet to an approved 12 ~ 95 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 Ocarina and Castanet, verify that all safety
precautions have been observed and that the installation procedures in
this manual have been followed.
Ocarina/Castanet Installation Guide Safety Information
MAN-OCSIG (Ver. 1.2)
1.3 Directives and Standards
The Ocarina and Castanet conform to the following industry safety standards:
Safety Standard Item
In compliance with UL508c Power Conversion Equipment
1-3
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 Ocarina and Castanet 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 Ocarina and Castanet 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 Ocarina and Castanet meet the provisions outlined in Council
Directive 73/23/EEC. The party responsible for ensuring that the equipment meet t he
limits required by EMC regulations is the manufacturer of the end product.
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.
Ocarina/Castanet Installation Guide Introduction
MAN-OCSIG (Ver. 1.2)
Chapter 2: Introduction
This Installation Guide is intended for design engineers who are integrating an Elmo
Motion Control Ocarina and Castanet servo amplifiers into a machine.
2.1 Product Description
The Ocarina and Castanet series of servo-amplifiers was designed to deliver “the highest
possible power density”. The Ocarina can deliver up to 1.4 kW of continuous power or
2.8 kW of peak power in a matchbox size (2.25 in³ or 38cc) package. The Castanet delivers
up to 240 W of continuous power or 480 W of peak power.
The Ocarina and Castanet are designed for OEMs. They operate from a DC power source in
current mode in conjunction with a DC Brush and Brushless motors (refer to section 4.1).
The Ocarina and Castanet can operate as a stand-alone device.
There are two categories of Ocarinas and Castanets, 60 VDC versions and 100 VDC
versions. Power to the 60 V products is provided by a separate 0 ~ 59 V isolated DC
power source. Power to the 100 V products is provided by a separate 0 ~
DC power source.
95 V isolated
2-1
Note: There is a separate VL terminal for the control/logic supply input. In the 60 VDC
models this terminal can be connected to an external 11 ~ 59 VDC isolated supply. In the
100 VDC models this terminal can be connected to an external 12 ~ 95 VDC isolated
supply whenever the user wants to control the logic supply with an auxiliary low power
voltage source.
If power separation is not needed the VL and VP+ terminals can be shorted so that the
main
power supply will also power the control/logic supply and there will be no need
for a separate control/logic supply.
The Ocarina and Castanet are PCB mounted devices which enable efficient and cost
saving
implementation.
2.2 Highlights
• Operates in current mode
• 0 ~ 59 VDC isolated DC power source for 60 V models
• 0 ~ 95 VDC isolated DC power source for 100 V models
• Zero deadband
• Excellent linearity
• Differential current command input
• Motor current monitor
• Current gain change for low inductance motors
• Status indication by four open collector optos
• External continuous and peak current-limit adjustments
• Interface via 2 mm pitch 0.51 mm square pins
• Package: plated AL 6063T5 with electroless nickel, plastic housing, UL94V0
recognized (Ocarina only)
• Ultra-compact size – Ocarina: 2.1" x 0.6" x 1.8" (55 x 15 x 46.5 mm), Castanet: 2" x
0.49" x 1.65" (51 x 12.5 x 42 mm)
Ocarina/Castanet Installation Guide Introduction
MAN-OCSIG (Ver. 1.2)
• Weight: Ocarina – 1.6 oz (45g), Castanet – 0.76 oz (21.5 grams)
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 Ocarina and Castanet
servo amplifiers. After carefully reading the safety instructions in the first chapter, the
following chapters provide you with installation instructions as follows:
2-2
Chapter 3, Installation, provides step-by-step instructions for unpacking, mounting and
connecting the Ocarina.
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.
Ocarina/Castanet Installation Guide Installation
MAN-OCSIG (Ver. 1.2)
Chapter 3: Installation
3.1 Before You Begin
3.1.1 Site Requirements
You can guarantee the safe operation of the Ocarina and Castanet by ensuring that they are
installed in an appropriate environment.
Feature Value
Ambient operating temperature 0 °C – 50 °C (32 °F – 122 °F)
Maximum relative humidity 90% non-condensing
Operating area atmosphere No flammable gases or vapors permitted in area
Note: Models for extended environmental conditions are available.
3-1
The Ocarina and Castanet dissipate their heat by convection. The maximum
ambient operating temperature of 0 °C – 50 °C (32 °F – 122 °F) must not be
exceeded.
3.2 Unpacking the Amplifier
To unpack the Ocarina and Castanet:
Carefully remove the servo amplifier from the box and the Styrofoam.
1. Check the amplifier to ensure that there is no visible damage to the instrument. If any
damage has occurred, report immediately to the carrier that delivered your amplifier.
2. To ensure that the Ocarina or Castanet you have unpacked is the appropriate type for
your requirements, find the part number sticker on the side of the product:
The P/N gives the type designation
as follows:
OCA- 5/100
Continuous Current
Operating Voltage
(Amps)
Maximum DC
3. Verify that the Ocarina or Castanet type is the one that you ordered, and ensure that the
voltage meets your specific requirements.
Ocarina/Castanet Installation Guide Installation
MAN-OCSIG (Ver. 1.2)
3.3 Dimensions
3.3.1 Ocarina Dimensions
3-2
Figure 3-1: Ocarina Dimensions
3.3.2 Castanet Dimensions
Figure 3-2: Castanet Dimensions
Ocarina/Castanet Installation Guide Installation
MAN-OCSIG (Ver. 1.2)
3.4 Mounting
3.4.1 Ocarina
The Ocarina was designed for mounting on a printed circuit board (PCB). It is connected by
2 mm pitch 0.51 mm square pins. When designing the Ocarina into a device, be sure to leave
about 1 cm (0.4") outward from the heatsink to enable free air convection around the Ocarina.
We recommend that the Ocarina be soldered directly to the board. Alternatively, the Ocarina
can be attached to socket connectors mounted on the PCB. If the PCB is enclosed in a metal
chassis, we recommend that the Ocarina be screw-mounted to it as well to help with heat
dissipation. The Ocarina has screw-mount holes on each corner of the heatsink for this purpose.
3.4.2 Castanet
The Castanet was designed for mounting on a printed circuit board (PCB). It is connected by
2mm pitch 0.51 mm square pins. When designing the Castanet into a device, be sure to leave
about 1 cm (0.4") outward from the lower board to enable free air convection around the
Castanet. We recommend that the Castanet be soldered directly to the board. Alternatively, the
Castanet can be attached to socket connectors mounted on the PCB.
3-3
Note: Elmo recommends you leave approximately 1 cm (0.4 in) of space on the side opposite
the terminals to allow for free air convection.
Ocarina/Castanet Installation Guide Installation
MAN-OCSIG (Ver. 1.2)
3.5 Integrating the Ocarina and Castanet on a PCB
The Ocarina and Castanet are designed to be mounted on a PCB, either by soldering its pins
directly to the PCB or by using suitable socket connectors. In both cases the following rules
apply:
3.5.1 Traces
1. The size of the traces on the PCB (thickness and width) is determined by the current
carrying capacity required by the application.
The rated continuous current limit (Ic)of the Ocarina and Castanet is the current
used for sizing the motor traces (M1, M2, M3 and PE) and power traces (VP+, PR
and PE).
For control, feedbacks and inputs/outputs conductors the actual current is very
small but “generous” thickness and width of the conductors will contribute to a
better performance and lower interferences.
2. The traces should be as short as possible to minimize EMI and to minimize the heat
generated by the conductors.
3. The spacing between the high voltage conductors (VP+, PR, M1, M2, M3, VL) must be
at least:
Surface layer: 1.5 mm
Internal layer: 0.10 mm
3-4
Complying with the rules above will help satisfy UL safety standards, MIL-STD-275 and the
IPC-D-275 standard for non-coated conductors, operating at voltages lower than 100 VDC
and at “unlimited altitudes” (above 10,000 meters – 30,000 feet).
3.5.2 Grounds and Returns
The “Returns” of the Ocarina and Castanet are structured internally in a star configuration.
The returns in each functional block are listed below:
Functional Block Return Pin
Power PR (Power Return)
Internal Switch Mode P.S. PR (Power Return)
Control section Internal, not accessible
Feedback SUPRET (J2/2)
The returns above are all shorted within the Ocarina and Castanet in a topology that results in
optimum performance.
1. When wiring the traces of the above functions, on the Integration Board, the returns of
each function must be wired sep arately to its designated terminal on the Ocarina and
Castanet. DO NOT USE A COMMON GROUND PLANE. Shorting the commons on the
Integration Board may cause performance degradation (ground loops, etc).
2. Return Traces: The return traces should be as large as possible, but without shorting
each other, and with minimal cross-overs.
3. Main Power Supply and Motor Traces: The power traces must be kept as far away as
possible from the feedback and control traces.
Ocarina/Castanet Installation Guide Installation
MAN-OCSIG (Ver. 1.2)
4. PE Terminal: The PE terminal is connected directly to the Ocarina's heatsink or to the
Castanet's two PE strips on its lower board. In the Ocarina, the heatsink serves as an EMI
common plane. The PE terminal should be connected to the system's Protective Earth.
Any other metallic parts (such as the chassis) of the assembly should be connected to the
Protective Earth as well.
5. Under normal operating conditions, the PE trace carries no current. The only time these
traces carry current is under abnormal conditions (such as when the device has become a
potential shock or fire hazard while conducting external EMI interferences directly to
ground). When connected properly the PE trace prevents these hazards from affecting
the drive.
Follow these instructions to ensure safe and proper implementation.
Failure to meet any of the above-mentioned requirements can result in
drive/controller/host failure.
3-5
3.6 Pin Functions
The Ocarina and Castanet are PCB mounted analog servo drives. Their pinouts are described
below.
3.6.1 Pinouts
No.
Pins Type
2X11 J1 I/O connector
2 M3 Motor power output 3
2 M2 Motor power output 2
2 M1 Motor power output 1
2 mm pitch
0.51 mm sq
2 PE Protective earth
2 PR Power input return
2 VP+ Positive power input
1
Port Function Connector Location
VL Auxiliary power input
Ocarina/Castanet Installation Guide Installation
MAN-OCSIG (Ver. 1.2)
3.6.2 Connector J1
3-6
Pin # Short
Form Function
Description
1 EN+ Enable + Positive voltage input of the “Amplifier Enable” function.
To enable operation of the amplifier, the optocoupler
must be energized by applying voltage between this pin
(+) and pin J1/22 (-).
The optocoupler is isolated from the amplifier. See Figure
3-4.
“OFF” voltage: 0 V < Vin < 1 V.
“ON” voltage: 2.5 V < Vin < 10 V, 5 V typically with
current consumption 2.5 mA.
2 AOK Amplifier OK When the amplifier is under normal operating conditions,
this output is in the “active low“ state. When a failure
occurs, this output is changed to the “open” state.
The optocoupler is an isolated, open collector NPN type.
See Figure 3-4.
Maximum voltage = 30 V
Maximum current = 8 mA
“On” voltage: V
OUT(On)
< 0.8 V
Refer to Section 4.4.
3 SO1 Status output 1 Specifications same as in pin J1/2.
4 HA Hall A input Logic levels: TTL
Maximum input voltage
: 15 VDC.
5 HB Hall B input Logic levels: TTL
Maximum input voltage
: 15 VDC.
6 HC Hall C input Logic levels: TTL.
Maximum input voltage: 15 VDC.
7 LATCH Latch mode Latch mode input. For more details see the Latch Mode
section in Chapter 4.
8 ECLRET Current limits
return
9 ECLC External
current limit
continuous
10 CM Current
monitor
11 CREF+ Current
command
positive
12 CREF- Current
command
negative
13 CMRET Current
monitor return
Current limit signals return.
External voltage scales down the rated value.
Voltage range: 0 V to 3.75 V (3.75 V = rated Ic)
Refer to Section 4.3.
Analog output with a scale of ± 3.9 V for ± Ip.
Output resistance: 1 kΩ
Positive input of a differential amplifier:
Input operating voltage range: ±3.75 V
Maximum input voltage: ±20 V
Maximum common mode voltage: ±6 V
Differential input impedance: 40 kΩ
Refer to Section 4.2.
Negative input of a differential amplifier.
Same specification as in pin J1/11.
Current monitor (CM) signal return.
Ocarina/Castanet Installation Guide Installation
MAN-OCSIG (Ver. 1.2)
Pin # Short
Form Function
Description
3-7
14 ECLP External
current limit
peak
External voltage scales down the rated value.
Voltage range: 0 V to 3.75 V (3.75 V = rated Ip)
Refer to Section 4.2.
15 LMRET Latch Mode
Return for Latch Mode signals.
return
16 GAIN Current gain
change
17 HARET Hall supply
Shorting this pin to LMRET pin (J1/15) reduces
the proportional gain of the current loop by 70%.
Return used only for Hall supply.
voltage return
18 HALL+
5V
19 SORET Status output
+5 V Hall
supply voltage
return
+5 V supply voltage for Hall sensors.
Output current: maximum of 13 mA.
Status output common AOK, SO1, SO2, SO3.
Isolated from circuit common. See Figure
3-4.
20 SO2 Status output 2 Status indication output 2.
Same specification as in pin J1/2.
21 SO3 Status output 3 Status indication output 3.
Same specification as in pin J1/2.
22 EN- Enable - Negative voltage input of “Amplifier Enable” function.
Optocoupler is isolated from the amplifier.
For details, see pin J1/1.
Ocarina/Castanet Installation Guide Installation
MAN-OCSIG (Ver. 1.2)
3.7 Ocarina/Castanet Connection Diagram
3-8
Figure 3-3: Ocarina/Castanet Connection Diagram
Ocarina/Castanet Installation Guide Installation
MAN-OCSIG (Ver. 1.2)
3.8 Main Power and Motor Power
Pin Function Cable Pin Positions
VP+ Pos. Power input Power
PR Power return Power
PE Protective earth Power
3-9
AC Motor DC Motor
PE Protective earth Motor Motor
M1 Motor phase Motor N/C
M2 Motor phase Motor Motor
M3 Motor phase Motor Motor
When connecting several amplifiers to several motors, all should be wired in the same
motor phases and feedback sequences. This will enable the same SimplIQ program to
run on all drives.
Table 4-1: Connector for Main Power and Motor
3.9 Evaluation Board and Cable Kit
A circuit board is available for evaluating the Ocarina and Castanet. It comes with standards
terminal blocks for power connections and D-sub plugs/sockets for signals connections. The
Evaluation Board is provided with a cable kit.
Evaluation Board Catalog Number
Evaluation Board User Manual
OCA-EVLBRD-1
MAN-EVLBRD-OCA (available on our web site)
Ocarina/Castanet Installation Guide Installation
MAN-OCSIG (Ver. 1.2)
3.10 DC Power Supply
The DC power supply can be at any voltage in the range defined in the technical
specifications (the Appendix of this guide). The supply source must comply with the safety
aspects of the relevant requirements, in accordance with the most recent version of the
standard EN60950 or equivalent Low Voltage Directive Standard, all according to the
applicable over-voltage category. If the power source to the power supply is the AC line
(through an isolated transformer), safety margins must be considered, in order to avoid
activating the under/over voltage protection due to line variations and/or voltage drop
under load.
In addition to the above, the transformer must comply with the safety aspects of the relevant
requirements in accordance with the most recent version of the standard EN60742 (Isolating
and Safety Isolating Transformers). The nominal DC bus voltage should be in the following
range:
3-10
1.2 V
< Vdc < 0.9 V
dcmin
dcmax
where:
V
is the minimum DC bus
dcmin
V
is the maximum DC bus
dcmax
The recommended minimum power supply capacitance for a single-phase rectified DC source
connection is as follows:
Amplifier Voltage Range 60 V 100 V
Recommended capacitance ≥ 470 µF ≥470 µF
The transformer power should be calculated such that it will be able to deliver power to the
amplifier (including peak power) without significant voltage drops.
The power supply should be located as close as possible to the amplifier. The maximum
distance is 30 cm (1 foot). While driving high-inertia loads, the power supply must be
equipped with a shunt regulator; otherwise, the amplifier will be disabled whenever the
capacitors are charged above the maximum voltage, during motor break down.
Ocarina/Castanet Installation Guide Installation
MAN-OCSIG (Ver. 1.2)
3-11
Figure 3-4: Detailed Ocarina/Castanet Internal Block Diagram
s
Ocarina/Castanet Installation Guide Installation
MAN-OCSIG (Ver. 1.2)
3.11 Heat Dissipation
3.11.1 Ocarina
The best way to dissipate heat from the Ocarina is to mount it so that its heatsink faces up.
For best results leave approximately 10 mm of space between the Ocarina's heatsink and any
other assembly.
3.11.1.1 Thermal Data
• Heat dissipation capability (θ): Approximately 10 °C/W.
• Thermal time constant: Approximately 240 seconds (thermal time constant means
that the Ocarina will reach 2/3 of its final temperature after 4 minutes).
• Shut-off temperature: 86 °C – 88 °C (measured on the heatsink)
3.11.1.2 Heat Dissipation Data
Heat Dissipation is shown in graphically below:
3-12
Power Dissipation (Watt
Ocarina
Whistle - 60 Series Power Dissipation
10.0
9.0
8.0
7.0
6.0
5.0
Standard 40 °°°°C Ambient Temp.
4.0
3.0
2.0
1.0
0.0
2
1
0
0
.
7
5
.
.
2
5
5
3
3
.
7
5
Peak Current (A)
50V
40V
30V
20V
External
Heatsink
Required
Heatsink
not
Required
4
5
.
.
5
2
5
6
6
.
7
5
8
7
.
.
2
5
5
9
9
.
7
5
)
Ocarina/Castanet Installation Guide Installation
MAN-OCSIG (Ver. 1.2)
Whistle 100 Series Power Dissipation
Ocarina -100
3-13
6.0
External
5.0
Standard 40 °°°°C Ambient Temp.
Heatsink
Required
4.0
Pow er D i ss ipati o n (W
3.0
2.0
1.0
Heatsink
not
Required
0.0
2
5
0
5
1
0.
1.5
2.
3
3.5
4
5
5
4.
Peak Curr ent (A)
85VDC
70VDC
50VDC
3.11.1.3 How to Use the Charts
The charts above are based upon theoretical worst-case conditions. Actual test results show
30% - 50% better power dissipation.
To determine if your application needs a heatsink:
1. Allow maximum heatsink temperature to be 80 °C or less.
2. Determine the ambient operating temperature of the Ocarina.
3. Calculate the allowable temperature increase as follows:
• for an ambient temperature of 40 °C , ∆T= 80 °C – 40 °C = 40 °C
4. Use the chart to find the actual dissipation power of the drive. Follow the voltage
curve to the desired output current and then find the dissipated power.
5. If the dissipated power is below 4W the Ocarina will need no additional cooling.
Note: The chart above shows that no heatsink is needed when the heatsink temperature is
80 °C, ambient temperature is 40 °C and heat dissipated is 4 W.
3.11.2 Castanet
The best way to dissipate heat from the Castanet is to mount it so that its lower board faces
upwards. For best results leave approximately 10 mm of space between the Castanet's lower
board and any other assembly.
Ocarina/Castanet Installation Guide
MAN-OCSRIG (Ver. 1.2)
Chapter 4: Servo Control Operation
4.1 Ocarina/Castanet Connected to DC Motors
In order to connect the Ocarina or Castanet to a DC motor, connect Hall A (J1 pin 4 of the
drive) to Hall return (J1 pin 17 of the drive). The motor should be connected to M2, M3.
4.2 Current Command Input
The Ocarina and Castanet have a single differential input. The input operating voltage range
is ± 3.75 V, meaning that a 3.75 V signal will result in a fully rated peak current. The current
limit circuits will override this signal if the peak duration exceeds 2.7 seconds and/or the
required current exceeds the values set by the ECLC and ECLP signals. If the input command
voltage exceeds 3.75 V, input scaling must be implemented by adding a pair of external
resistors, according to the following formula:
Rin (kΩ) = (5.33 * Vin) - 20
4-1
Be careful not to apply input voltage above the maximum allowed input voltage as this will
cause the input operational amplifier to operate beyond its limits (±20 V) and in extreme
cases, may even damage it.
4.3 External Current Limit - Continuous (ECLC)
The continuous current limit of the Ocarina and Castanet amplifiers can be scaled down by an
external voltage or by an external resistor connected from pin J1/9 (ECLC) to pin J1/8
(ECLRET).
4.3.1 External Voltage
V
V
ECLC
IC(new) =
IC(new) =
An external positive voltage (0 to 3.75 V) to terminal J1/9 (ECLC) in reference to terminal J1/8
(ECLRET) will control the continuous current limit from zero to Ic (nom).
The voltage is internally clamped to 3.75 V whenever the external VECLC is greater than
3.75V.
ECLC
3.75V
3.75V
* Ic(nom)
* Ic(nom)
The external voltage source must be able to source/ sink at least ±0.2 mA.
The maximum absolute VECLC allowed to be connected is 5 V.
Ocarina/Castanet Installation Guide Servo Control Operation
MAN-OCSRIG (Ver. 1.2)
4.3.2 External Resistor
Ic(new)
R
R
R
(Kohm) = 37.4 *
(Kohm) = 37.4 *
(Kohm) = 37.4 *
ECLC
ECLC
ECLC
Connect an external resistor between terminal J1/9 (ECLC) and terminal J1/8 (ECLRET).
The resistor value is given by:
0 < RECLC < 36.4 K (1/8 Watt)
At RECLC greater than 36.4 K, the current limit will be internally clamped to the nominal
value.
IC(nom) is the nominal continuous current limit of the amplifier.
Ic(new)
Ic(nom)
Ic(nom)
-1
-1
4-2
4.3.3 External Current Limit - Peak (ECLP)
The peak current limit of the Ocarina and Castanet amplifiers can be scaled down by an
external voltage or by an external resistor connected between pin J1/14 (ECLP) and J1/8
(ECLRET).
4.3.4 External Voltage
An external positive voltage (0 to 3.75 V) to terminal J1/14 (ECLP) in reference to terminal
J1/8 (ECLRET) will control the peak current limit from zero to Ip(nom).
V
V
ECLP
Ip(new) =
Ip(new) =
The voltage is internally clamped to 3.75 V whenever the external VECLP is higher than 3.75 V.
The external voltage source must be able to source/sink at least ±0.2 mA.
The maximum absolute VECLP allowed to be connected is 5 V.
ECLP
3.75V
3.75V
* Ip(nom)
* Ip(nom)
Ocarina/Castanet Installation Guide Servo Control Operation
MAN-OCSRIG (Ver. 1.2)
4.3.5 External Resistor
Ip(new)
R
R
R
(Kohm) = 37.4 *
(Kohm) = 37.4 *
(Kohm) = 37.4 *
ECLP
ECLP
ECLP
Connect an external resistor between terminal J1/14 (ECLP) and terminal J1/8 (ECLRET).
The resistor value is given by:
Ip(new)
Ip(nom)
Ip(nom)
-1
-1
4-3
0 < R
< 36.4 K (1/8 Watt)
ECLP
At RECLP greater than 36.4 K, the current limit will be internally clamped to the nominal
value.
IP(nom) is the nominal peak current limit of the amplifier.
4.3.6 Latch Mode (LM)
By connecting J1/7 to J1/15, the amplifier is latched to disable mode whenever a Short,
Commutation or Over Temperature failure occurs. Disabling the amplifier temporarily by
removing the power from Enable pin J1/1 resets the latch. Be sure to restore the Enable
connection when the reason for the event no longer exists.
4.4 Status Indications
The following table lists the Ocarina and Castanet amplifier status indications.
Function
Latch
Option
AOK
SO1
SO2
SO3
1 Amplifier OK (AOK) N/A Low Open
Open collector Open collector
collector
2 External disable No Low Low Open collector Low
3 Current limit No Low Open
Open collector Low
collector
4 Short Yes Open
Low Open collector Low
collector
5 Over temperature Yes Open
collector
6 Internal supplies
protection
No Open
collector
7 Under voltage No Open
Open
Low Low
collector
Low Low Open collector
Low Open collector Open collector
collector
8 Over voltage No Open
collector
9 Shunt* No Low Open
Open
collector
Low Open collector
Low Open collector
collector
Ocarina/Castanet Installation Guide Servo Control Operation
MAN-OCSRIG (Ver. 1.2)
4-4
Function
10 Power up reset No Open
11 Commutation failure Yes Open
Latch
Option
AOK
collector
SO1
Open
SO2
Open collector Open collector
collector
Low Low Low
collector
* This indication can be used as a digital input for activating an external shunt regulator.
Table 4-1: Ocarina/Castanet Status Indications
Notes:
Without latch mode:
The status indications are reset when the fault disappears.
With latch mode:
The Short, Over Temperature and Commutation Failure status indications are reset
when the enable signal is temporarily removed from the enable input.
Multiple faults:
Only the reading of the first fault is reliable. Additional faults add on to the status
outputs and the indication is therefore meaningless.
SO3
Ocarina/Castanet Installation Guide
MAN-OCSIG (Ver. 1.1)
A-1
Appendix: Specifications
A.1 General Specifications
A.1.1 Ocarina
Feature Units 1/60 2.5/60 5/60 10/60 15/60 1/100 2.5/100 5/100 10/100 15/100
Minimum
supply voltage
Nominal
supply voltage
Maximum
supply voltage
Maximum continuous
power output
Efficiency at rated power
(at nominal conditions)
Maximum output voltage 93% of DC bus voltage at f=32 kHz
DC and trapezoidal
commutation continuous
current limit (Ic)
Peak current limit A 2 x Ic
Weight g (oz) 45 g (1.6 oz)
Dimensions
VDC 11 20
VDC 50 85
VDC 59 95
W 55 140 280 570 850 90 230 460 920 1400
% Up to 99%
A 1 2.5 5 10 15 1 2.5 5 10 15
mm
(in)
55 x 15 x 46.5 (2.1"x 0.6" x 1.8")
Mounting method PCB mount (with 2mm pitch, 0.51 mm sq. pins)
Ocarina/Casta net Installation Gu ide Specifications
MAN-OCSIG (Ver. 1.1)
A-2
A.1.2 Castanet
Feature Units 3/60 2.5/100
Minimum
supply voltage
Nominal
supply voltage
Maximum
supply voltage
Maximum continuous
power output
VDC 11 20
VDC 50 85
VDC 59 95
W 190 240
Efficiency at rated power % Up to 99%
Maximum output voltage 93% of DC bus voltage at f=32 kHz
DC and trapezoidal
commutation continuous
A 3.3 2.5
current limit (Ic)
Peak current limit A 2 x Ic
Weight g (oz) 21.5 g (0.76 oz)
Dimensions
mm
(in)
51 x 12.5 x 42 (2" x .49" x 1.65")
Mounting method PCB mount (with 2 mm pitch, 0.51 mm sq. pins)
Ocarina/Casta net Installation Gu ide Specifications
MAN-OCSIG (Ver. 1.1)
A.2 Standards Compliance
A.2.1 Quality Assurance
Specification Details
ISO 9001:2000 Quality Management
A.2.2 Design
Specification Details
MIL-HDBK- 217F Reliability prediction of electronic equipment
(rating, de-rating, stress, etc.)
A-3
IPC-D-275
IPC-SM-782
Printed wiring for electronic equipment (clearance,
creepage, spacing, conductors sizing, etc.)
IPC-CM-770
UL508c
UL840
In compliance with IEC68 Type testing
A.2.3 Safety
Specification Details
Recognized UL508c Power conversion equipment
In compliance with UL840 Insulation coordination, including clearance and
creepage distances of electrical equipment
In compliance with UL60950 Safety of information technology equipment,
including electrical business equipment
In compliance with EN60204-1 Low voltage directive, 73/23/EEC
Ocarina/Casta net Installation Gu ide Specifications
MAN-OCSIG (Ver. 1.1)
A.2.4 EMC
Specification Details
A-4
In compliance with
Electromagnetic compatibility (EMC)
EN55011 Class A with EN61000-6-2:
Immunity for industrial environment,
according to:
IEC61000-4-2 / criteria B
IEC61000-4-3 / criteria A
IEC61000-4-4 / criteria B
IEC61000-4-5 / criteria B
IEC61000-4-6 / criteria A
IEC61000-4-8 / criteria A
IEC61000-4-11 / criteria B/C
A.2.5 Workmanship
Specification Details
In compliance with IPC-A-610, level 2 Acceptability of electronic assemblies
A.2.6 PCB
Specification Details
In compliance with IPC-A-600, level 2 Acceptability of printed circuit boards
A.2.7 Packing
Specification Details
In compliance with EN100015 Protection of electrostatic sensitive devices
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