Cymbal Analog Servo Amplifier Installation Guide November 2011 (Ver. 1.3) www.elmomc.
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 Cymbal 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 Worldwide Head Office Elmo Motion Control Ltd. 60 Amal St., P.O. Box 3078, Petach Tikva 49516 Israel Tel: +972 (3) 929‐2300 • Fax: +972 (3) 929‐2322 • info‐il@elmomc.com North America Elmo Motion Control Inc. 42 Technology Way, Nashua, NH 03060 USA Tel: +1 (603) 821‐9979 • Fax: +1 (603) 821‐9943 • info‐us@elmomc.com Europe Elmo Motion Control GmbH Hermann‐Schwer‐Strasse 3, 78048 VS‐Villingen Germany Tel: +49 (0) 7721‐944 7120 • Fax: +49 (0) 7721‐944 7130 • info‐de@elmomc.
Cymbal Installation Guide MAN-CYMIG (Ver. 1.3) Table of Contents Chapter 1: 1.1. 1.2. 1.3. 1.4. 1.5. Warnings .................................................................................................................... 7 Cautions ..................................................................................................................... 7 Directives and Standards ........................................................................................... 8 CE Mark Conformance .............
Cymbal Installation Guide Table of Contents MAN-CYMIG (Ver. 1.3) 4.4. 4.3.1. External Voltage........................................................................................ 33 4.3.2. External Resistor ....................................................................................... 34 4.3.3. External Current Limit ‐ Peak (ECLP) ......................................................... 34 4.3.4. External Voltage...............................................................................
Cymbal Installation Guide 6 MAN-CYMIG (Ver. 1.3) Chapter 1: Safety Information In order to achieve the optimum, safe operation of the Cymbal 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 Cymbal as well as the accompanying equipment. Please read this chapter carefully before you begin the installation process.
Cymbal Installation Guide Safety Information MAN-CYMIG (Ver. 1.3) 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 Cymbal from all voltage sources before it is opened for servicing. • The Cymbal servo drives contain grounding conduits for electric current protection.
Cymbal Installation Guide Safety Information MAN-CYMIG (Ver. 1.3) 1.3.
Cymbal Installation Guide 9 MAN-CYMIG (Ver. 1.3) Chapter 2: Introduction This Installation Guide is intended for design engineers who are integrating 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.
Cymbal Installation Guide Introduction MAN-CYMIG (Ver. 1.3) 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 • Overheating • Undervoltage/overvoltage • 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.
Cymbal Installation Guide 11 MAN-CYMIG (Ver. 1.3) Chapter 3: 3.1. Installation Before You Begin 3.1.1. Site Requirements You can guarantee the safe operation of the Cymbal by ensuring that they are installed in an appropriate environment. Feature Value Ambient operating temperature 0 °C to 50 °C (32 °F to 122 °F) Maximum non‐condensing humidity 90% Operating area atmosphere No flammable gases or vapors permitted in area Note: Models for extended environmental conditions are available.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) 3.3. Mounting the Cymbal The Cymbal has been designed for Wall Mount along the back (it can also be mounted horizontally on a metal surface) M5 socket head cap screws, one through each opening in the heatsink, are used to mount the Cymbal (see the diagram below). For full power output capability the Cymbal is designed to be mounted on an external heatsink.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) 3.4. Connecting the Cables 3.4.1. Wiring the Cymbal Once the Cymbal is mounted, you are ready to wire the device. Proper wiring, grounding and shielding are essential for ensuring safe, immune and optimal servo performance of the Cymbal. Caution: Follow these instructions to ensure safe and proper wiring: • Use twisted pair shielded cables for control, feedback and communication connections.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) Figure 2: Cymbal Connection Diagram www.elmomc.
Cymbal Installation Guide Installation 15 MAN-CYMIG (Ver. 1.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) 3.5. Cymbal Connection Diagram Figure 3: Cymbal Connection Diagram www.elmomc.
Cymbal Installation Guide Installation 17 MAN-CYMIG (Ver. 1.3) 3.5.1. Connecting the Power Cables The main power connector located at the bottom of the Cymbal, as follows: Pin Function Cable Pin Positions VP+ Pos. Power input Power VN‐ Neg.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) 3.5.1.1. Connecting the Motor Cable Connect the motor power cable to the M1, M2, and M3 terminals of the main power connector and the fourth wire to the PE (Protective Earth) on the heatsink (see diagram above). Notes for connecting the motor cables: • For best immunity, it is highly recommended to use a shielded (not twisted) cable for the motor connection. A 4‐wire shielded cable should be used.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) Figure 5: Isolated DC Power Supply In this case the isolation is achieved by the isolation transformer. It is highly recommended to connect the network PE to the Return (negative terminal) of the Power Supply. Figure 6: Isolated Power Supply In this case the isolation is achieved by using a battery. It is highly recommended to connect the PE to the Return (negative terminal) of the Power Supply. 3.5.1.2.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) Figure 7: Non‐Isolated DC Power Supply The Power Supply is directly connected to the AC line (The AC must be limited to 135 VAC not to exceed the max 190 VDC in case of 200 VDC drive). The network PE must not be connected to the Return of the Power Supply. Figure 8: Non‐Isolated DC Power Supply The Power Supply is directly connected to the AC line through an Autotransformer.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) Notes for connecting the DC power supply: • Be aware: The Cymbal can operate from either an: isolated DC power supply or non‐isolated DC power supply • For best immunity, it is highly recommended to use twisted cables for the DC power supply cable. A 3‐wire shielded cable should be used. The gauge is determined by the actual current consumption of the motor.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) Pin Signal Function J1‐9 Backup+ Supply +VDC backup supply J1‐8 Backup‐ Supply Return (common) of the backup supply Pin Position J1 Male Table 6: Backup Cable Plug Figure 9: Backup Supply Connection Diagram Note: The return of the backup supply must not be connected to PE, as such a connection can damage the drive.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) 3.5.2. Control, I/Os and Halls Cable Assemblies The Cymbal features easy‐to‐use D‐Sub type connections for all Control, I/Os and halls cables. Below are instructions and diagrams describing how to assemble these cables. • Use 24, 26 or 28 AWG twisted‐pair shielded cables (24 AWG cable is recommended). For best results, the shield should have aluminum foil covered by copper braid. • Use only a D‐Sub connector with a metal housing.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) 3.5.3. 25 J2 Control Port Port J2 has a 15‐pin High‐Density D‐Sub male connector. When assembling this Control cable, follow the instructions in Section 3.5.2 Control, I/Os and Halls Cable Assemblies using a 15‐pin High‐ Density metal case D‐Sub female cable connector (socket). Pin Signal Function Description 1 ANLRET Return Analog Return signal 2 CREF‐ Current Command negative Negative input of a differential amplifier.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) Pin Signal Function Description 12 ECLP External current limit peak External voltage scales down the rated value. 13 14 ECLC EN+ External current limit continuous Enable + Pin Location Voltage range: 0 V to 3.75 V (3.75 V = rated Ip) External voltage scales down the rated value. Voltage range: 0 V to 3.75 V (3.75 V = rated Ic) Positive voltage input of the “Amplifier Enable” function.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) 3.5.3.1. J3 General I/O Port Port J3 has a 9‐pin D‐Sub female connector. When assembling this I/O cable, follow the instructions in Section 3.5.2 Control, I/Os and Halls Cable Assemblies using a 9‐pin a metal case D‐Sub male connector (plug). Pin Signal Function Description 1 AOK Amplifier OK When the amplifier under normal operating conditions, this output is in the “active low“ state.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) 3.5.3.2. J4 Hall’s Signal Port Port J4 is a 15‐pin D‐Sub female connector. When assembling this cable, follow the instructions in Section 3.5.2 Control, I/Os and Halls Cable Assemblies using a 15‐pin a metal case D‐Sub male connector (plug). Pin Signal Function Description 1 HALL+15V +15 V Hall supply voltage:15 V ± 10% at 30 mA +15 V supply voltage for Hall sensors. Output current: maximum of 30 mA.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) 3.6. DC Power Supply The DC power supply can be at any voltage in the range defined in the technical specifications (Chapter 5 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.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) 3.7.1. Cymbal Thermal Data • Free air convection thermal resistance (θ): Approximately 3.6 to 4 °C/W. • Thermal time constant: Approximately 40 minutes/ 2400 seconds (thermal time constant means that the Cymbal will reach 2/3 of its final temperature after 4 minutes). • Self heat dissipation capability (no external heatsink): 12 W for 40 °C/W temperature rise. • Shut‐off temperature: 86 °C to 88 °C (measured on the heatsink).
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) 31 Power Dissipation 100V series 120 Power Dissipation (W) 100 80 20VDC 40VDC 60VDC 80VDC 96VDC 60 40 20 Heatsink Required Standard 40 °C Ambient Temp. 0 0 8.3 16.7 25.0 33.3 41.7 50.0 58.3 66.7 75.0 Heatsink not Required Motor's Current (Ampere) www.elmomc.
Cymbal Installation Guide Installation MAN-CYMIG (Ver. 1.3) 32 Power Dissipation 200V series 250 Power Dissipation (W) 200 40VDC 80VDC 120VDC 160VDC 196VDC 150 100 50 Heatsink Required 0 0 6.7 13.3 20.0 26.7 33.3 40.0 46.7 53.3 60.0 Heatsink not Required Motor's Current (Ampere) 3.7.3. How to Use the Charts The charts above are based upon theoretical worst‐case conditions. Actual test results show 30% to 50% better power dissipation.
Cymbal Installation Guide 33 MAN-CYMIG (Ver. 1.3) Chapter 4: Servo Control Operation 4.1. Cymbal Connected to DC Motors In order to connect the Cymbal to a DC motor, connect Hall A (J4 pin 5 of the drive to Hall return (J4 pin 3 of the drive). The motor should be connected to M2, M3. 4.2. Current Command Input The Cymbal has a single differential input. The input operating voltage range is ±10 V, meaning that a 10 V signal will result in a fully rated peak current.
Cymbal Installation Guide Servo Control Operation MAN-CYMIG (Ver. 1.3) 4.3.2. External Resistor Connect an external resistor between terminal J2/13 (ECLC) and terminal J2/8 (ECLRET). RECLC (Kohm) = 37.4 * Ic(new) -1 Ic(nom) 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. 4.3.3.
Cymbal Installation Guide Servo Control Operation MAN-CYMIG (Ver. 1.3) 4.4. 35 Status Indications The following table lists the Cymbal amplifier status indications.
Cymbal Installation Guide Technical Specifications 36 MAN-CYMIG (Ver. 1.3) Chapter 5: Technical Specifications 5.1.
Cymbal Installation Guide Technical Specifications MAN-CYMIG (Ver. 1.
Cymbal Installation Guide Technical Specifications MAN-CYMIG (Ver. 1.3) 5.2. Dimensions www.elmomc.
Cymbal Installation Guide Technical Specifications MAN-CYMIG (Ver. 1.3) 5.3. Compliance with Standards Specification Details Quality Assurance ISO 9001:2008 Quality Management Design In compliance with MIL‐HDBK‐ 217F • IPC‐D‐275 • IPC‐SM‐782 • IPC‐CM‐770 Reliability Prediction of Electronic Equipment (rating, de‐rating, stress, etc.) Printed wiring for electronic equipment (clearance, creepage, spacing, conductors sizing, etc.
Cymbal Installation Guide Technical Specifications MAN-CYMIG (Ver. 1.3) Specification Details Packing In compliance with EN 100015 Protection of electrostatic sensitive devices Environmental In compliance with 2002/96/EC Waste Electrical and Electronic Equipment regulations (WEEE) Note: Out‐of‐service Elmo drives should be sent to the nearest Elmo sales office.
