SAXophone
Installation Guide
April 2002
Elmo Motion Control
http://www.elmomc.com
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Important 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
Saxophone servo amplifier.
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.
Information in this document is subject to change without notice. Corporate and
individual names and data used in examples herein are fictitious unless otherwise
noted.
Doc. no. SAXUGEN0402
Copyright  2002
Elmo Motion Control Ltd.
All rights reserved.
The Elmo Motion Control warranty for this product covers only the elimination of problems due to
manufacturing defects that result in impaired function. Specifically excluded from this warranty is the
elimination of problems caused by abuse, damage, neglect, overloading, wrongful operation and
unauthorized manipulations of the product. This product warranty is for a period of 12 months from the time
of operational startup but no longer than 18 months from shipment from the manufacturing plant. Damage
claims that exceed the warranty obligation – including consequential damages – will be rejected in all
cases. If any term or condition in this warranty is at variance or inconsistent with any provision or
condition (whether general or special) contained in or referred to in the Terms of Conditions of Sale
outlined at the back of Elmo’s Standard Acknowledgement form, then the latter shall prevail and be
effective.
Microsoft and Windows are registered trademarks of Microsoft Corporation. All other product and
company names mentioned in this manual maybe trademarks of their respective owners.
Elmo Motion Control Ltd.
64 Gisin St., P.O. Box 463
Petach Tikva
49103
Israel
Elmo Motional Control Inc.
900(H) River St., Kennedy
Industrial Park
Windsor, CT 06095
USA
Elmo Motion Control GmbH
Steinbeisstrasse 41
D-78056
Villingen-Schwenningen
Germany
Tel: +972 3 929-2300
Fax: +972 3 929-2322
Tel: +1 860 683-0095
Fax: +1 860 683-0036
+49 07720 8577-60
+49 07720 8577-70
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Elmo SAXophone Installation Guide
SAXUGEN0402
Contents
Chapter 1: Safety Information............................................................................................... 1-1
1.1 Amplifier Compliance ................................................................................................... 1-1
1.2 Safety Precautions.......................................................................................................... 1-1
1.3 Power Precautions ......................................................................................................... 1-2
Chapter 2: Introduction .......................................................................................................... 2-1
2.1 System Description ........................................................................................................ 2-1
2.2 System Architecture....................................................................................................... 2-2
2.3 How to Use this Guide .................................................................................................. 2-3
Chapter 3: Installation ............................................................................................................ 3-1
3.1 Unpacking the System Components............................................................................ 3-1
3.2 Mounting the Saxophone .............................................................................................. 3-2
3.2.1
Mounting Directly onto Wall......................................................................... 3-2
3.2.2
Mounting on a DIN Rail................................................................................. 3-3
3.3 Connecting the Cables................................................................................................... 3-4
3.3.1
Wiring the Saxophone .................................................................................... 3-4
3.3.2
Connecting the Power Cables........................................................................ 3-5
3.3.3
Connecting the Motor Cables ........................................................................ 3-7
3.4 Powering Up ................................................................................................................ 3-10
3.5 Initializing the System................................................................................................. 3-10
Chapter 4: Status Indications................................................................................................. 4-1
Appendix A: Pin Assignments ............................................................................................. A-1
A.1 Auxiliary Power Connector ......................................................................................... A-1
A.2 Committed I/O Connector .......................................................................................... A-1
A.3 General I/O Connector ................................................................................................ A-2
A.4 Feedback A – Encoder Option ..................................................................................... A-3
A.5 Feedback A – Resolver Option .................................................................................... A-4
A.6 Analog I/O Connector ................................................................................................. A-5
A.7 Com1 .............................................................................................................................. A-6
A.8 Com2 .............................................................................................................................. A-7
A.9 Feedback B ..................................................................................................................... A-7
Appendix B: Technical Specifications .................................................................................B-1
B.1 Power Ratings ................................................................................................................B-1
B.1.1
1x230 VAC or 3x230 VAC Power Ratings ....................................................B-1
B.1.2
3x400 VAC Power Ratings .............................................................................B-1
B.1.3
Rated Specifications........................................................................................B-2
B.1.4
Auxiliary Power Supply.................................................................................B-2
B.1.5
Analog Input and Output ..............................................................................B-2
B.1.6
Feedback Supply Voltage..............................................................................B-3
B.2 Control Specifications....................................................................................................B-3
B.3 Feedback Options ..........................................................................................................B-4
B.4 Digital Input Interface ...................................................................................................B-5
B.5 Digital Output Interface ................................................................................................B-6
B.6 Fault Output ...................................................................................................................B-7
B.7 Single-Phase Operation .................................................................................................B-7
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B.8
B.9
B.10
B.11
B.12
Mechanical Specifications .............................................................................................B-8
Recommended Wire Cross-sections.............................................................................B-8
Environmental Conditions............................................................................................B-8
Resolver ..........................................................................................................................B-9
Compliance Standards ..................................................................................................B-9
B.12.1 Quality Assurance ..........................................................................................B-9
B.12.2 Design ..............................................................................................................B-9
B.12.3 Safety................................................................................................................B-9
B.12.4 EMC................................................................................................................B-10
B.12.5 Workmanship................................................................................................B-10
B.12.6 PCB .................................................................................................................B-10
B.12.7 Packing...........................................................................................................B-10
B.13 Dimensional Drawings................................................................................................B-11
B.13.1 General Dimensions .....................................................................................B-11
B.13.2 Mounting Dimensions..................................................................................B-12
Appendix C: Supplemental Configuration Schematics ................................................... C-1
C.1 CANopen Configuration.............................................................................................. C-1
C.2 Auxiliary Encoder Configurations .............................................................................. C-2
Index...........................................................................................................................................I-1
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SAXUGEN0402
Chapter 1: Safety Information
In order to achieve the optimum, safe operation of the Saxophone servo amplifier, 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 Saxophone and its accompanying equipment. Read this chapter carefully
before you begin the installation process.
1.1
Amplifier Compliance
The end product used with the Saxophone must comply with the European Safety of
Machinery Directive 89/392/EEC safety requirements, and with the most recent versions
of the EN60204-1 and EN292-2 standards.
The Saxophone conforms to the following industry safety standards:
Item
Safety Standard
Power conversion equipment
Recognized UL508c
Insulation coordination, including clearance and
creepage distances of electrical equipment
In compliance with UL840
Safety of information technology equipment,
including electrical business equipment
In compliance with UL1950
Low Voltage Directive, 73/23/EEC
In compliance with EN60204-1
1.2
Safety Precautions
Follow these safety guidelines when installing the Saxophone servo amplifier:
Power connection during operations: Disconnect the Saxophone servo amplifier
from its power source during all operations, such as installation, adjustment
maintenance and repair.
Qualified personnel: Ensure that only qualified personnel carry out any operation
relating to the Saxophone servo amplifier.
Live servo operations: Perform operations when the amplifier is disconnected from
the power source. Only qualified personnel who are fully aware of the dangers of
performing operations connected to the power source should carry out these
operations.
Components: Only certified Elmo representatives may replace damaged Saxophone
servo amplifier components.
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1.3
Power Precautions
Observe the following safety precautions when connecting the Saxophone servo
amplifier to a power supply or during power-up.
Power supply: The maximum AC/DC power supply connected to the instrument
must comply with the parameters outlined in this guide.
Grounding: The Saxophone servo amplifier contains grounding conduits for electric
current protection. Any disruption to these conduits may cause the instrument to
become hot (live) and dangerous.
Powering up: Before switching the Saxophone on, verify that all safety precautions
have been observed and that the installation procedures in this manual have been
followed.
The Saxophone SAX-xx/400 series is designed to operate only
from a 3-phase voltage source. The Saxophone SAX-xx/230
series is designed to operate from a 1- or 3-phase voltage
source. It can be connected directly to the line voltage. An
isolation transformer is not needed.
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Chapter 2: Introduction
The Saxophone system includes the Saxophone servo amplifier and the Composer
software, which run in conjunction with your permanent-magnet synchronous motor.
The servo amplifier connects easily to your motor. You use the Composer software to set
the various servo and motor parameters that meet your specific configuration.
The Composer software is Windows-based and provides a plug-and-run tool that enables
users to quickly and simply set up the communication and the servo system. Refer to the
Composer Software Manual for more information.
This installation guide describes the Saxophone system and the steps for its setup,
installation and powering up. Following these guidelines ensures maximum functionality
of the Saxophone system.
2.1
System Description
The Saxophone system is designed for use with high-performance automated machinery.
The Saxophone series of servo amplifiers has been developed for permanent magnet
synchronous motors and incorporates digital velocity loop, a digital current loop and
sinusoidal commutation.
The Saxophone's basic configuration is a trimmerless velocity servo amplifier. All
adjustments to the velocity, current and commutation functions are made via the serial or
field bus (CANopen option) communication line, using a PC.
Independent control of the magnetic flux and the torque-generating current component
in motors is provided by sinusoidal control with phase advance algorithms. This is
particularly significant for permanent magnet synchronous motors and brushless motors
used in high-performance drives.
The Saxophone series' power source is a three-phase 400 VAC or one- or three-phase
230 VAC line. The control and auxiliary supplies are derived from a 24V AC or DC
supply that is isolated from the AC power bus. This allows a safe and economical "power
backup" feature that is essential for positioning systems.
The Saxophone series meets UL508C and the relevant CE regulations.
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2.2
System Architecture
Contactor
RS485
Interface
(Option)
AC1
Bridge Commands
(6 x PWM)
RS232
AC2
AC3
CANopen
Interface
(option)
PE
Status Lines
Analog command
Aux.
Encoder
Aux. Encoder
Interface
Main Encoder
Interface
Circuit
breaker
Main Power:
3x400 AC
3x230AC
Power
Stage
PE
M1
M2
MCU
+
I/O
Current Feedback
Phase - M1
Phase - M3
M3
Motor
Encoder output
Resolver
Interface
(option)
Dadicated I/O:
Enable/Disable
Limit Switches
Abort
Fault
Feedback
+5v,
15v, 24v
Internal
Power
Supply
Aux. Power:
24VDC
or
24VAC
General I/O
Figure 2-1: Saxophone Architecture Block Diagram
For three-phase supply voltage:
The circuit breaker current rating should be between 150% to 200% of the amplifier
current.
The circuit breaker voltage rating should be 460 VAC.
The contactor should be up to 150% of the amplifier current.
For single-phase supply voltage:
The circuit breaker current rating should be between 200% to 300% of the amplifier
current.
The circuit breaker voltage rating should be 460 VAC.
The contactor should be up to 200% of the amplifier current.
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Introduction
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2.3
2-3
How to Use this Guide
In order to install and operate your Elmo Saxophone servo amplifier, you will use this
manual in conjunction with a set of Elmo documentation. Installation is your first step;
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,
connecting and powering up the Saxophone.
Chapter 4, Status Indications, lists the different symbols shown on the Saxophone display.
Appendix A, Pin Assignments, gives the pin-out information you need when preparing
the Saxophone cables.
Appendix B, Technical Specifications, lists all the amplifier ratings and specifications.
Appendix C, Supplemental Configuration Schematics, are additional diagrams to assist with
CANopen and encoder configurations.
Upon completing the instructions in this guide, your Saxophone servo amplifier should
be successful mounted and installed. From this stage, you need to consult higher-level
Elmo documentation in order to set up and fine-tune the system for optimal operation.
The following figure describes the accompanying documentation that you will require.
Programming
Implementing Motion Control with Elmo Products
Command reference manual
Setup
Installation
Composer software manual (doc. no. COMSFEN0202)
Hardware installation guides
Figure 2-2: Elmo Documentation Hierarchy
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SAXUGEN0402
Chapter 3: Installation
Before configuring and operating the Saxophone, you need to perform a number of
procedures to guarantee the best working conditions for the amplifier.
This chapter describes how to fully install the Saxophone: from unpacking it and
verifying its type designation, through wiring and mounting it, and then connecting it to
the required power.
There are five main steps in the Saxophone installation:
1.
Unpacking and checking the system components
2.
Mounting the Saxophone
3.
Connecting the power cables and motor cables
4.
Powering up
5.
Performing initial setup and initialization
3.1
Unpacking the System Components
Before you begin working with the Saxophone system, verify that you have all of its
components, as follows:
The Saxophone servo amplifier
The Composer software and software manual
Optional mounting clips
The Saxophone is shipped in a cardboard box with Styrofoam protection.
To unpack the Saxophone:
1.
Carefully remove the servo amplifier from the box and the Styrofoam.
2.
Check the amplifier to ensure that there is no visible damage to the instrument.
3.
To ensure that the Saxophone you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Saxophone:
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The P/N number at the top gives the type designation as follows:
4.
Verify that the Saxophone type is the one that you ordered, and ensure that the
voltage meets your specific requirements.
3.2
Mounting the Saxophone
The Saxophone has been designed for two standard mounting options:
Attaching directly to the wall with screws
Mounting on a DIN rail
With either type of mounting, be sure to leave about 10 cm (4 in) above and below the
instrument for heat dissipation.
3.2.1
Mounting Directly onto Wall
The vertical mounting strip at the back of the Saxophone enables you to screw the
amplifier directly into a wall.
To mount the Saxophone with the mounting strip:
1.
On the back of the amplifier, push the mounting strip up until it clicks and locks.
The top lip (with the hole) should be exposed.
Figure 3-1: Extending the Mounting Strip
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Figure 3-2: Mounting Strip Fully Extended
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2.
Mount the Saxophone vertically onto the wall with two screws, one through the top
hole of the mounting strip and one at the bottom.
3.2.2
Mounting on a DIN Rail
At the top rear of the Saxophone, a horizontal groove lets you quickly and easily snap the
Saxophone onto a DIN rail in your work area
To mount the Saxophone on a DIN rail:
1.
Be sure that the vertical mounting strip (with the hole at the top) is pressed down
fully and does not protrude from the top of the instrument.
Figure 3-3: Mounting Strip Pressed Down
2.
Tilt the Saxophone back towards the top part of the DIN rail.
Figure 3-4: Attaching Top Part of Mounting Groove to DIN Rail
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3.
Press the Saxophone down to a vertical position until it clicks onto the DIN rail.
Figure 3-5: Saxophone Mounted on DIN Rail
3.3
Connecting the Cables
3.3.1
Wiring the Saxophone
Once the Saxophone is mounted, you are ready to wire the device. Proper wiring,
grounding and shielding are essential for ensuring peak servo operation and
performance.
Follow these instructions to ensure safe and proper wiring:
Keep the motor wires as far as possible from the signal level wiring (such as for
feedback and control).
If additional inductors (chokes) are required, keep the wires between them and the
amplifier as short as possible.
Minimize lead lengths as much as is practical. Although the amplifier is protected
against long (inductive) supply wires, the leads should be as short as possible. If the
cable length exceeds 10 m (35 ft), consult Elmo for further instructions.
Use twisted pairs and shielded wires whenever possible. Avoid running them in
close proximity to power leads or other sources of EMI noise.
Tie grounded components together at a single point (star connection). Then tie this
point with a single conductor to an earth ground point.
After completing the wiring, carefully inspect all wires to ensure tightness, good
solder joints and general safety.
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3.3.2
Connecting the Power Cables
Access the power terminal connections on the Saxophone servo amplifier by removing
the front safety cover located at the bottom of the front panel of the unit, as shown below:
Figure 3-6: Removable Bottom Saxophone Panel
After removing the safety cover, the power terminal connections are visible, as follows:
1
3
4
Connector No.
5
6
7
2
8
9
Signal
Function
1
24V
AC/DC auxiliary power
2
24V
AC/DC auxiliary power
3
M1
Motor phase U
4
M2
Motor phase V
5
M3
Motor phase W
6
PE
Protective earth
7
AC1
Main voltage phase 1
8
AC2
Main voltage phase 2
9
AC3
Main voltage phase 3
Figure 3-7: Saxophone Power Cable Connectors
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Before connecting cables to the power terminal, it is important to organize your cables to
simplify the connection process. Refer to Appendix A, Pin Assignments, for more
information about the cables required for connection to the Saxophone.
The power connections are as follows:
Auxiliary power supply: Supplies power to the Saxophone logic board. The required
voltage is 24V AC/DC.
Motor supply: Supplies power for the motor output.
SAXOPHONE
A
M1
B
M2
C
M3
PE
Chassis
Motor
Figure 3-8: Saxophone – Motor Power Connections
Power supply: Supplies power to the Saxophone.
To connect the power cables:
1.
On the open section at the bottom of the Saxophone front panel, connect the
auxiliary power supply to the J2-Aux Power points.
Note:
The DC cables (plus and minus) can be placed in either connector.
2.
Connect the motor power cables to the J1-Power M1, M2 and M3 points. Ground the
motor to the PE point. Refer to the data sheet of your motor to determine which
cables are for the motor and which is for grounding.
3.
Connect the 3-phase power supply to the J1-Power AC1, AC2 and AC3 points. Also,
be sure to ground the power supply to the PE point.
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Note:
You may connect the motor power cables in any order and the Composer
software will automatically configure the system. For more information
about configuration, refer to the Composer Software Manual.
4.
Reattach the safety panel to cover the motor and power connectors.
3.3.3
Connecting the Motor Cables
The Saxophone servo amplifier has a front panel that provides easy-to-use connections
for all required cables. These connections are through 9-pin, 15-pin or 25-pin D-type
ports; they support several types of configurations and interfaces.
Figure 3-9: Saxophone Front Panel
The following cables must be connected:
Main feedback cable
Communication cable
I/O cables
Refer also to Appendix A, Pin Assignments.
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3.3.3.1 Main Feedback Cable
The main feedback cable is used to transfer feedback information from the motor to the
Saxophone. You should select this cable according to the feedback type of your motor:
either Encoder or Resolver. Consult your motor documentation for more information.
Refer to Appendix A for more information about this cable.
To connect the main feedback cable, insert the main feedback cable from the motor into the
Feedback A port on the Saxophone servo amplifier, using a 15-pin, D-type female
connector.
3.3.3.2 Communication Cable
The communication cable is used to transfer configuration information from the PC to the
Saxophone.
The communication interface may differ according to the user’s hardware. The
Saxophone can communicate using the following options (explained fully in Appendix
A):
RS-232: Connects to the Com1 port of the Saxophone. This is the most common
option.
RS-485: Connects to the Com1 port of the Saxophone.
CANopen: Connects to the Com2 port of the Saxophone (field bus). Also requires an
RS-232 cable.
Note:
Ensure that each servo drive is allocated a unique ID. Otherwise, the
CANopen network may hang.
In order to benefit from CANopen communication and the CiA DS-301 CANopen
standard, the user must have a good understanding of the basic programming and
timing issues of a CANopen network.
To connect the communication cable:
For an RS-232 connection, insert the communication cable from the serial port of the
PC (Com1 or Com2) into the Com1 port on the Saxophone servo amplifier, using a
9-pin, D-type female connector.
For CANopen communication, connect a communication cable from the CANopen
network to Com2 of the Saxophone servo amplifier.
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Figure 3-10: Saxophone with Connected Communication and Feedback Cables
3.3.3.3 I/O Cables
The following table lists the I/O cables that you should connect according to your
specific requirements:
Cable
Description
General
Uncommitted digital IO
Type Plus: 2 input/output
Type Plus Plus: 6 digital input/output
Analog
2 analog input
1 analog output
Committed
4 dedicated input
1 dedicated output
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3.4
Powering Up
After the Saxophone has been mounted, check that the cables are intact. The Saxophone
servo amplifier is then ready to be powered up.
To power up the system, switch on the main and auxiliary power supplies. A d appears on
the front panel display. The Saxophone is powered up and functional. For more
information about the display, refer to Chapter 4, Status Indications.
3.5
Initializing the System
After the Saxophone has been connected and mounted, the system must be set up and
initialized. This is accomplished using the Composer, Elmo’s proprietary Windows-based
software application. Install the application and then perform setup and initialization
according to the directions in the Composer Software Manual.
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Chapter 4: Status Indications
The following table lists the symbols shown on the Saxophone display.
Symbol
Status
Action
Disable
Bridge is disabled (all switches are off), no fault.
Enable
All OK, amplifier is ready.
Under Voltage
Bus voltage is too low.
Over Voltage
Bus voltage is too high.
SVP
Internal power supply problem.
Shunt
The shunt is operating.
Short
Phases are shorted to each other or to the ground.
Ishort = 3 × Ipeak
Temperature
Amplifier temperature is too high.
Feedback
Feedback loss.
FLS
Forward switch is active according to the defined
logic (IL[3]).
RLS
Reverse switch is active according to the defined
logic (IL[4]).
FLS&RLS
Both switches are active.
Over Speed
Speed exceeded high or low limitation (HL[2],
LL[2]).
IC
Continuous current limit is active.
Over Current
Current exceeded peak current limitation.
Undeclared
Fault
Fault not declared on LED; may be detected with
MF command.
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Appendix A: Pin Assignments
The following connectors are used in the Saxophone installation:
Type
Used For
Remarks
7-pin terminal
Main power
Mains, motor power
2-pin terminal
Auxiliary power
Logic power supply
9-pin D-type male
Committed I/O
Enable, Abort, Limits
25-pin D-type female
General I/O
Programmable I/O
15-pin D-type female
Feedback A
Encoder option
15-pin D-type female
Feedback A
Resolver option
9-pin D-type female
Analog I/O
9-pin D-type female
Com1
RS-232 or RS-485 interface
9-pin D-type male
Com2
CAN interface
15-pin D-type male
Feedback B
Auxiliary encoder, encoder output
A.1 Auxiliary Power Connector
Pin #
Signal
Function
1
APS1 (24 V)
Auxiliary power supply 24 VDC/VAC
2
APS2 (24 V)
Auxiliary power supply 24 VDC/VAC
A.2 Committed I/O Connector
Pin #
Signal
Function
1
FLS
Forward limit switch
2
RLS
Reverse limit switch
3
LSRET
Limit switch return
4
ENABLE
Amplifier enable (disabling resets any protective latch)
5
ENRET
Amplifier enable return
6
STOP
Applying power will stop the motor at maximum deceleration
7
STRET
Stop return
8
FAULT
Fault relay
9
FAULT
Fault relay
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Elmo SAXophone Installation Guide
Pin Assignments
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A.3 General I/O Connector
Pin #
Signal
Function
1
IN1
Programmable input 1
2
IN2
Programmable input 2
3
IN3
Programmable input 3
Sax-PP only
4
IN4
Programmable input 4
Sax-PP only
5
IN5
Programmable input 5:
Event capture input
Main Home input
Sax-PP only
6
IN6
Programmable input 6
Event capture input
Auxiliary Home input
Sax-PP only
7
NA
8
OUT1
Programmable output 1
9
OUT2
Programmable output 2
10
OUT3
Programmable output 3
SAX-PP only
11
OUT4
Programmable output 4
SAX-PP only
12
OUT5
Programmable output 5
SAX-PP only
13
OUT6
Programmable output 6
SAX-PP only
14
INRET1
Programmable input return 1
15
INRET2
Programmable input return 2
16
INRET3
Programmable input return 3
SAX-PP only
17
INRET4
Programmable input return 4
SAX-PP only
18
HOMERET
Home return 1
SAX-PP only
19
AHOMERET
Auxiliary home return 1
SAX-PP only
20
OUTRET1
Programmable output return 1
21
OUTRET2
Programmable output return 2
22
OUTRET3
Programmable output return 3 SAX-PP only
23
OUTRET4
Programmable output return 4 SAX-PP only
24
OUTRET5
Programmable output return 5 SAX-PP only
25
OUTRET6
Programmable output return 6 SAX-PP only
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Remarks
A-2
Elmo SAXophone Installation Guide
Pin Assignments
SAXUGEN0402
A.4 Feedback A – Encoder Option
Pin #
Signal
Function
1
HC
Hall sensor C input
2
HA
Hall sensor A input
3
SUPRET
Hall sensor/Encoder supply voltage return
4
+5V
Hall sensor/Encoder +5V supply voltage
5
CHA-
Channel A complement
6
CHA
Channel A
7
INDEX-
Index complement
8
INDEX
Index
9
SUPRET
Supply return
10
HB
Hall sensor B input
11
SUPRET
Supply return
12
+15V
Hall sensor +15V supply voltage
13
SUPRET
Supply return
14
CHB-
Channel B complement
15
CHB
Channel B
The following diagram illustrates the Hall sensor/encoder sensor pin assignment:
SAX - FEEDBACK A
MOTOR
15 Pin Female
Connector
Encoder/ Hall Sensor
HC
1
Hall C
HA
2
Hall A
SUPRET
3
Hall / Encoder Supply Voltage Return
+5v
4
Encoder / Hall +5v Supply
CHA-
5
CHA-
CHA
6
CHA
INDEX-
7
Index -
INDEX
8
Index
SUPRET
9
HB
10
Hall Sensor B Input
SUPRET 11
+15v
12
Hall +15v Supply ( if required)
SUPRET 13
CHB-
14
CHB -
CHB
15
CHB
Figure A-1: Hall/Encoder Sensor Pin Assignment
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A-3
Elmo SAXophone Installation Guide
Pin Assignments
SAXUGEN0402
A.5 Feedback A – Resolver Option
Pin #
Signal
Function
6
R1
Resolver reference output R1
7
S2
Resolver cosine input S2
8
S1
Resolver sine input S1
9
S3
Resolver sine input S3
11
SCREEN
Cable shield should be connected to this terminal
3,13
SUPRET
Supply return
14
R2
Resolver reference output R2
15
S4
Resolver cosine input S4
The following diagram illustrates resolver connections:
SAX - FEEDBACK A
(RESOLVER OPTION)
D Type 15 Pin Female
Connector
Resolver
R1
6
S2
7
S1
8
Sine S1
S3
9
Sine S3
SUPRET 3
Reference R1
SCREEN 11
Reference R2
SUPRET 13
Cosine S2
R2 14
Cosine S4
S4 15
Figure A-2: Resolver Connections
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Motor
A-4
Elmo SAXophone Installation Guide
Pin Assignments
SAXUGEN0402
A.6 Analog I/O Connector
Pin #
Signal
Function
1
ANLIN1+
Analog input 1
2
ANLIN1-
Analog input 1
3
ANLRET
Analog ground
4
ANLIN2+
Analog input 2
5
ANLIN2-
Analog input 2
6
GND
Common circuit
7
ANLOUT
Analog output
8
ANLRET
Analog ground
9
GND
Common circuit
The following diagram illustrates an analog input with a single-ended source
configuration:
Single-Ended
Source
SAX
-
ANLIN1+
1
ANLIN1-
2
ANLRET
3
ANLIN2+
4
ANLIN2-
5
20K
+
20K
-
20K
+
20K
-
4.99K
+
4.99K
RETURN
Figure A-3: Analog Input with Single-ended Source
Note:
It is recommended that you connect the ANLRET line to GND, even when
the analog interface is not used.
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A-5
Elmo SAXophone Installation Guide
Pin Assignments
SAXUGEN0402
A.7 Com1
Pin #
Signal
1
RS-232 Function
RS-485 Function
–
–
2
Tx
Transmit
–
3
Rx
Receive
–
–
–
4
5
COMRET
Communication return
Communication return
6
TR+
–
TR+
7
TR-
–
TR-
8
–
–
9
–
–
The following diagrams illustrate the two COM1 connection options.
D-Type
9 pin
Female
Figure A-4: RS-232 Connections
D-Type
Figure A-5: RS-485 Connections
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A-6
Elmo SAXophone Installation Guide
Pin Assignments
SAXUGEN0402
Note:
When the RS-485 option is used, a standard RS-232 cable may damage
the RS-485 transceiver, because the RS-232 control signals conflict
with the RS-485 input. In this case, a three-wire cable is required, as
shown in the diagram above.
A.8 Com2 (SAX Plus and SAX Plus Plus)
Pin #
Signal
1
Function
–
2
CAN_L
CAN_L bus line (dominant low)
3
CAN_GND
CANopen ground
4
–
5
CAN_SHLD
CANopen shield
6
CAN_GND
CANopen ground
7
CAN_H
CAN_H bus line (dominant high)
8
9
–
(CAN_V+)
Optional CANopen external positive power
A.9 Feedback B
Pin #
Signal
Function
1
INDEX
Auxiliary index high input
2
CHB
Auxiliary channel B high input
3
CHA
Auxiliary channel A high input
4
+5V
Encoder supply voltage
5
SUPRET
Supply return
6
CHAO
Channel A output
7
CHBO
Channel B output
8
INDEXO
Index output
9
INDEX-
Auxiliary index low input
10
CHB-
Auxiliary channel B low input
11
CHA-
Auxiliary channel A low input
12
SUPRET
Encoder supply voltage return
13
CHAO-
Channel A complement output
14
CHBO-
Channel B complement output
15
INDEXO-
Index complement output
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A-7
Elmo SAXophone Installation Guide
B-1
SAXUGEN0402
Appendix B: Technical Specifications
B.1
Power Ratings
B.1.1
1x230 VAC or 3x230 VAC Power Ratings
Specifications
SAX-8/230
Phase RMS continuous current
8.5 A
Phase RMS peak current
17 A
Nominal operating voltage
1x230 VAC or 3x230VAC
DC bus over-voltage protection
390 V
DC bus under-voltage protection
78 V
Shunt current
8.0 V
B.1.2
3x400 VAC Power Ratings
Specifications
SAX-4/400
SAX-8/400
SAX-10/400
SAX-14/400
Phase RMS continuous current
4.5 A
8.5 A
10.5 A
14.0 A
Phase RMS peak current
9.0 A
17.0 A
21.0 A
28.0 A
Nominal operating voltage
3x400 VAC
3x400 VAC
3x400 VAC
3x400 VAC
DC bus over-voltage protection
765 V
765 V
765 V
765 V
DC bus under-voltage protection
153 V
153 V
153 V
153 V
Shunt current
7.0 A
7.0 A
14.0 A
14.0 A
The power rating is defined for 10 KHz switching frequency on the motor’s winding. The
default is 18 KHz.
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Elmo SAXophone Installation Guide
Technical Specifications
SAXUGEN0402
B.1.3
Rated Specifications
Rated Specifications
SAX-xx/230
SAX-xx/400
Rated supply voltage
3 x 240 VAC max 10%
3 x 460 VAC max
Pulse power of ballast circuit
1.5/3 KW
5/10 KW
Continuous power of ballast
circuit
80/160 W
80/160 W
Switch-off threshold at over
voltage
390 VDC
765 VDC
In-rush current limit
<85 A
<140 A
Efficiency @ rated power
>95 %
>97 %
B.1.4
Auxiliary Power Supply
Auxiliary power supply
An AC or a DC source.
AC voltage input
18 VAC< VIN(AC) < 28 VAC
DC voltage input
18 VDC < VIN(DC) < 40 VDC
Power rating of the source
40 VA
Input frequency
45 Hz < f IN < 500 Hz
B.1.5
Analog Input and Output
Analog input - differential mode + 20V maximum
voltage
Analog input - common mode
voltage
+ 10V maximum
Input resistance
5 KΩ
Analog output voltage
+ 10 V maximum (10 KΩ impedance)
Analog output accuracy
+ 3%
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B-2
Elmo SAXophone Installation Guide
Technical Specifications
SAXUGEN0402
B.1.6
Feedback Supply Voltage
Encoder supply voltage
5V +5%
Hall effect supply voltage
5V or 15V +5%
Encoder supply current (pin 4 of
feedback A and B)
300 mA maximum (total for both outputs)
Hall effect supply current
50 mA maximum
B.2
Control Specifications
Feature
Description
Velocity loop bandwidth
x4 current loop
Current control
Digital
Sinusoidal with vector control
Programmable PI control filter based
on a pair of PI controls of AC current
signals and constant power at high
speed
Current loop bandwidth
Approximately 1.2 KHz
Current loop step response
(including settling time)
300 - 400 µs
Current rise time
150 - 200 µs
Current rise delay time
The time it takes from applying the
command until the current starts to rise.
This delay is due to the digital processing
(100 - 200 µs).
Resolution of current loop
12 bits
Resolution of analog input command 12-bit inputs
Commutation feedback options
Digital Hall effects and incremental
encoder
Resolver
Incremental encoder only
Pulse/direction
Velocity control
Digital
Programmable PID and FFW control
filter
Sampling rate x4 current loop sample
time
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B-3
Elmo SAXophone Installation Guide
Technical Specifications
SAXUGEN0402
Feature
Description
Resolver
Incremental encoder
Digital Hall effect (velocity only)
Velocity and position feedback
options
Note: With all feedback options, 1/T with
automatic modes switching will be
activated (gap, frequency and derivative).
Analog
Velocity command options
Internally calculated by either jogging
or step
Note: All software-calculated profiles
support on-the-fly changes.
PWM switching frequency
Factory default 18 KHz on the motor
Reduction for dissipation (30%)
Can be reduced to half without reducing
bandwidth
Switching method
Advanced unipolar PWM
Control inputs
PLC level only
B.3
Feedback Options
Feature
Type of encoder
Description
Differential
Quadrature
Interface
RS-422
Input resistance
300 Ω
Maximum incremental encoder Maximum absolute: 2 MHz single;
frequency
8 MHz quadrature
Input voltage range for the
encoder
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Maximum common mode: ±7V
Maximum differential mode: ±7V
B-4
Elmo SAXophone Installation Guide
Technical Specifications
SAXUGEN0402
B.4
Digital Input Interface
Feature
Description
Optically isolated
Single ended
Type of input
Input current
Iin =
Vin − 6.5V
Rin
* Iin = 2.2mA @ Vin = 12V
Minimum input current @ Vi=24V
Iin = 7mA
High level input voltage
12V < Vin < 30V
Low level input voltage
0V < Vin < 7V
Min pulse width (IN1 - IN4)
1 msec
Execution time (all inputs)
500µs < T ≤ 2ms
High speed input capture minus
pulse width capture on input
transition (IN5 - IN6)
20µs < T ≤ 50µs
The following diagram shows a digital input schematic for the Saxophone series of servo
amplifiers:
Vz=5.1v
Rin=2.49K
In(i)
VF =1.5v
Group
Common
Figure B-1: Saxophone Digital Input
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B-5
Elmo SAXophone Installation Guide
Technical Specifications
SAXUGEN0402
B.5
Digital Output Interface
Feature
Description
Type of output
Optically isolated
Maximum supply output (Vcc)
30V
Maximum output current Io (max)
(Vout = Low)
TTL level: IOL < 2mA, VOL < 0.8
PLC level: IOL ≅ 10mA, VOL < 3v
VOL @ maximum output voltage
(low level)
TTL level: Vcc = 5v, Vout = 0.8v
PLC level: Vcc = 24v, Vout = 3v
Minimum RL
RL ≥
Executable time
VCC − VOL
IO (max)
Up to 2 msec
The following diagram shows a digital output schematic for the Saxophone series of
servo amplifiers:
Vcc
RL
SAX
Rout=25.5Ω
Output(i)
Vout
33v
Output(i)
Figure B-2: Saxophone Digital Output
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B-6
Elmo SAXophone Installation Guide
Technical Specifications
SAXUGEN0402
B.6
Fault Output
The following table lists specifications for the fault output switches, to be used if a
hardware failure occurs.
Amp Status
Relay Contact Status
No fault
Close
Fault
Open
Switching current
0.25A maximum
Switching voltage
40v AC/DC
The following diagram describes the relay connection:
8
RELAY
N.O.
FAULT
9
Figure B-3: Saxophone Relay Connection
B.7
Single-Phase Operation
When operating with a single-phase supply (SAX-xx/230 only), the voltage drop must be
considered. Voltage drop can be calculated using the following equation:
Vout (Max Phase to phase) = 0.85*[ Vsupply (AC) - Vdrop]
Vdrop AC
RMS
35.00
30.00
25.00
20.00
Vdrop AC
RMS
15.00
10.00
5.00
0.00
1
2
3
4
5
6
7
8
9
10
Motor's phase current RMS
Figure B-4: Single-phase Voltage Drop Concept
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11
B-7
Elmo SAXophone Installation Guide
Technical Specifications
SAXUGEN0402
B.8
Mechanical Specifications
Mounting Method
Bookshelf
Overall dimensions
247 x 188 x 92 mm (9.72 x 7.4 x 3.6 in)
Weight
SAX-5/400: 2.7 kg (6 lb)
B.9
Recommended Wire Cross-sections
Model
AC Input
Motor
SAX-3/230
1.5 mm2 16 AWG
1.5 mm2
16 AWG
0.5-1 mm2 18-22 AWG
SAX-5/230
1.5 mm2 16 AWG
1.5 mm2
16 AWG
0.5-1 mm2 18-22 AWG
SAX-3/400
1.5 mm2 16 AWG
1.5 mm2
16 AWG
0.5-1 mm2 18-22 AWG
SAX-4/400
1.5 mm2 16 AWG
1.5 mm2
16 AWG
0.5-1 mm2 18-22 AWG
SAX-8/400
2.0 mm2 14 AWG
2.0 mm2
14 AWG
0.5-1 mm2 18-22 AWG
SAX-10/400
2.0 mm2 14 AWG
2.0 mm2
14 AWG
0.5-1 mm2 18-22 AWG
SAX-14/400
2.0 mm2 14 AWG
2.0 mm2
14 AWG
0.5-1 mm2 18-22 AWG
B.10
Auxiliary
Environmental Conditions
Feature
Description
Operating ambient temperature
Figure B-5
Storage temperature
-20 to +85° C (-4 to +185° F)
Humidity
90% maximum non-condensing
Maximum operation altitude
above sea level
2000 m (about 6000 ft)
Protection level
IP20
The following graph shows the Saxophone operating ambient temperature at nominal
operating voltage:
I (RMS)
Ic
0.6 Ic
t 0C
45
60
Figure B-5: Operating Ambient Temperature at Nominal Operating Voltage
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B-8
Elmo SAXophone Installation Guide
Technical Specifications
SAXUGEN0402
B.11
Resolver
The optional resolver feedback processor is set for the following type of resolver.
Reference voltage
7 V RMS
Frequency
5.0 or 10 KHz software selectable
Maximum load current
70mA RMS
Transformation ratio
0.5
R/D resolution
12-bit
Maximum velocity
8,000 RPM
1024 pulse per revolution resolution
Differential outputs CHA, CHB
An index with the complementary signals
RS-422: 20 mA load maximum.
Encoder outputs
B.12
Compliance Standards
B.12.1
Quality Assurance
ISO9001
B.12.2
Design
Reliability prediction of electronic
equipment (rating, de-rating, stress,
etc.)
Printed wiring for electronic
equipment (clearance, creepage,
spacing, conductors sizing, etc.)
Type testing
B.12.3
MIL-HDBK- 217F
IPC-D-275
IPC-SM-782
IPC-CM-770
UL508c
UL840
In compliance with VDE0160 -7
Safety
Power conversion equipment
Recognized UL508c
Insulation coordination, including
clearance and creepage distances of
electrical equipment
In compliance with UL840
Safety of information technology
equipment, including electrical
business equipment
In compliance with UL1950
Low voltage directive, 73/23/EEC
In compliance with EN60204-1
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B-9
Elmo SAXophone Installation Guide
Technical Specifications
SAXUGEN0402
B.12.4
EMC
Electromagnetic compatibility (EMC)
B.12.5
Workmanship
Acceptability of electronic assemblies
B.12.6
In compliance with IPC-A-610, level 2
PCB
Acceptability of printed circuit
boards
B.12.7
In compliance with IEC 1800-3,
Part 3: 1996
(Adjustable speed electrical power-drive
systems - EMC products standard,
including specific test methods)
In compliance with IPC-A-600, level 2
Packing
Protection of electrostatic sensitive
devices
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In compliance with EN100015
B-10
Elmo SAXophone Installation Guide
Technical Specifications
SAXUGEN0402
B.13
Dimensional Drawings
B.13.1
General Dimensions
Rear View
Front View
Side View
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B-11
Elmo SAXophone Installation Guide
SAXUGEN0402
B.13.2
Mounting Dimensions
Rear View
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Technical Specifications
B-12
Elmo SAXophone Installation Guide
C-1
SAXUGEN0402
Appendix C: Supplemental
Configuration Schematics
C.1
CANopen Configuration (SAX Plus and SAX Plus Plus)
The following schematic shows the pinout for CANopen communication using Com2.
SAX P1
Optically
Isolated
CAN - Interface
6
7
CAN
Transceiver
CANH
2
CANL
3
COMRET
SAX P2
Optically
Isolated
CAN Host
CAN - Interface
6
7
CAN
Transceiver
2
3
SAX Pn
Optically
Isolated
CAN - Interface
6
7
CAN
Transceiver
2
3
Figure C-1: Saxophone Configuration with CANopen Communication
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Elmo SAXophone Installation Guide
Supplemental Configuration Schematics
SAXUGEN0402
C.2
Auxiliary Encoder Configurations
SAX - Plus Plus
Feedback A
Master
Driver
Slave
Driver
CONNECTOR
FEEDBACK B
CONNECTOR
FEEDBACK B
CHAO
CHAOCHBO
CHBOINDEXO
INDEXO-
Master
Axis
6
3
13
11
7
2
14
10
8
1
15
9
CHA
Feedback A
CHACHB
CHBINDEX
INDEX-
SUPRET
Slave
Axis
Figure C-2: Master-Slave Configuration for Auxiliary Encoder
Independent
Encoder
SAX - Plus Plus
Aux. Encoder
3 CHA
11 CHA-
Isolated
Encoder
Power
Supply
+5v Supply
5v RET
2 CHB
10 CHB1 INDEX
9 INDEXFEEDBACK
Figure C-3: Independent Configuration for Auxiliary Encoder
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Motor
C-2
Elmo SAXophone Installation Guide
I-1
SAXUGEN0402
Index
A
Amplifier compliance · 1-1
Analog I/O connector · A-5
Analog input and output · B-2
Auxiliary encoder configurations · C-2
Auxiliary power connector · A-1
Auxiliary power supply · 3-6, B-2
C
Cables
CANopen · 3-8
Communication · 3-8
I/O · 3-9
Main feedback · 3-8
Motor · 3-7
Power · 3-5
RS-232 · 3-8
RS-485 · 3-8
Cabling · 3-4
CANopen
Cable · 3-8
Configuration · C-1
Com1 connector · A-6
Com2 connector · A-7
Communication cables · 3-8
CANopen · 3-8
RS-232 · 3-8
RS-485 · 3-8
Compliance standards · B-9
Composer · 3-10
Connecting
Motor cables · 3-7
Power cables · 3-5
Control specifications · B-3
D
Digital input interface · B-5
Digital output interface · B-6
DIN rail mounting · 3-3
Display panel · 4-1
E
Encoder connections · A-3
Environmental conditions · B-8
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F
Fault output · B-7
Feedback A - encoder · A-3
Feedback A - resolver · A-4
Feedback B · A-7
Feedback options · B-4
G
General I/O connector · A-2
Grounding · 1-2
I
I/O cables · 3-9
Initializing the Saxophone · 3-10
Installing the Saxophone · 3-1
L
Live servo operations · 1-1
M
Main feedback cable · 3-8
Mechanical specifications · B-8
Mounting the Saxophone · 3-2
Directly on wall · 3-2
On DIN rail · 3-3
P
Pin assignments · A-1
Analog I/O connector · A-5
Auxiliary power connector · A-1
CANopen · C-1
Com1 · A-6
Com2 · A-7
Committed I/O connector · A-1
Feedback A - encoder · A-3
Feedback A - resolver · A-4
Feedback B · A-7
General I/O connector · A-2
Power
Disconnecting · 1-1
Grounding · 1-2
Precautions · 1-2
Source · 2-1
Supply · 1-2
Elmo SAXophone Installation Guide
Index
SAXUGEN0402
Power ratings · B-1
Power supply · 3-6
Powering up the Saxophone · 1-2, 3-10
R
Rated specifications · B-2
Replacing components · 1-1
Resolver · B-9
Connections · A-4
Specifications · B-9
RS-232 cable · 3-8
RS-485 cable · 3-8
S
Safety
Amplifier compliance · 1-1
Compliance standards · B-9
Disconnecting power · 1-1
Live servo operations · 1-1
Precautions · 1-1, 1-2
Replacing components · 1-1
Saxophone
Cables · 3-7
Display · 4-1
Initializing · 3-10
Installation · 3-1
Mounting
Directly on wall · 3-2
On DIN rail · 3-3
System architecture · 2-2
System description · 2-1
Technical specifications · B-1
Type designation number · 3-1
Wiring · 3-4
Single-phase
Operation · B-7
Voltage · 2-2
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Specifications
1x230 VAC power ratings · B-1
3x230 VAC power ratings · B-1
3x400 VAC power ratings · B-1
Analog input and output · B-2
Auxiliary power supply · B-2
Control · B-3
Digital input interface · B-5
Digital output interface · B-6
Environment · B-8
Fault output · B-7
Feedback options · B-4
Mechanical · B-8
Rated · B-2
Resolver · B-9
Supply voltage · B-3
Status indications · 4-1
Supply voltage · B-3
System architecture · 2-2
T
Technical specifications · B-1
Three -phase voltage · 2-2
Type designation number · 3-1
U
Unpacking the Saxophone · 3-1
V
Voltage
Single-phase · 2-2
Three-phase · 2-2
W
Wire cross-sections · B-8
Wiring the Saxophone · 3-4
I-2