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Condor Analog Servo Amplifier

Installation Guide

November 2011 (Ver. 1.1)

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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 Condor servo drive in its installation.

• The text and graphics included in this manual are for the purpose of illustration and reference only. The specifications on which they are based are subject to change without notice.

• Elmo Motion Control and the Elmo Motion Control logo are registered trademarks of Elmo Motion Control Ltd. EtherCAT is a registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany.

• Information in this document is subject to change without notice.

Document no. MAN‐CONIG (Ver. 1.1)

Copyright © 2011 Elmo Motion Control Ltd.

All rights reserved.

Catalog Number

Revision History Ver. 1.0 Initial Release

Ver. 1.1 PR changed to VN‐

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‐[email protected]

North America Elmo Motion Control Inc.

42 Technology Way, Nashua, NH 03060 USA

Tel: +1 (603) 821‐9979 • Fax: +1 (603) 821‐9943 • info‐[email protected]

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‐[email protected]

China Elmo Motion Control Technology (Shanghai) Co. Ltd.

Room 1414, Huawen Plaza, No. 999 Zhongshan West Road, Shanghai (200051) China

Tel: +86‐21‐32516651 • Fax: +86‐21‐32516652 • info‐[email protected]

Asia Pacific Elmo Motion Control

#807, Kofomo Tower, 16‐3, Sunae‐dong, Bundang‐gu, Seongnam‐si, Gyeonggi‐do, South Korea

Tel: +82‐31‐698‐2010 • Fax: +82‐31‐698‐2013 • info‐[email protected]

mailto:[email protected]





Condor Installation Guide MAN-CONIG (Ver. 1.1)

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Table of Contents

Chapter 1: Safety Information ....................................................................................... 6

1.1. Warnings .................................................................................................................... 7 1.2. Cautions ..................................................................................................................... 7 1.3. Directives and Standards ........................................................................................... 8 1.4. CE Mark Conformance ............................................................................................... 8 1.5. Warranty Information ............................................................................................... 8

Chapter 2: Introduction ................................................................................................. 9

2.1. Product Description ................................................................................................... 9 2.2. Standard Features ..................................................................................................... 9 2.3. Fault Protection ....................................................................................................... 10 2.4. How to Use this Guide ............................................................................................. 10

Chapter 3: Installation ................................................................................................. 11

3.1. Before You Begin ..................................................................................................... 11 3.1.1. Site Requirements .................................................................................... 11

3.2. Unpacking the Amplifier .......................................................................................... 11 3.3. Mounting the Condor .............................................................................................. 12 3.4. Connecting the Cables ............................................................................................. 13

3.4.1. Wiring the Condor .................................................................................... 13 3.5. Condor Connection Diagram ................................................................................... 16

3.5.1. Connecting the Power Cables ................................................................... 17 3.5.1.1. Connecting the Motor Cable ................................................... 19 3.5.1.2. Connecting the DC Power ........................................................ 20 3.5.1.3. Connecting the Optional Backup Supply Cable ....................... 22

3.5.2. Control, I/Os and Halls Cable Assemblies ................................................. 24 3.5.3. J2 Control Port .......................................................................................... 25

3.5.3.1. J3 General I/O Port .................................................................. 27 3.5.3.2. J4 Hall’s Signal Port .................................................................. 28

3.6. DC Power Supply ..................................................................................................... 29 3.6.1. Powering Up ............................................................................................. 29 3.6.2. Initializing the System ............................................................................... 29

3.7. Heat Dissipation ....................................................................................................... 29 3.7.1. Condor Thermal Data ............................................................................... 30 3.7.2. Heat Dissipation Data ............................................................................... 30 3.7.3. How to Use the Charts .............................................................................. 32

Chapter 4: Servo Control Operation ............................................................................. 33

4.1. Condor Connected to DC Motors ............................................................................ 33 4.2. Current Command Input ......................................................................................... 33 4.3. External Current Limit ‐ Continuous (ECLC) ............................................................. 33

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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 ........................................................................................ 34 4.3.5. External Resistor ....................................................................................... 34 4.3.6. Latch Mode (LM) ....................................................................................... 34

4.4. Status Indications .................................................................................................... 35

Chapter 5: Technical Specifications .............................................................................. 36

5.1. General Specifications ............................................................................................. 36 5.2. Environmental Conditions ....................................................................................... 37 5.3. Dimensions .............................................................................................................. 38 5.4. Compliance with Standards ..................................................................................... 39


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Chapter 1: Safety Information In order to achieve the optimum, safe operation of the Condor 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 Condor as well as the accompanying equipment.

Please read this chapter carefully before you begin the installation process.

Before you start, ensure that all system components are connected to earth ground. Electrical safety is provided through a low‐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 Condor 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.

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Condor Installation Guide Safety Information MAN-CONIG (Ver. 1.1)

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

• The Condor servo drives contain grounding conduits for electric current protection. Any disruption to these conduits may cause the instrument to become hot (live) and dangerous.

• After shutting off the power and removing the power source from your equipment, wait at least 1 minute before touching or disconnecting parts of the equipment that are normally loaded with electrical charges (such as capacitors or contacts). Measuring the electrical contact points with a meter, before touching the equipment, is recommended.

1.2. Cautions • The Condor 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 Condor to an approved 12 to 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 Condor, verify that all safety precautions have been observed and that the installation procedures in this manual have been followed.

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Condor Installation Guide Safety Information MAN-CONIG (Ver. 1.1)

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1.3. Directives and Standards The Condor conforms to the following industry safety standards:

Safety Standard Item

In compliance with UL 508C Power Conversion Equipment

In compliance with UL 840 Insulation Coordination, Including Clearance and Creepage Distances of Electrical Equipment

In compliance with UL 60950‐1 (formerly UL 1950)

Safety of Information Technology Equipment, Including Electrical Business Equipment

In compliance with EN 60204‐1 Low Voltage Directive, 73/23/EEC

The Condor servo drives have been developed, produced, tested and documented in accordance with the relevant standards. Elmo Motion Control is not responsible for any deviation from the configuration and installation described in this documentation. Furthermore, Elmo is not responsible for the performance of new measurements or ensuring that regulatory requirements are met.

1.4. CE Mark Conformance The Condor 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 EN 60204‐1 and EN 292‐2 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 designed for use within certain voltage limits, the Condor meet the provisions outlined in Council Directive 73/23/EEC. The party responsible for ensuring that the equipment meets the limits required by EMC regulations is the manufacturer of the end product.

1.5. 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.


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Chapter 2: Introduction This Installation Guide is intended for design engineers who are integrating Elmo Motion Control Condor servo amplifiers into a machine.

2.1. Product Description The Condor series of servo amplifiers is designed to operate in the current mode controlling permanent‐magnet trapezoidal brushless motor and DC brush motor.

The Condor exhibits “the highest density of power and intelligence” and can deliver up to 11.3 kW of continuous power or 13.6 k W of peak power in a most compact and efficient package.

The Condor operates from a DC power source in the range from 12 to 195 VDC.

The Power stage of the Condor is fully isolated from other sections of the Condor, such as the control stage and the heatsink. This contributes very significantly to the safety and the EMI immunity of the Condor. In addition it simplifies the requirements of the DC power supply used to power the DC bus of the Condor and allows also the operation with a non‐isolated DC power source.

The Condor incorporates full custom mixed analog/digital ICs and a hybrid power stage. The basic configuration is a current mode amplifier targeting the OEM market. As such, no trimmers are used in the basic version. In addition to its compliance with relevant MIL standards, the Condor amplifier also meets UL 508C and the relevant CE regulations.

The Condor power stage is implemented on ceramic substrates. This design enables very high thermal conductivity, high current carrying capacity, improved EMC and good mechanical strength. The control section is implemented by dedicated custom ICs that contribute to enhanced performance and reliability.

2.2. Standard Features • Operates in current mode

• Internal DC‐to‐DC converter, which allows for operation from a single supply

• Zero dead‐band

• Excellent linearity

• One differential input

• Motor current monitor

• Current gain change for low inductance motors

• Remote current gain control

• Status indication and remote control functions by four open collector transistors

• External continuous and peak current‐limit adjustments

• Package: plated‐aluminum base plate, plastic housing, UL 94V0 recognized

• Ultra‐lightweight of 700 grams (24.7 oz)

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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 Condor servo amplifiers. After carefully reading the safety instructions in the first chapter, the following chapters provide you with installation instructions as follows:

• Chapter 3, Installation, provides step‐by‐step instructions for unpacking, mounting and connecting the Condor.

• Chapter 4, Servo Control Operation, explains how to control the operation of the servo amplifier.

• Chapter 5, Technical Specifications, lists all the drive ratings and specifications.


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Chapter 3: Installation

3.1. Before You Begin

3.1.1. Site Requirements

You can guarantee the safe operation of the Condor by ensuring that it is installed in an appropriate environment.

Feature Value

Ambient operating temperature ‐40 °C to +70 °C (‐40 °F to 160 °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.

Caution: The Condor dissipates its heat by convection. The maximum ambient operating temperature of ‐40 °C to +70 °C (‐40 °F to 160 °F) must not be exceeded.

3.2. Unpacking the Amplifier To unpack the Condor:

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. If any damage has occurred, report it immediately to the carrier that delivered your amplifier.

3. To ensure that the Condor 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:

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4. Verify that the Condor type is the one that you ordered, and ensure that the voltage meets your specific requirements.

3.3. Mounting the Condor The Condor 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 Condor (see the diagram below).

For full power output capability the Condor is designed to be mounted on an external heatsink. It is highly recommended that the wall on which the Condor is mounted will have heat dissipation capabilities. The Condor at “free air convection” (without an additional heatsink) can dissipate around 12 W to 15 W.

Figure 1: Mounting the Condor

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3.4. Connecting the Cables

3.4.1. Wiring the Condor Once the Condor 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 Condor.

Caution: Follow these instructions to ensure safe and proper wiring:

• Use twisted pair shielded cables for control, feedback and communication connections. For best results, the cable should have an aluminum foil shield covered by copper braid, and should contain a drain wire.

The drain wire is a non‐insulated wire that is in contact with parts of the cable, usually the shield. It is used to terminate the shield and as a grounding connection.

• The impedance of the wire must be as low as possible. The size of the wire must be thicker than actually required by the carrying current. A 24, 26 or 28 AWG wire for control and feedback cables is satisfactory although 24 AWG is recommended.

• Use shielded wires for motor connections as well. If the wires are long, ensure that the capacitance between the wires is not too high: C < 30 nF is satisfactory for most applications.

• Keep all wires and cables as short as possible.

• Keep the motor wires as far away as possible from the feedback, control and communication cables.

• Ensure that in normal operating conditions, the shielded wires and drain carry no current. The only time these conductors carry current is under abnormal conditions, when electrical equipment has become a potential shock or fire hazard while conducting external EMI interferences directly to ground, in order to prevent them from affecting the drive. Failing to meet this requirement can result in drive/controller/host failure.

• After completing the wiring, carefully inspect all wires to ensure tightness, good solder joints and general safety.

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Figure 2: Condor Connection Diagram

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Type Function Port Connector Location

Barrel Connector + M6 Spring Washer + M6 Nut

Power VP+, VN‐

Motor M1, M2, M3

Barrel Connector + M5 Flat Washer + M5 Spring Washer + M5 screw

Ground PE, PE, PE, PE

Note: If longer screws are required consult Elmo.

Table 1: Power Connectors on the Condor


15‐Pin D‐Sub female

Halls signals. J4

9‐Pin D‐Sub female Inputs, Outputs (IO)

J3

Table 2: Halls signals and I/O Connectors on the Condor


9‐Pin D‐Sub male Backup Supply

J1

15‐Pin High Density D‐Sub male

Control J2

Table 3: Controls and Backup Connectors on the Condor

PEPE

J4 Female: Halls signals J3 Female: I/O

J1 Male: Optional Backup Supply

J2 Male: logic

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3.5. Condor Connection Diagram

Figure 3: Condor Connection Diagram

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3.5.1. Connecting the Power Cables The main power connector located at the bottom of the Condor, as follows:

Pin Function Cable Pin Positions

VP+ Pos. Power input Power

VN‐ Neg. Power input Power

PE Protective earth Power

AC Motor Cable

DC Motor Cable

PE Protective earth Motor Motor

M1 Motor phase Motor N/C

M2 Motor phase Motor Motor

M3 Motor phase Motor Motor

Notes:

• When connecting several motors, all must be wired in an identical manner.

• If longer screws are required consult Elmo.

PEPE

PEPE

Table 4: Connector for Main Power and Motor Cables

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M6 nut (available with the drive)

M6 spring washer

Step 1: PE Connection

Note: PE connection can also be accomplished by attaching the Condor to ground surface.

Step 2: Power and Motor Connection

Table 5: Connecting the Main Power and Motor Cables

M5 screw

Barrel connector

M5 spring washer

Barrel connector M5 flat washer

M5 screw

M5 spring washer

M5 flat washer Barrel connector

M6 nut (available with the drive)

M6 spring washer

Barrel connector

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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. The gauge is determined by the actual current consumption of the motor.

• Connect the shield of the cable to the closest ground connection at the motor end.

• Connect the shield of the cable to the PE terminal on the heatsink.

• Be sure that the motor chassis is properly grounded.

• To close the motor cable into the drive, use the barrel connector, M6 spring washer and M6 nut (in the drive). The required torque is 3 to 4 Nm.

• To close the PE wire into the drive, use the barrel connector, M5 flat washer, M5 spring washer and M5 screw to the heatsink. The required torque is 3 to 4 Nm.

• Use flex wire 6/8/10 AWG to barrel connector.

Figure 4: AC Motor Power Connection Diagram

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3.5.1.2. Connecting the DC Power

The Power stage of the Condor is fully isolated from other sections of the Condor, such as the control stage and the heatsink. This contributes very significantly to the safety and the EMI immunity of the Condor. In addition it simplifies the requirements of the DC power supply used to power the DC bus of the Condor and allows also the operation with a non‐isolated DC power source.

3.5.1.2.a Operation with an Isolated DC power Supply:

The PE (Protective Ground of the AC network) is connected to the VN‐ terminal (the Negative Power Input terminal).

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.

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3.5.1.2.b Operation with a Non‐ Isolated DC power Supply:

The PE (Protective Ground of the AC network) must not be connected to the Negative Power Input (the VN‐ terminal) of the Condor.

Figure 7: Non‐Isolated DC Power Supply

The Power Supply is directly connected to the AC line.

(In the case of a 200 VDC drive, for example, the AC must be limited to 135 VAC so as not to exceed the maximum of 190 VDC.)

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.

The network PE must not be connected to the Return of the Power Supply.

Caution: Connecting the PE to the VN‐ with a non‐ isolated power supply will cause damages to the system (Any component that is connected to the system might be damaged).

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Notes for connecting the DC power supply:

• The Condor can operate from either an:

isolated DC power supply

or a

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.

• Connect both ends of the cable shield to the closest ground connection, one end near the power supply and the other end to the PE terminal on the Condor’s heatsink.

• Only when using an isolated power DC source, connect the VN‐ of the power supply to the closest ground connection for safety reasons.

• To close the power supply cable into the drive, use the barrel connector, M6 spring washer and M6 nut (in the drive). The required torque is 3 to 4 Nm.

• To close the PE wire into the drive, use the barrel connector, M5 flat washer, M5 spring washer and M5 screw to the heatsink. The required torque is 3 to 4 Nm.

3.5.1.3. Connecting the Optional Backup Supply Cable

Power to the Condor is provided by a 12 to 195 VDC source (depending on model type). A “smart” control‐supply algorithm enables the Condor to operate with the power supply only, with no need for an auxiliary supply voltage. If backup functionality is required for storing control parameters in case of power‐outs, an external 12 to 195 VDC power supply can be connected, providing maximum flexibility and optional backup functionality when needed.

To connect the backup supply to the Auxiliary port, use the Condor's J1 connector (Back up supply connector). Remember, you are working with DC power so be sure to exercise caution.

Notes for backup supply connections:

• Use a 24 AWG twisted pair shielded cable. The shield should have copper braid.

• The source of the backup supply must be isolated.

• Connect the cable shield to the closest ground near the power source.

• Before applying power, first verify the polarity of the connection.

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Pin Signal Function Pin Position

J1‐9 Backup+ Supply +VDC backup supply

J1‐8 Backup‐ Supply Return (common) of the backup supply

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.

“Smart” Control Supply Options

Internal DC‐to‐DC converter that allows operation from DC power (no need for auxiliary external supply for normal operation).

12 to 195 VDC supply for backing up the control parameters if DC power is shut off.

J1 Male

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3.5.2. Control, I/Os and Halls Cable Assemblies The Condor 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.

• Attach the braid shield tightly to the metal housing of the D‐type connector.

• On the motor side connections, ground the shield to the motor chassis.

• On controller side connections, follow the controller manufacturer’s recommendations concerning the shield.

Figure 10: Control, I/Os and Halls Cable Assemblies

Note: All D‐Sub type connectors, used with the Condor, should be assembled in this way.

Metal Housing

Make sure that the braid shield is in tight contact with the metal housing

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3.5.3. 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 Pin Location

1 ANLRET Return Analog Return signal

15‐Pin High‐ Density D‐Sub

2 CREF‐ Current Command negative

Negative input of a differential amplifier.

Same specification as in pin J2/3.

3 CREF+ Current Command positive

Positive input of a differential amplifier:

Input operating voltage range:

±10 V

Maximum input voltage: ±20 V

Maximum common mode voltage:

±6 V Differential input impedance: 40 kΩ

4 GAIN Current gain change

Shorting this pin to LMRET pin (J2/10) reduces

The proportional gain of the current loop by 70%.

5 LATCH Latch mode Latch mode input. For more details see the Latch Mode (LM) section in Chapter 4.

6 CMRET Return Current monitor (CM) signal return.

7 ECLRET Return Current limit signals return.

8 ECLRET Return Current limit signals return.

9 GAINRET Return Return for Gain signal

10 LMRET Return Return for Latch Mode signal.

11 CM Current monitor

Analog output with a scale of ±3.9 V for ± Ip.

Output resistance: 1 kΩ

J2 Male

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Pin Signal Function Description Pin Location

12 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)

13 ECLC External current limit continuous

External voltage scales down the rated value.

Voltage range: 0 V to 3.75 V (3.75 V = rated Ic)

14 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 J2/15 (‐).

The optocoupler is isolated from the amplifier.

“OFF” voltage: 0 V < Vin < 1 V.

“ON” voltage: 2.5 V < Vin < 10 V, 5 V typically with current consumption 2.5 mA.

15 EN‐ Enable ‐ Negative voltage input of “Amplifier Enable” function.

Optocoupler is isolated from the amplifier.

For details, see pin J2/14.

Table 7: J2, Control Connector Cable‐ Pin Assignments

Note: All of the XXRETs are shorted internally.

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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 Pin Position

1 AOK Amplifier OK

When the amplifier 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. Maximum voltage = 30 V Maximum current = 8 mA “On” voltage: V OUT(On) < 0.8 V

9‐Pin Female

2 SO1 Status output 1

Status indication output 1. Specification same as in pin J3/1.





5 EN+ Enable + “Amplifier Enable” function. To enable operation of the amplifier, the optocoupler must be energized by applying voltage between this pin (+) and pin J3/6 (‐). The optocoupler is isolated from the amplifier. “OFF” voltage: 0 V < Vin < 1 V. “ON” voltage: 2.5 V < Vin < 10 V, 5 V typically with current consumption 2.5 mA.

6 EN‐ Enable ‐ Negative voltage input of “Amplifier Enable” function. Optocoupler is isolated from the amplifier. For details, see pin J3/5.

7 SORET Status output return

Status output common AOK, SO1, SO2, SO3. Isolated from circuit common.





Table 8: J3 I/O Cable ‐ Pin Assignments

Note: Amplifier enable (EN+, EN‐) can be enabled from J2 or J3.

J3 Female

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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 Pin Position

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.

15‐Pin Female

2 HALL+ 5V +5 V Hall supply voltage: 5 V ± 10% at 30 mA

+5 V supply voltage for Hall sensors. Output current: maximum of 30 mA.

3 HARET Hall supply voltage return

Return used only for Hall supply.

4 HARET Hall supply voltage return

Return used only for Hall supply.

5 HA Hall A input Logic levels: TTL Maximum input voltage: 15 VDC.

6 HB Hall B input Logic levels: TTL Maximum input voltage: 15 VDC.

7 HC Hall C input Logic levels: TTL Maximum input voltage: 15 VDC.

8 N.C.

9 N.C.

10 N.C.

11 N.C.

12 N.C.

13 N.C.

14 N.C.

15 N.C.

J4 Female

Table 9: J4 Halls Cable ‐ Pin Assignments

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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 overvoltage category. If the power source to the power supply is the AC line (through an isolated or a NON 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:

1.2 Vdcmin < Vdc < 0.9 Vdcmax

Where: Vdcmin is the minimum DC bus Vdcmax is the maximum DC bus

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. 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.

3.6.1. Powering Up After the Condor is connected to its devices, the Condor is ready to be powered up.

Caution: Before applying power, ensure that the DC supply is within the specified range and that the proper plus‐minus connections are in order.

3.6.2. Initializing the System After the Condor has been connected and mounted, the system must be set up and initialized.

3.7. Heat Dissipation For full power output capability the Condor is designed to be mounted on an external heatsink. It is highly recommended that the “Wall” on which the Condor is mounted will have heat dissipation capabilities. The Condor at “free air convection” (without an additional heatsink)

can dissipate around 12 W for 40 °C ambient temperature and not exceeding 80 °C on the heatsink.

When “Free Air Convection” is sufficient for the application it is recommended to leave approximately 10 mm of space between the Condor's heatsink and any other assembly.

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3.7.1. Condor 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 Condor 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).

• The thermal resistance when connecting to an external heat sink:

The surface of the external heatsink is 50 μm: 0.18 °C/W. Thermal conductive compound. By proper Smearing of the surface a significant

improvement of the thermal resistance is achieved: 0.13 °C/W

3.7.2. Heat Dissipation Data Heat Dissipation is shown in graphically below:

Power Dissipation 60V series

0

10

20

30

40

50

60

70

80

90

100

0 12 20 30 40 50 60 70 80 90

Motor's Current (Ampere)

Pow

er D

issi

patio

n (W

) 12VDC20VDC30VDC40VDC50VDC56VDC

HeatsinkRequired

Heatsinknot

Required Standard 40 °C Ambient Temp.

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0

20

40

60

80

100

120

0 8.3 16.7 25.0 33.3 41.7 50.0 58.3 66.7 75.0


Pow

er D

issi

patio

n (W

) 20VDC40VDC60VDC80VDC96VDC

HeatsinkRequired Standard 40 °C Ambient Temp.

Heatsinknot

Required

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0

50

100

150

200

250

0 6.7 13.3 20.0 26.7 33.3 40.0 46.7 53.3 60.0


Pow

er D

issi

patio

n (W

) 40VDC80VDC120VDC160VDC196VDC

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.

To determine if your application needs a heatsink:

1. Allow maximum heatsink temperature to be 80°C or less (shunt down is 6 °C to 8 °C higher).

2. Determine the ambient operating temperature of the Condor as ≤ 40 °C.

3. Calculate the allowable temperature increase as follows:

For an ambient temperature of 40°C , ΔT= 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 12 W the Condor needs 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.


33

Chapter 4: Servo Control Operation

4.1. Condor Connected to DC Motors In order to connect the Condor 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 Condor 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. 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 10 V, input scaling must be implemented by adding a pair of external resistors, according to the following formula:

Rin (kΩ) = (5.33 * Vin) – 53.6

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 Condor amplifiers can be scaled down by an external voltage or by an external resistor connected from pin J2/13 (ECLC) to pin J2/8 (ECLRET).

4.3.1. External Voltage

VECLCIC(new) =

3.75V* Ic(nom)

VECLCIC(new) =

3.75V* Ic(nom)

An external positive voltage (0 to 3.75 V) to terminal J2/13 (ECLC) in reference to terminal J2/8 (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 3.75 V.

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.

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Condor Installation Guide Servo Control Operation MAN-CONIG (Ver. 1.1)

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4.3.2. External Resistor Connect an external resistor between terminal J2/13 (ECLC) and terminal J2/8 (ECLRET).

The resistor value is given by:

(Kohm) = 37.4 * Ic(new)

Ic(nom)- 1RECLC (Kohm) = 37.4 * (Kohm) = 37.4 *

Ic(new)

Ic(nom)- 1RECLC RECLC

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. External Current Limit Peak (ECLP) The peak current limit of the Condor amplifiers can be scaled down by an external voltage or by an external resistor connected between pin J2/12 (ECLP) and J2/7 (ECLRET).

4.3.4. External Voltage An external positive voltage (0 to 3.75 V) to terminal J2/12 (ECLP) in reference to terminal J2/7 (ECLRET) will control the peak current limit from zero to Ip(nom).

VECLPIp(new) =

3.75V* Ip(nom)

VECLPIp(new) =

3.75V* Ip(nom)

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.

(Kohm) = 37.4 * RECLP Ip(new)

Ip(nom)- 1(Kohm) = 37.4 * RECLP (Kohm) = 37.4 * RECLP

Ip(new)

Ip(nom)- 1

4.3.5. External Resistor Connect an external resistor between terminal J2/12 (ECLP) and terminal J2/7(ECLRET). The resistor value is given by:

0 < RECLP < 36.4 K (1/8 Watt)

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 J2/5 to J2/10, 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 J2/14 resets the latch. Be sure to restore the Enable connection when the reason for the event no longer exists.

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Condor Installation Guide Servo Control Operation MAN-CONIG (Ver. 1.1)

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4.4. Status IndicatiThe fo le lists the Con lifier indicat

llowing tab

ons dor amp status ions.

Function

Latch O n ptio

AOK

SO1

SO2

SO3

1 Amplifier OK (AOK) Open ctor N/A Low Open collector Open collector colle

2 External disable No Low Low Open collector Low

3 Current limit No Low Open collector Open collector Low

4 Short Yes collector

Low Open collector Low Open

5 rature Yes collector

Open collector Low Low Over tempe Open

6 Internal supplies protection

No collector

Low Low Open collector Open

7 Undervoltage No collector

Low Open collector Open collector Open

8 Overvoltage No Open collector

Open collector Low Open collector

9 Shunt* No Low Open collector Low Open collector

10 Power up reset Nocollector

Open collector Open collector Open collectorOpen

1 1 Commutation failure Yes Open Low Low Lowcollector

* This indication can be used as a digital input for activating an external shunt regulator.

Table 10: Condor Status Indications

Notes:

• Without latch modThe status indications are reset when the fault disappears.

e:

• : Temperature and Commutation Failure status indications are reset when

• 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.

With latch modeThe Short, Over the enable signal is temporarily removed from the enable input.


36

Chapter 5: Technical Specifications

5.1. General Specifications Feature Units 70/48 70/60 R90/60 50/100 R75/100 35/200 R60/200 18/400

Minimum supply voltage

VDC 11 12 18 36 72

Nominal supply voltage

VDC 42 50 85 170 360

Maximum supply voltage

VDC 48 59 95 195 390

Maximum continuous power output

W 3200 4000 5100 4600 6900 6600 11300 6800

Efficiency at rated power

% > 97

Maximum output voltage

97% of DC bus voltage at f=32 kHz

DC and trapezoidal commutation continuous current limit (Ic)

A 70 70 90 50 75 35 60 18

Peak current limit A 2 x Ic 2 x Ic No Peak 2 x Ic No Peak 2 x Ic No Peak 2 x Ic

Weight g (oz) 700 g (24.7 oz)

Dimensions mm (in)

134 x 95 x 60 (5.3" x 3.7" x 2.4")

Mounting method Panel mount

Feature Units Specification

PWM switching frequency kHz 32 ± 5% default on motor

Switching method Advanced Unipolar PWM

Current loop bandwidth kHz Up to 4

Maximum case temperature °C (°F) 87 °C (188 °F)

Storage temperature °C (°F) ‐40 °C to 100 °C (‐40 °F to +212 °F)

Servo Modes Current

Commands ±10 VDC

Feedbacks Digital Halls

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Condor Installation Guide Technical Specifications MAN-CONIG (Ver. 1.1)

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5.2. Environmental Conditions

Ambient Temperature Range

Non‐operating conditions

‐50 °C to +100 °C (‐58 °F to 212 °F)

Operating conditions ‐40 °C to +70 °C (‐40 °F to 160 °F)

Temperature Shock


‐40 °C to +70 °C (‐40 °F to 160 °F) within 3 min.

Altitude Non‐operating conditions

Unlimited

Operating conditions ‐400 m to 155,000 m (‐1,300 ft to 510,000 ft)

Maximum Noncondensing Humidity


Up to 95% at 35 °C (95 °F)

Operating conditions Up to 95% at 25 °C (77 °F), up to 90% at 42 °C (108 °F)

Vibration Operating conditions 20 Hz to2,000 Hz, 14.6g

Mechanical Shock

Non-operating conditions

±40g; Half sine, 11 msec

Operating conditions ±20g; Half sine, 11 msec

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5.3. Dimensions

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5.4. Compliance with Standards

Specification Details

Quality Assurance

ISO 9001:2008 Quality Management

Design

In compliance with MIL‐STD‐704 Aircraft, Electric Power Characteristics

In compliance with MIL‐STD‐810 Environmental Engineering Considerations and Laboratory Tests

In compliance with MIL‐STD‐1275 Characteristics of 28 Volt DC Electrical Systems in Military Vehicles

In compliance with MIL‐STD‐461 Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

In compliance with MIL‐HDBK‐ 217F Reliability Prediction of Electronic Equipment (rating, de‐rating, stress, etc.)

• IPC‐D‐275

• IPC‐SM‐782

• IPC‐CM‐770

• UL 508C

• UL 840

Printed wiring for electronic equipment (clearance, creepage, spacing, conductors sizing, etc.)

In compliance with VDE0160‐7 (IEC 68) Type testing

Safety

Recognized UL 508C Power Conversion Equipment

In compliance with UL 840 Insulation Coordination Including Clearances and Creepage Distances for Electrical Equipment

In compliance with UL 60950 Safety of Information Technology Equipment Including Electrical Business Equipment

In compliance with EN 60204‐1 Low Voltage Directive 73/23/EEC

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Specification Details

EMC

Approved IEC/EN 61800‐3, EMC Adjustable speed electrical power drive systems

In compliance with EN 55011 Class A with EN 61000‐6‐2: Immunity for industrial environment, according to: IEC 61000‐4‐2 / criteria B IEC 61000‐4‐3 / criteria A IEC 61000‐4‐4 / criteria B IEC 61000‐4‐5 / criteria B IEC 61000‐4‐6 / criteria A IEC 61000‐4‐8 / criteria A IEC 61000‐4‐11 / criteria B/C

Electromagnetic compatibility (EMC)

Workmanship

In compliance with IPC‐A‐610, level 3 Acceptability of electronic assemblies

PCB

In compliance with IPC‐A‐600, level 2 Acceptability of printed circuit boards (PCBs)

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.

In compliance with 2002/95/EC (effective July 2006)

Restrictions on Application of Hazardous Substances in Electric and Electronic Equipment (RoHS)

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