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. Elmo Motional Control Inc. Elmo Motion Control GmbH
64 Gisin St., P.O. Box 463 900(H) River St., Kennedy Steinbeisstrasse 41
Petach Tikva Industrial Park D-78056
49103 Windsor, CT 06095 Villingen-Schwenningen
Israel USA Germany
Tel: +972 3 929-2300 Tel: +1 860 683-0095 +49 07720 8577-60
Fax: +972 3 929-2322 Fax: +1 860 683-0036 +49 07720 8577-70

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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 Mechanical Specifications .............................................................................................B-8

B.9 Recommended Wire Cross-sections.............................................................................B-8
B.10 Environmental Conditions............................................................................................B-8
B.11 Resolver ..........................................................................................................................B-9
B.12 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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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 In compliance with UL840
creepage distances of electrical equipment
Safety of information technology equipment, In compliance with UL1950
including electrical business equipment
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) Main Power:
AC1 3x400 AC
Bridge Commands 3x230AC
RS232 AC2 Circuit
(6 x PWM)
breaker
AC3
CANopen
Interface PE
(option)
Status Lines Power PE
Analog command Stage
M1
Aux.
Encoder Aux. Encoder M2
Interface MCU Current Feedback M3
+ Phase - M1
I/O Phase - M3
Main Encoder
Interface
Motor
Encoder output

Resolver Feedback
Interface
(option)

Dadicated I/O: Internal Aux. Power:

+5v, 15v, 24v 24VDC
Enable/Disable Power
or
Limit Switches Supply
24VAC
Abort
Fault

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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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.

Implementing Motion Control with Elmo Products

Programming
Command reference manual

Setup Composer software manual (doc. no. COMSFEN0202)

Installation Hardware installation guides

Figure 2-2: Elmo Documentation Hierarchy

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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 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 2

3 4 5 6 7 8 9

Connector No. 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 not declared on LED; may be detected with

Fault 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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A.3 General I/O Connector

Pin # Signal Function Remarks
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: Sax-PP only
Event capture input
Main Home input
6 IN6 Programmable input 6 Sax-PP only
Event capture input
Auxiliary Home input
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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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 Encoder/ Hall Sensor

Connector

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.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 Motor

Figure A-2: Resolver Connections

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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
SAX
Source

+ ANLIN1+ 1
20K +
4.99K

ANLIN1- 2
- 20K -

ANLRET 3

RETURN
ANLIN2+ 4
20K +
4.99K

ANLIN2- 5
20K -

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.7 Com1
Pin # Signal RS-232 Function RS-485 Function
1 – –
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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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 Function
1 –
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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B-1

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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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 80/160 W 80/160 W
circuit
Switch-off threshold at over 390 VDC 765 VDC
voltage
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 + 10V maximum
voltage
Input resistance 5 KΩ
Analog output voltage + 10 V maximum (10 KΩ impedance)
Analog output accuracy + 3%

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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 300 mA maximum (total for both outputs)
feedback A and B)
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 300 - 400 µs
(including settling time)
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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Feature Description
Velocity and position feedback Resolver
options Incremental encoder
Digital Hall effect (velocity only)
Note: With all feedback options, 1/T with
automatic modes switching will be
activated (gap, frequency and derivative).
Velocity command options Analog
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 Description
Type of encoder 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 Maximum common mode: ±7V
encoder Maximum differential mode: ±7V

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B.4 Digital Input Interface

Feature Description
Type of input Optically isolated
Single ended
Input current Vin − 6.5V
Iin =
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 20µs < T ≤ 50µs
transition (IN5 - IN6)

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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SAXUGEN0402

B.5 Digital Output Interface

Feature Description
Type of output Optically isolated
Maximum supply output (Vcc) 30V
Maximum output current Io (max) TTL level: IOL < 2mA, VOL < 0.8
(Vout = Low) PLC level: IOL ≅ 10mA, VOL < 3v

VOL @ maximum output voltage TTL level: Vcc = 5v, Vout = 0.8v
(low level) PLC level: Vcc = 24v, Vout = 3v

Minimum RL VCC − VOL

RL ≥
IO (max)
Executable time Up to 2 msec

The following diagram shows a digital output schematic for the Saxophone series of
servo amplifiers:
Vcc

SAX RL
Rout=25.5Ω Output(i)

33v Vout

Output(i)

Figure B-2: Saxophone Digital Output

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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
15.00 RMS

10.00
5.00
0.00
1 2 3 4 5 6 7 8 9 10 11
Motor's phase current RMS

Figure B-4: Single-phase Voltage Drop Concept

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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 Auxiliary
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 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 2000 m (about 6000 ft)
above sea level
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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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
Encoder outputs 1024 pulse per revolution resolution
Differential outputs CHA, CHB
An index with the complementary signals
RS-422: 20 mA load maximum.

B.12 Compliance Standards

B.12.1 Quality Assurance

ISO9001

B.12.2 Design
Reliability prediction of electronic MIL-HDBK- 217F
equipment (rating, de-rating, stress,
etc.)
Printed wiring for electronic IPC-D-275
equipment (clearance, creepage, IPC-SM-782
spacing, conductors sizing, etc.) IPC-CM-770
UL508c
UL840
Type testing In compliance with VDE0160 -7

B.12.3 Safety
Power conversion equipment Recognized UL508c
Insulation coordination, including In compliance with UL840
clearance and creepage distances of
electrical equipment
Safety of information technology In compliance with UL1950
equipment, including electrical
business equipment
Low voltage directive, 73/23/EEC In compliance with EN60204-1

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B.12.4 EMC
Electromagnetic compatibility (EMC) In compliance with IEC 1800-3,
Part 3: 1996
(Adjustable speed electrical power-drive
systems - EMC products standard,
including specific test methods)

B.12.5 Workmanship
Acceptability of electronic assemblies In compliance with IPC-A-610, level 2

B.12.6 PCB
Acceptability of printed circuit In compliance with IPC-A-600, level 2
boards

B.12.7 Packing
Protection of electrostatic sensitive In compliance with EN100015
devices

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B.13 Dimensional Drawings

B.13.1 General Dimensions

Rear View Front View

Side View

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SAXUGEN0402

B.13.2 Mounting Dimensions

Rear View

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 Elmo SAXophone Installation Guide
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C-1

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

7 CANH
CAN
Transceiver 2
CANL
3 COMRET

SAX P2
CAN Host

Optically
Isolated CAN - Interface

7
CAN
Transceiver 2

SAX Pn

Optically
Isolated CAN - Interface

7
CAN
Transceiver 2

Figure C-1: Saxophone Configuration with CANopen Communication

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 Elmo SAXophone Installation Guide Supplemental Configuration Schematics
C-2
SAXUGEN0402

C.2 Auxiliary Encoder Configurations

SAX - Plus Plus

Master Slave
Driver Driver

CONNECTOR CONNECTOR
FEEDBACK B FEEDBACK B
6 3 Feedback A
Feedback A CHAO CHA
13 11
CHAO- CHA-
7 2
CHBO CHB
14 10
CHBO- CHB-
8 1
INDEXO INDEX
15 9
INDEXO- INDEX-
Master SUPRET Slave
Axis Axis

Figure C-2: Master-Slave Configuration for Auxiliary Encoder

SAX - Plus Plus

Independent
Encoder
Aux. Encoder

3 CHA
11 CHA-
Isolated 2 CHB
Encoder +5v Supply
Power 10 CHB-
Supply 5v RET
1 INDEX
9 INDEX-

FEEDBACK Motor

Figure C-3: Independent Configuration for Auxiliary Encoder

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I-1

Index
A F
Amplifier compliance · 1-1 Fault output · B-7
Analog I/O connector · A-5 Feedback A - encoder · A-3
Analog input and output · B-2 Feedback A - resolver · A-4
Auxiliary encoder configurations · C-2 Feedback B · A-7
Auxiliary power connector · A-1 Feedback options · B-4
Auxiliary power supply · 3-6, B-2
G
C General I/O connector · A-2
Cables Grounding · 1-2
CANopen · 3-8
Communication · 3-8 I
I/O · 3-9 I/O cables · 3-9
Main feedback · 3-8 Initializing the Saxophone · 3-10
Motor · 3-7 Installing the Saxophone · 3-1
Power · 3-5
RS-232 · 3-8 L
RS-485 · 3-8 Live servo operations · 1-1
Cabling · 3-4
CANopen
M
Cable · 3-8
Main feedback cable · 3-8
Configuration · C-1
Mechanical specifications · B-8
Com1 connector · A-6
Mounting the Saxophone · 3-2
Com2 connector · A-7
Directly on wall · 3-2
Communication cables · 3-8
On DIN rail · 3-3
CANopen · 3-8
RS-232 · 3-8
RS-485 · 3-8 P
Compliance standards · B-9 Pin assignments · A-1
Composer · 3-10 Analog I/O connector · A-5
Connecting Auxiliary power connector · A-1
Motor cables · 3-7 CANopen · C-1
Power cables · 3-5 Com1 · A-6
Control specifications · B-3 Com2 · A-7
Committed I/O connector · A-1
D Feedback A - encoder · A-3
Feedback A - resolver · A-4
Digital input interface · B-5
Feedback B · A-7
Digital output interface · B-6
General I/O connector · A-2
DIN rail mounting · 3-3
Power
Display panel · 4-1
Disconnecting · 1-1
Grounding · 1-2
E
Precautions · 1-2
Encoder connections · A-3 Source · 2-1
Environmental conditions · B-8 Supply · 1-2

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SAXUGEN0402

Power ratings · B-1 Specifications

Power supply · 3-6 1x230 VAC power ratings · B-1
Powering up the Saxophone · 1-2, 3-10 3x230 VAC power ratings · B-1
3x400 VAC power ratings · B-1
R Analog input and output · B-2
Rated specifications · B-2 Auxiliary power supply · B-2
Replacing components · 1-1 Control · B-3
Resolver · B-9 Digital input interface · B-5
Connections · A-4 Digital output interface · B-6
Specifications · B-9 Environment · B-8
RS-232 cable · 3-8 Fault output · B-7
RS-485 cable · 3-8 Feedback options · B-4
Mechanical · B-8
S Rated · B-2
Safety Resolver · B-9
Amplifier compliance · 1-1 Supply voltage · B-3
Compliance standards · B-9 Status indications · 4-1
Disconnecting power · 1-1 Supply voltage · B-3
Live servo operations · 1-1 System architecture · 2-2
Precautions · 1-1, 1-2
Replacing components · 1-1 T
Saxophone Technical specifications · B-1
Cables · 3-7 Three -phase voltage · 2-2
Display · 4-1 Type designation number · 3-1
Initializing · 3-10
Installation · 3-1 U
Mounting Unpacking the Saxophone · 3-1
Directly on wall · 3-2
On DIN rail · 3-3 V
System architecture · 2-2 Voltage
System description · 2-1 Single-phase · 2-2
Technical specifications · B-1 Three-phase · 2-2
Type designation number · 3-1
Wiring · 3-4 W
Single-phase Wire cross-sections · B-8
Operation · B-7 Wiring the Saxophone · 3-4
Voltage · 2-2

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