Detailed Introduction to ELMO G-TUB30/480ERSS0 High-Performance Servo Drive
1. Product Description
The ELMO G-TUB30/480ERSS0 is a flagship high-power-density servo drive belonging to Elmo Motion Control’s Gold Tuba Series—a premium product line engineered for mission-critical industrial automation applications requiring ultra-precise motion control and rapid dynamic response. Designed as a “direct-to-mains” networking drive, it integrates advanced power electronics with intelligent motion algorithms to regulate permanent-magnet synchronous brushless motors, DC brush motors, linear motors, and voice coils across sectors like semiconductor manufacturing, robotics, medical imaging, and aerospace .
What distinguishes this drive from conventional alternatives is its exceptional power density (delivering up to 25 kW of continuous power in a compact form factor) and Elmo’s proprietary “Fast & Soft Switching Technology,” which achieves ≈99% efficiency while minimizing electromagnetic interference (EMI)—critical for sensitive environments like wafer fabrication cleanrooms . As a core component of distributed motion systems, it supports real-time deterministic communication via EtherCAT and CANopen, enabling seamless synchronization of multi-axis setups such as robotic arms or automated assembly lines .
Its rugged design and comprehensive protection mechanisms (over-current, over-temperature, under-voltage, and over-voltage safeguards) ensure reliable operation in harsh industrial conditions, while compatibility with diverse feedback sensors (incremental/absolute encoders, resolvers, Hall effect devices) enables flexible integration into single, dual, or gantry loop configurations . Certified for global industrial standards, it is trusted in applications ranging from high-speed packaging machinery to precision MRI scanner positioning systems .
2. Product Technical Specifications
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Specification Category
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Details
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Electrical Input
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– AC Supply Voltage: 3-phase 140 VAC to 528 VAC (direct-to-mains rectification)- Auxiliary Supply: 24 VDC ±10%, 20 VA typical power consumption- Power Factor: >0.95 at rated load
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Current & Power Output
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– Continuous RMS Current (IC): 30 A (sinusoidal commutation); 21 A (DC trapezoidal commutation)- Peak Current: 80 A (1-second duration)- Maximum Continuous Power: Up to 25 kW (depending on motor configuration)
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Control Capabilities
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– Operating Modes: Current, velocity, position, and advanced position control (electronic gearing, cam profiling)- Commutation: Sinusoidal and trapezoidal (vector control optimized for brushless motors)- Feedback Support: Incremental encoders (up to 2500 ppr + commutation signals), absolute encoders, resolvers, digital Hall sensors, analog Hall devices, tachometers – Control Bandwidth: >1 kHz (current loop); >200 Hz (velocity loop); >50 Hz (position loop)
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I/O & Communication
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– Digital I/O: 10 configurable digital inputs (DI), 6 digital outputs (DO)- Analog I/O: 2 analog inputs (AI, 12-bit resolution)- Networks: EtherCAT (CoE, FoE), CANopen (DS301/DS402); Host interfaces: USB 2.0, Ethernet – Data Update Rate: 100 µs (EtherCAT synchronous mode)
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Physical & Environmental
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– Dimensions: 247 mm (W) × 190 mm (H) × 92 mm (D) (panel-mountable enclosure) – Weight: 2.7 kg – Operating Temperature: -10°C to +55°C (ambient); up to +70°C with derating- Storage Temperature: -40°C to +85°C- Protection Rating: IP20 (front panel); IP00 (rear connections)- Vibration Resistance: IEC 60068-2-6 (10-500 Hz, 5 g peak)
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Safety & Reliability
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– Protection Mechanisms: Over-current, over-voltage (DC bus > 800 VDC), under-voltage (DC bus < 100 VDC), over-temperature (heatsink > 85°C), short-circuit (motor phase-to-phase), ground fault- Certifications: CE (EMC/EMI compliance), UL 508C, IEC 61800-5-1- Mean Time Between Failures (MTBF): >100,000 hours (per MIL-HDBK-217F)
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3. Usage Instructions
3.1 Installation & Physical Setup
- Pre-Installation Checks
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- Verify compatibility with the target motor (e.g., 3-phase brushless motor with rated current ≤30 A); confirm the drive’s part number (G-TUB30/480ERSS0) matches the system bill of materials.
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- Inspect for shipping damage (bent connectors, cracked enclosure) and ensure all labeling (voltage rating, serial number) is intact.
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- Prepare tools: torque screwdriver (0.5-2.0 N·m), ESD wristband, shielded motor cables (2.5 mm² copper), and EtherCAT communication cables .
- Mechanical Mounting
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- Location: Install in a panel with minimum 100 mm clearance on all sides for airflow; avoid proximity to heat sources (e.g., motor controllers) or high-voltage cables.
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- Securing: Fasten the drive to the panel using four M4 × 12 mm screws torqued to 1.5 N·m; ensure the heatsink is in direct contact with the panel (for passive cooling) .
- Wiring Connections
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- Power Wiring:
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- Connect 3-phase AC supply (140-528 VAC) to terminals L1/L2/L3; install a 50 A circuit breaker upstream.
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- Connect auxiliary 24 VDC (positive to terminal AUX+, ground to AUX-) with a 2 A inline fuse .
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- Motor Wiring:
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- Connect motor power leads (U/V/W) to terminals M1/M2/M3; use shielded cable and ground the shield at both ends.
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- Connect encoder/resolver cables to the feedback port (J1); ensure alignment with pinouts (e.g., A/B/Z signals for incremental encoders) .
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- Communication Wiring:
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- Connect EtherCAT cable to port ETH1; terminate the bus with a 120 Ω resistor at the last drive in the chain.
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- Connect USB cable to port USB-B for initial configuration .
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- Post-Installation Verification
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- Power on the auxiliary supply first; check the “PWR” LED (green) illuminates. Then apply 3-phase power; confirm no fault LEDs (red) activate.
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- Use a multimeter to verify 24 VDC at auxiliary terminals and continuity of motor/feedback circuits .
3.2 Configuration & Operation
- Software Setup with Elmo Application Studio (EAS)
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- Installation: Download EAS (v7.0+ for Windows) from Elmo’s website; install drivers for USB/EtherCAT communication.
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- Device Connection:
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- Connect via USB: EAS auto-detects the drive; set a static IP (e.g., 192.168.1.10) for EtherCAT integration.
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- Run the “Motor Identification Wizard” to auto-calibrate motor parameters (resistance, inductance, back-EMF) .
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- Parameter Configuration:
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- Navigate to “Control Modes” and select operation type (e.g., “Position Mode” for robotic arms).
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- Set current limits (30 A continuous, 80 A peak) and feedback resolution (e.g., 2500 ppr for incremental encoders).
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- Configure EtherCAT mapping (CoE objects for position commands/actual values) .
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- Normal Operation
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- Local Control: Use EAS’s “Jog” function to test motor movement; adjust velocity (0-5000 RPM) and acceleration (0-10,000 RPM/s) via the interface.
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- Remote Control: Activate EtherCAT mode; send position/speed commands from the master controller (e.g., Siemens S7-1500). The drive synchronizes with other axes via distributed clocks .
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- Status Monitoring: EAS displays real-time data (current, voltage, position error); configure DO outputs to trigger alarms for over-temperature (>85°C) or position deviation (>0.1 mm) .
- Maintenance & Troubleshooting
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- Routine Checks: Monthly inspect wiring terminals for tightness; clean the heatsink with compressed air to remove dust buildup.
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- Common Faults:
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- Over-Current (OC Fault): Reduce peak current limit or check for motor phase short-circuits.
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- EtherCAT Communication Loss: Verify bus termination and IP settings; reset the drive via EAS.
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- Over-Temperature (OT Fault): Improve ventilation or derate current by 10% for every 5°C above 55°C .
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- Firmware Update: Use EAS’s “Firmware Manager” to install latest updates for enhanced control algorithms .
4. System Introduction
The G-TUB30/480ERSS0 is a cornerstone of Elmo’s Gold Line Motion Control System—a modular, scalable ecosystem designed to optimize precision motion in distributed multi-axis setups. This system integrates servo drives, motors, feedback sensors, and software tools to deliver sub-micron positioning accuracy and millisecond response times .
4.1 System Architecture
- Sensing Layer: Comprises encoders, resolvers, and Hall sensors that provide real-time position/velocity feedback to the G-TUB30/480ERSS0. Dual-loop configurations (motor + load feedback) are supported for gantry systems .
- Control Layer: The drive processes feedback data, executes vector control algorithms, and regulates motor current/speed/position. Elmo’s proprietary “Gold Core” technology ensures stable operation even under dynamic load changes .
- Communication Layer: Enables synchronization with the system master via EtherCAT (100 µs update rate) or CANopen. USB/Ethernet interfaces facilitate configuration and diagnostic data logging .
- Safety Layer: Integrates emergency stop (E-stop) inputs and fault-trip mechanisms to 切断 power within 10 ms of critical failures, complying with IEC 61508 SIL 2 requirements .
4.2 Key System Features
- High Regeneration Capability: Captures kinetic energy during deceleration and feeds it back to the AC mains, reducing energy consumption by up to 30% in cyclic applications (e.g., pick-and-place robots) .
- Multi-Axis Synchronization: EtherCAT distributed clocks ensure <1 µs synchronization error between drives, ideal for coordinated motion (e.g., 6-axis robotic arms) .
- Flexible Integration: Compatible with third-party PLCs (Siemens, Allen-Bradley) and HMI systems via standard protocols, simplifying retrofits of legacy machinery .
- Predictive Diagnostics: EAS software monitors drive parameters (temperature, current ripple) to predict component wear, enabling proactive maintenance and minimizing downtime .
5. Recommended Related Models in the Same Series
For applications requiring different power ratings, communication options, or environmental ruggedness, the following Gold Tuba Series models are recommended:
- ELMO G-TUB12/480ERSS0: A lower-power variant with 12 A continuous current (30 A peak) for small linear motors in medical devices (e.g., diagnostic scanners). Maintains all G-TUB30 features in a compact form factor .
- ELMO G-TUB40/480ERSS0: Delivers 40 A continuous current (100 A peak) for high-torque applications like heavy-duty robotic grippers. Enhanced with dual EtherCAT ports for daisy-chain configurations .
- ELMO G-TUB30/230ERSS0: Optimized for 3-phase 230 VAC supply (140-264 VAC) for industrial machinery in regions with lower mains voltage. Matches the G-TUB30/480’s current output and control capabilities .
- ELMO G-TUB30/480ERSS1: Explosion-proof variant (ATEX Zone 2) with reinforced enclosure and intrinsic safety barriers. Suitable for oil & gas automation or chemical processing equipment .
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