Introduction to ELMO G-TUB30/480FEHSNA2 1080-01355
Product Description
The ELMO G-TUB30/480FEHSNA2 1080-01355 is a high-performance, compact servo drive designed for demanding industrial motion control applications that require high power density, precise torque/speed regulation, and robust environmental resilience. As a flagship model in ELMO Motion Control’s G-TUB series—specialized for medium-to-high power servo systems—this drive excels at powering large servo motors in industries such as heavy-duty material handling, robotics (large payload arms), metalworking (CNC milling/lathing), and renewable energy (solar tracker positioning), where 480V three-phase power and reliable high-current output are critical.
The model designation “G-TUB30/480FEHSNA2 1080-01355” decodes its core specifications: “G-TUB” denotes ELMO’s “Global Tubular” compact form factor, “30” specifies a 30A continuous output current rating, “480” indicates compatibility with 480V AC three-phase input, “FEHS” signifies advanced features (Fieldbus integration, Enhanced thermal management, High-speed feedback, Safety compliance), “NA2” references North American electrical standards compliance, and “1080-01355” is the unique part number for inventory and configuration tracking. Unlike low-power servo drives, this model integrates a high-efficiency power stage, advanced control algorithms (e.g., ELMO’s proprietary SimplIQ® motion control technology), and built-in safety functions—enabling it to handle dynamic loads (e.g., sudden torque spikes in robotic lifting) while maintaining precision. Its compact tubular design (a hallmark of the G-TUB series) saves valuable cabinet space, while its rugged construction supports operation in harsh industrial environments with dust, vibration, and temperature fluctuations.
Technical Parameters
- Electrical Input:
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- Voltage: 480V AC three-phase (400–528V AC, 50/60 Hz)
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- Input Current: 18A RMS (continuous); 45A RMS (peak, 1s)
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- Power Factor: ≥0.95 (at full load)
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- Efficiency: ≥96% (at 50–100% load)
- Output Specifications:
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- Continuous Output Current: 30A RMS
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- Peak Output Current: 90A RMS (10s duration)
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- Output Voltage: 0–480V AC (variable frequency, sinusoidal)
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- Power Rating: Up to 22 kW (at 480V AC input, 30A current)
- Control Capabilities:
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- Control Modes: Position (with electronic gearing/camming), velocity, torque, current, and PWM control
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- Control Algorithm: ELMO SimplIQ® (field-oriented control, PID with feedforward, anti-windup)
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- Positioning Accuracy: ±0.001° (with 17-bit absolute encoder)
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- Speed Regulation: ≤0.01% (at constant load)
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- Torque Ripple: ≤1% (at rated torque)
- Feedback Compatibility:
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- Incremental Encoders: TTL/HTL, up to 2 MHz (A/B/Z signals)
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- Absolute Encoders: SSI, BiSS-C, EnDat 2.2, HIPERFACE® DSL, up to 5 Mbps
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- Resolvers: 4-wire, 5V/11V excitation (with internal resolver-to-digital converter)
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- Linear Scales: Heidenhain, Fanuc, via optional interface
- Communication Interfaces:
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- Fieldbus: EtherCAT (CoE), PROFINET IRT, EtherNet/IP, Modbus TCP/IP (configurable via software)
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- Serial: RS232/RS485 (for configuration and diagnostics, Modbus RTU)
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- USB: USB 2.0 (for local programming and firmware updates)
- Safety Features:
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- Safe Torque Off (STO): SIL 3/PL e (IEC 61508, ISO 13849-1)
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- Overcurrent, Overvoltage, Undervoltage Protection: Class 3 (IEC 61800-5-1)
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- Overheating Protection: Thermal shutdown at 105°C (heatsink temperature)
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- Short-Circuit Protection: Phase-to-phase, phase-to-ground (≤1µs response time)
- Environmental and Mechanical Ratings:
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- Operating Temperature: -10°C to +55°C (ambient); up to +100°C (heatsink)
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- Storage Temperature: -40°C to +85°C
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- Relative Humidity: 5–95% RH (non-condensing, IEC 60068-2-3)
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- Vibration Resistance: 10–500 Hz, 2g peak (IEC 60068-2-6)
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- Shock Resistance: 50g peak (11ms duration, IEC 60068-2-27)
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- Protection Rating: IP20 (drive body); IP54 (with optional protective cover)
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- Dimensions: 45mm (diameter) × 180mm (length) (tubular form factor)
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- Weight: Approximately 1.5 kg
- Certifications: UL 508C, CSA C22.2 No. 14, CE, RoHS, IEC 61800-3 (EMC compliance), ISO 13849-1 (safety)
Usage Methods
- Installation:
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- Mounting: Install the drive on a flat metal surface or in a 19-inch rack using ELMO’s optional mounting brackets. The tubular design allows vertical or horizontal mounting, but vertical orientation is recommended for optimal heat dissipation (critical for the 30A continuous current rating). Ensure a minimum clearance of 100mm around the drive to facilitate airflow—avoid blocking the integrated heatsink fins.
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- Environmental Preparation: Install in a control cabinet with ambient temperature ≤55°C, away from direct heat sources (e.g., power resistors, large transformers) and high-voltage 480V cables (to minimize EMI). Use a cabinet fan or air conditioner if the drive is operated at >40°C ambient to prevent thermal shutdown.
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- Grounding: Connect the drive’s protective ground terminal to the cabinet chassis using a 4mm² stranded copper cable (torque: 8 Nm). For 480V systems, additional earth grounding (per local electrical codes, e.g., NEC 250) is required to ensure safety and reduce noise.
- Wiring and Connection:
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- Power Input Wiring: Connect the 480V three-phase input to the L1, L2, L3 terminals using 6mm² copper cable (rated for 30A). Install a 40A circuit breaker and a line reactor (ELMO part no. L-480-30) in series with the input to reduce harmonic distortion and protect against voltage spikes.
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- Motor Output Wiring: Link the U, V, W output terminals to the servo motor using 6mm² copper cable (rated for 30A), ensuring correct phase sequence (reverse two phases if motor rotation is inverted—adjustable via software if needed). Secure cable lugs with 5 Nm torque to prevent overheating at the terminals.
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- Feedback Wiring: Connect the encoder/resolver to the drive’s feedback port using ELMO’s shielded feedback cable (part no. C-FB-05). For absolute encoders (e.g., BiSS-C), use twisted-pair, shielded cable with the shield grounded at both the drive and motor ends to minimize EMI. Enable the internal resolver-to-digital converter via software if using a resolver.
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- Fieldbus and Control Wiring: Connect the fieldbus (e.g., EtherCAT) to the dedicated port using Cat5e/Cat6 cable (for EtherCAT, use twisted-pair, shielded cable with 120Ω termination resistor at bus ends). Wire digital inputs (e.g., emergency stop, enable) to the drive’s DI terminals using 0.75mm² cable—configure input logic (PNP/NPN) via software.
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- Safety Wiring: Connect the STO input terminals to a safety relay (e.g., Pilz PNOZ) using 0.75mm² cable, ensuring compliance with SIL 3/PL e requirements. Test the STO function before commissioning to verify that motor torque is disabled when the input is triggered.
- Configuration and Programming:
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- Software Setup: Use ELMO’s Motion Composer 3 software (v3.8+) to configure the drive. Install the software on a PC, connect to the drive via USB or Ethernet, and load the motor’s parameter set (available in ELMO’s motor database or importable from the motor manufacturer’s datasheet).
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- Motor Tuning: Run ELMO’s “Auto-Tune” function to optimize control parameters (PID gains, feedforward terms) for the connected motor and load. For dynamic loads (e.g., robotic arms), use the “Advanced Tuning” wizard to adjust jerk limits and torque bandwidth to minimize overshoot and settling time.
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- Control Mode Configuration:
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- Position Mode: Enable electronic gearing (set gear ratio via software) or import cam profiles (CSV format) for applications like CNC milling. Configure position limits (soft stops) to prevent mechanical damage.
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- Torque Mode: Set torque limits (0–100% of rated torque) and enable torque feedforward to compensate for load inertia—critical for robotic lifting applications.
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- Fieldbus Integration: Map fieldbus signals (e.g., position setpoints, status flags) to the drive’s internal registers via the software’s “Fieldbus Mapping” tool. For EtherCAT, configure the drive as a slave device with a unique node ID.
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- Testing: Verify functionality in “Test Mode” first: jog the motor at low speed (500 RPM) to check rotation direction and feedback accuracy. Use the software’s real-time oscilloscope to monitor current, voltage, and position error—ensure current ripple is ≤1% at rated load.
- Operation and Maintenance:
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- Startup Verification: Power on the drive and check the status LED (solid green = normal operation; flashing blue = fieldbus connected; red = fault). Use Motion Composer 3’s diagnostic tool to troubleshoot faults (e.g., overcurrent, STO activation, feedback loss) with step-by-step resolution guides.
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- Real-Time Monitoring: Track key parameters via the HMI or SCADA system (connected via fieldbus): output current, motor speed, torque, and heatsink temperature. Set alarms for abnormal conditions (e.g., current >25A for >10s, heatsink temp >90°C) to prevent drive damage.
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- Routine Maintenance:
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- Monthly: Inspect wiring connections (especially power input and motor output terminals) for tightness and signs of overheating (discoloration). Clean dust from the heatsink fins with compressed air (pressure ≤50 psi) to maintain thermal performance.
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- Quarterly: Verify STO functionality by triggering the safety input and confirming motor torque is disabled. Check fieldbus communication integrity using the software’s network analyzer.
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- Annually: Update the drive’s firmware via USB or Ethernet to access new features (e.g., expanded feedback compatibility, enhanced control algorithms). Replace the internal electrolytic capacitors every 5 years (or as recommended by ELMO) to prevent power stage failure.
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System Introduction
The ELMO G-TUB30/480FEHSNA2 1080-01355 functions as the “power bridge” between 480V industrial power grids and high-torque servo motors, integrating five critical functional layers to deliver precise, high-power motion control:
- Power Conversion Layer: Converts 480V three-phase AC input to DC bus voltage (via a diode rectifier) and then to variable-frequency, variable-voltage AC output (via a three-phase inverter). The high-efficiency power stage (≥96% efficiency) minimizes heat generation, allowing the compact tubular design to handle 30A continuous current.
- Control Layer: Executes ELMO’s SimplIQ® algorithm to deliver field-oriented control (FOC) of the servo motor. This layer adjusts current, voltage, and frequency in real time (≤10µs loop update rate) to maintain precise torque/speed/position, even during dynamic load changes (e.g., sudden payload increases in robotics).
- Feedback Layer: Processes data from encoders/resolvers/linear scales to close the control loop. The internal resolver-to-digital converter and high-speed feedback interface (up to 5 Mbps) ensure accurate position tracking—critical for applications like CNC machining, where ±0.001° accuracy is required.
- Safety Layer: Implements STO (SIL 3/PL e) and protective functions (overcurrent, overheating) to disable motor torque safely during emergencies. For 480V systems, this layer prevents high-current faults from damaging the motor or endangering operators.
- Communication Layer: Exchanges data with motion controllers (e.g., ELMO’s Gold Maestro) and enterprise systems via fieldbus (EtherCAT, PROFINET). This enables synchronized multi-axis operation (e.g., coordinated motion in robotic arms) and remote monitoring for predictive maintenance.
In a large robotic palletizer application, the G-TUB30/480FEHSNA2 drives a 20 kW servo motor that lifts 50kg payloads. The motion controller sends torque setpoints via EtherCAT, and the drive adjusts output current to maintain smooth lifting—compensating for payload variations via feedforward control. The resolver feedback ensures the arm positions within ±0.5mm of the target, while the STO function integrates with the robot’s safety system to stop torque if a human enters the workspace. The drive’s compact design allows it to fit in the robot’s control cabinet, saving space for other components.
Related Models in the Series
- ELMO G-TUB20/480FEHSNA2 1080-01354: 30A → 20A continuous current variant, ideal for medium-power applications (e.g., solar trackers, small CNC lathes) requiring 480V input.
- ELMO G-TUB40/480FEHSNA2 1080-01356: 30A → 40A continuous current model, designed for heavy-duty applications (e.g., large robotic arms, industrial presses) with high torque demands.
- ELMO G-TUB30/240FEHSNA2 1080-01357: 480V → 240V three-phase input variant, optimized for regions with 240V power grids (e.g., parts of Europe, Asia) while retaining 30A current output.
- ELMO G-TUB30/480FEHSAE2 1080-01358: “NA2” → “AE2” (European standards compliance) model, certified to IEC 61800-5-1 for use in EU countries, with identical electrical specifications.
- ELMO G-TUB30/480FEHSNA2-EC 1080-01359: Enhanced communication variant with dual fieldbus ports (EtherCAT + PROFINET), suitable for redundant network applications (e.g., critical manufacturing lines).
- ELMO G-TUB30/480FEHSNA2-EX 1080-01360: Explosion-proof variant (ATEX Zone 2, IECEx) with reinforced housing and isolated power stage, designed for hazardous environments (e.g., chemical processing, oil & gas robotics).
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