Elmo Gold Whistle Series Installation Manual

Digital servo drive

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Gold Whistle

Digital Servo Drive

Installation Guide

April 2018 (Ver. 1.400)

www.elmomc.com

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Summary of Contents for Elmo Gold Whistle Series

Page 1 Gold Whistle Digital Servo Drive Installation Guide April 2018 (Ver. 1.400) www.elmomc.com...
Page 2 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 Gold Whistle servo drive in its installation.
Page 3 Table of Contents MAN-G-WHI (Ver. 1.400) Chapter 1: This Installation Guide ................5 Chapter 2: Safety Information ..................5 2.1. Warnings ........................6 2.2. Cautions ........................6 2.3. CE Marking Conformance ................... 6 2.4. Warranty Information ....................6 Chapter 3: Product Description ..................
Page 4 Table of Contents MAN-G-WHI (Ver. 1.400) 9.5.4.2. Shared Supply ................30 9.6. Connector J2 - Feedback, Analog Inputs, RS-232, USB, EtherCAT, Ethernet, and CAN 9.6.1. Feedback Port A ..................34 9.6.1.1. Incremental Encoder ..............34 9.6.1.2. Hall Sensors ................35 9.6.1.3.
Page 5 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 and all Elmo Motion Control manuals: Warning: This information is needed to avoid a safety hazard, which might cause bodily injury or death as a result of incorrect operation.
Page 6 All Elmo drives are warranted for a period of 12 months from the date of shipment. No other warranties, expressed or implied — and including a warranty of merchantability and fitness for a particular purpose —...
Page 7 The drive can operate as a stand-alone device or as part of a multi-axis system in a distributed configuration on a real-time network. The Gold Whistle drive is easily set up and tuned using the Elmo Application Studio (EASII) software tools. As part of the Gold product line, it is fully programmable with the Elmo motion control language.
Page 8 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) Chapter 4: Technical I nform ation 4.1. Physical Specifications Feature Units All Types Weight g (oz) 55 g (1.94 oz) Dimension mm (in) 55 x 46 x 15 mm (2.2" x 1.8" x 0.6") Mounting method PCB mount 4.2.
Page 9 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) Elmo offers a 200 VDC maximum output rating selection of Gold Whistle, according to the following technical data: Feature Units 3/200 6/200 9/200 Minimum supply voltage Nominal supply voltage Maximum supply voltage Maximum continuous power output...
Page 10 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 4.2.2. Product Features Main Feature Details Presence and No. √ Digital Input Open Collector-emitter (isolated) Digital Output TTL 3.3V(Non Isolation) Differential ±10V Analog Input Single Ended Standard Port A, B, & C √ Feedback √...
Page 11 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 4.2.3. Environmental Conditions You can guarantee the safe operation of the Gold Whistle by ensuring that it is installed in an appropriate environment. Feature Details Operating ambient temperature 0 °C to 40 °C (32 °F to 104 °F) according to IEC60068-2-2 Storage temperature -20 °C to +85 °C ( -4 °F to +185 °F)
Page 12 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 4.2.4. Gold Line Standards The following table describes the Main Standards of the Gold Whistle servo drive. For further details refer to Chapter 17 in the MAN-G-Board Level Modules Hardware Manual. Main Standards Item The related standards below apply to the performance of the servo drives as stated in the environmental conditions in section 4.2.3 Environmental Conditions above.
Page 13 • The Gold Whistle servo drive • The Elmo Application Studio (EASII) software and user guide The Gold Whistle is shipped in a cardboard box with Styrofoam protection. To unpack the Gold Whistle: Carefully remove the servo drive from the box and the Styrofoam.
Page 14 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) Chapter 6: M ounting the Gold W histle The Gold Whistle was designed for mounting on a printed circuit board (PCB) via 1.27 mm pitch 0.41 mm square pins and 2 mm pitch 0.51 mm square pins. When integrating the Gold Whistle into a device, be sure to leave about 1 cm (0.4") outward from the heat-sink to enable free air convection around the drive.
Page 15 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) that you connect an external heat sink. Elmo has an external heat sink (Catalog number: WHI-HEAT- SINK-2) that can be ordered for this purpose, see Figure 2 below. Figure 2: Gold Whistle External Heat Sink |Connector J2 www.elmomc.com...
Page 16 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) Chapter 7: I ntegrating the Gold W histle on a PCB The Gold Whistle is designed to be mounted on a PCB by soldering its pins directly to the PCB. Refer to Chapter 5 in the MAN-G-Board Level Modules Hardware Manual and the drawings in the Gold Line Whistle Design Guide MAN-G-WHIIDG for further information.
Page 17 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 7.4. Power Return (PR), Common Return (COMRET) and Earth Connections (PE) Safety regulations (UL61800-5-1, IEC61800-5-1, and UL508C) require that the servo drive, as a “stand alone”, must withstand breakdown voltages of 2KV for the 200V models, and 1.7KV for the 100V models, between PE to PR.
Page 18 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 7.5. Power Conductors PCB layout The PCB virtually divided into two zones; Power Zone, and Control & Communication Zone. Power Zone • This area is dedicated to Power conductors only: VP+, PR, PE, VL+, VL-, VN- and motor leads. Control and Communication Zone •...
Page 19 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) Chapter 8: The Gold W histle Connection Diagram Figure 5: The Gold Whistle Connection Diagram |Connector J2 www.elmomc.com Table of Contents...
Page 20 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) Chapter 9: PCB Connections 9.1. Wiring legend The following table legend describes the wiring symbols detailed in all installation guides. All the wiring diagrams show wiring for D-TYPE connectors. Wiring Symbol Description Earth connection (PE) Earth Connection Common at the Controller Shielded cable with drain wire.
Page 21 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) Wiring Symbol Description Analog Ground Encoder Earthing. The cable`s shield is connected to the chassis (PE) in the connector. Earthing the Encoder and connecting the Earth (PE) to the drive COMRET is mandatory to insure reliable operation, high noise immunity and rejection of voltage common mode...
Page 22 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.2. Connector Types The Gold Whistle has nine connectors. 9.2.1. Connector Types Port Pins Type Function Connector Location 2x24 1.27 mm pitch Feedbacks, Digital Halls, 0.41 mm sq Analog Inputs, Communications 2x12 I/O, LEDs, STO 2 mm pitch Motor power output 3 0.51 mm sq...
Page 23 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.4. Motor Power Connector Pinouts For full details see Chapter 8 in the MAN-G-Board Level Modules Hardware Manual. Function Cable Pin Positions Brushless Brushed DC Motor Motor Protective earth Motor Motor Motor phase Motor Motor phase Motor...
Page 24 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) Figure 7: Brushed Motor Power Connection Diagram |Connector J2 www.elmomc.com Table of Contents...
Page 25 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.5. Main Power and Control Connector There are two power ratings for the Gold Whistle: 100V for is 12 to 95 VDC • 200V for the 12 to 195 VDC • For power rating 200V Two DC power sources are required, a DC power source of 12 - 195V isolated from the Mains, and a control supply 12-95V (isolated from the Mains) for the logic.
Page 26 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.5.2. Control Supply The Control supply is required for the 200V power rating, and can be added for the 100V power Note: rating. The source of the Control Supply must be from the Mains. Function Pin Positions Control Supply Input...
Page 27 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.5.3. Power Supply for the Power Rating 200 V For Power Rating 200 V, two DC power sources are required, a main power 12 to 195V DC power source isolated from the Mains, and a control supply 12 to 95V (isolated from the Mains) for the logic.
Page 28 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.5.4. Power Supply for power rating 100 V 9.5.4.1. Single Power Supply Only one power supply is required for the main and control power. It is strongly recommended to add a filter on the VL+ Input Pin at the Gold Whistle, in order to avoid interference from the power stage e.g.
Page 29 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) Figure 10: Single Power Supply Connection Diagram with VL+ Connected Externally Note: Make sure to connect the PR to the closest earth connection near the power supply. |Connector J2 www.elmomc.com Table of Contents...
Page 30 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.5.4.2. Shared Supply A single DC Power Supply can supply the power for logic as well as the main power. If separation between the main DC power source and a control supply is required, then a control supply (isolated from the Mains) can be connected by implementing “diode coupling"...
Page 31 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6. Connector J2 - Feedback, Analog Inputs, RS-232, USB, EtherCAT, Ethernet, and CAN Feedback A/B/C, Digital Halls – see Chapter 10: Feedbacks in the MAN-G-Board Level Modules Hardware Manual. Analog Inputs - For full details on Analog Inputs, see Chapter 12 in the MAN-G-Board Level Modules Hardware Manual.
Page 32 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) Signal Function (J2) PortC_ENCO_B+ Port C - channel B output PortA_ENC_INDEX+ Port A – index PortC_ENCO_INDEX- Port C - index complement output PortA_ENC_INDEX- Port A - index complement PortC_ENCO_INDEX+ Port C - index output PortB_ENC_A+/SIN+ Port B - channel A/SIN+ Hall sensor C input...
Page 33 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) Signal Function (J2) EtherCAT: PHY_OUT_TX+ EtherCAT Out transmit CAN: Reserved Reserved PHY_IN_TX- EtherCAT In transmit complement EtherCAT: PHY_OUT_TX- EtherCAT Out transmit complement CAN: Reserved Reserved PHY_IN_LINK_ACT EtherCAT In active LED EtherCAT: PHY_OUT_LINK_ACT EtherCAT Out active LED CAN: CAN_L CAN_L BUS Line(dominant low) PHY_IN_SPEED...
Page 34 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6.1. Feedback Port A Port A supports the following sensor inputs: Digital Hall sensors • • Incremental encoder or absolute serial encoder, depending on the specific model • Differential pulse-width modulation (PWM) signal input can be connected to port A Differential Pulse &...
Page 35 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6.1.2. Hall Sensors Figure 13: Hall Sensors Connection Diagram |Connector J2 www.elmomc.com Table of Contents...
Page 36 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6.1.3. Absolute Serial Encoder The following Absolute Encoder are supported: • Endat 2.2 Biss C and Biss B • Pansonic • • Tamagawa • Sanyo Danki • • Hiperface The following is the diagram connection of the Endat, Biss, SSI: Figure 14: Absolute Serial Encoder –...
Page 37 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) The following is the diagram connection of the Pansonic, Tamgawai, Sanyo-Danki: Figure 15: Absolute Serial Encoder – Recommended Connection Diagram for Pansonic, Tamgawai, Sanyo-Danki |Connector J2 www.elmomc.com Table of Contents...
Page 38 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6.1.4. Hiperface The following figure describes the connection diagram. Figure 16: Absolute Serial Encoder – Recommended Connection Diagram for Stegmann Hiperface Note: When the Hiperface protocol is used the RS232 in not available |Connector J2 www.elmomc.com Table of Contents...
Page 39 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6.2. Feedback Port B Port B supports any of the following sensors: Incremental encoder, interpolated analog encoder or analog Hall sensors • • Resolver (separate hardware option) Differential PWM signal input can be connected to port B Differential Pulse &...
Page 40 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6.2.2. Interpolated Analog (Sine/Cosine) Encoder Figure 18: Port B - Interpolated Analog Encoder Connection Diagram |Connector J2 www.elmomc.com Table of Contents...
Page 41 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6.2.3. Resolver Figure 19: Port B – Resolver Connection Diagram |Connector J2 www.elmomc.com Table of Contents...
Page 42 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6.3. Port C – Emulated Encoder Output Port C provides emulated encoder output derived from port A or port B feedback inputs, or from internal variables. Figure 20: Emulated Encoder Differential Output – Recommended Connection Diagram |Connector J2 www.elmomc.com Table of Contents...
Page 43 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6.4. Analog Inputs There are two possible types of Analog Inputs in the Gold Whistle: Analog Input 1 – Differential ±10 V using Connector J2 in the Gold Whistle • • Analog Input 2 – Single ended using Connector J1 in the Gold Whistle 9.6.4.1.
Page 44 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6.4.2. Analog Input 2 The Gold Whistle allows an additional single ended Analog input. Figure 22 describes the input interface of the Analog_input2 in the Gold Whistle. It also describes implementation examples for a differential analog input of 10V: Figure 22: Analog Input 2 Example |Connector J2...
Page 45 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6.5. RS232 TTL Logic Level Figure 23 describes the standard RS232 connection diagram. Figure 23: Standard RS232 Voltage Level incorporating RS232 TX/RX Transceiver Connection Diagram |Connector J2 www.elmomc.com Table of Contents...
Page 46 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6.6. USB 2.0 Figure 24: USB Network Diagram Note ①: In the Gold Whistle the shield of the USB connector should be connected to the COMRET. |Connector J2 www.elmomc.com Table of Contents...
Page 47 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6.7. EtherCAT/Ethernet The Gold Whistle serves as an EtherCAT slave device, therefor it includes EtherCAT_IN and EtherCAT_OUT ports. It also includes LED indicators. The EtherCAT_IN port can be configured to an Ethernet port. The following figure describes EtherCAT connection with a standard RJ-45 connector that includes transformer isolation.
Page 48 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.6.8. Figure 26 displays the CAN connectivity. Important: Figure 26: CANbus Connections A 120 Ω termination resistor should be connected at each end of the network cable. |Connector J2 www.elmomc.com Table of Contents...
Page 49 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.7. Connector J1 - Digital I/O, Analog Inputs, LEDs, and STO For full details on Digital and Analog I/Os, see Chapter 11 and 12 in the MAN-G-Board Level Modules Hardware Manual. For full details on the LEDs, see Chapter 7 Drive Status Indicator, and section 14.2.6 EtherCAT Status Indicator in the in the MAN-G-Board Level Modules Hardware...
Page 50 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) Pin (J1) Signal Function OUTRET1 OUT 1 return LED2 Bi-color indication output 2 (Cathode) LED1 Bi-color indication output 1 (Cathode) OUT4 Programmable output 4 not isolated (3.3V TTL level) OUT3 Programmable output 3 not isolated (3.3V TTL level) COMRET Common return...
Page 51 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.7.1. Digital Inputs 9.7.1.1. TTL voltage level Figure 27: Digital Input TTL Mode Connection Diagram |Connector J2 www.elmomc.com Table of Contents...
Page 52 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.7.2. Digital Outputs 9.7.2.1. Isolated Open Collector and Open Emitter The following diagram describes theOUT1 and OUT2 outputs: Figure 28: Digital Output Connection Diagram – Isolated Open Collector and Open Emitter Connection 9.7.3. Analog Inputs For details of the Analog Input 2 –...
Page 53 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) 9.7.4. STO Input Interfaces - TTL Mode The diagram below describes the TTL option connection for the STO input interfaces. Figure 29: STO Input Connection – TTL Option 9.7.5. EtherCAT Status Indicator For details of the EtherCAT Status Indicator, refer to the section 14.2.6 EtherCAT Status Indicator in the in the MAN G Board Level Modules Hardware manual for full details.
Page 54 After the Gold Whistle has been connected and mounted, the system must be set up and initialized. This is accomplished using the EASII, Elmo’s Windows-based software application. Install the application and then perform setup and initialization according to the directions in the EASII User Manual.
Page 55 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) Chapter 11: Heat Dissipation The best way to dissipate heat from the Gold Whistle is to mount it so that its heat-sink faces up. For best results leave approximately 10 mm of space between the Gold Whistle's heat-sink and any other assembly.
Page 56 The chart above shows that no heat-sink is required when the heat-sink temperature is 80 °C, ambient temperature is 40 °C and heat dissipated is 4 W. When an external heat-sink is required, you can use the Elmo external heat-sink (Catalog number: WHI-HEAT-SINK-2).
Page 57 Gold Whistle Installation Guide MAN-G-WHI (Ver. 1.400) Chapter 12: Dim ensions This chapter provides detailed technical dimensions regarding the Gold Whistle. |How to Use the Charts|www.elmomc.com Table of Contents...
Page 58 |How to Use the Charts|www.elmomc.com Table of Contents...

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