Elmo Cello Installation Manual
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Elmo Cello Installation Manual

Digital servo drive
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Cello
Digital Servo Drive
Installation Guide
March 2010 (Ver. 1.5)
www.elmomc.com

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Summary of Contents for Elmo Cello

  • Page 1 Cello Digital Servo Drive Installation Guide March 2010 (Ver. 1.5) www.elmomc.com...
  • Page 2 The specifications on which they are based are subject to change without notice. Elmo Motion Control and the Elmo Motion Control logo are trademarks of Elmo Motion Control Ltd. Information in this document is subject to change without notice.
  • Page 3 Revision History: Version Release Date Changes/Remarks Ver. 1.5 March 2010 MTCR 07-009-56: Added note to 3.4.8.2 Ver. 1.4 August 2008 Added 3.4.7.4: Differential pulse-and–direction input Ver. 1.3 April 2008 Updated Power Ratings Table in Appendix...

  • Page 4: Table Of Contents

    Before You Begin .................... 3-1 3.1.1 Site Requirements..................3-1 3.1.2 Hardware Requirements ................3-1 Unpacking the Drive Components ............... 3-3 Mounting the Cello ..................3-4 Connecting the Cables ................... 3-4 3.4.1 Wiring the Cello..................3-4 3.4.2 Connecting the Power Cables..............3-8 3.4.2.1 Connecting the Motor Cable ............3-8 3.4.2.2 Connecting the Main Power Cable..........
  • Page 5 Cello Installation Guide Contents MAN-CELIG (Ver. 1.5) 3.4.9.2 CANopen Communication ............3-37 Powering Up ....................3-39 Initializing the System ................. 3-39 Appendix: Technical Specifications..................A-1 Features ......................A-1 A.1.1 Motion Control Modes ................A-1 A.1.2 Advanced Positioning Motion Control Modes ........A-1 A.1.3...

  • Page 6: Chapter 1: Safety Information

    MAN-CELIG (Ver. 1.5) Chapter 1: Safety Information In order to achieve the optimum, safe operation of the Cello servo drive, 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 Cello and accompanying equipment.

  • Page 7: Warnings

    The maximum DC power supply connected to the instrument must comply with the parameters outlined in this guide. The Cello can operate only through an isolated power source, using an isolated transformer and a rectifier circuit. Power to this device must be supplied by DC voltage, within the boundaries specified for the Cello.

  • Page 8: Directives And Standards

    CE Mark Conformance The Cello servo drive is intended for incorporation in a machine or end product. The actual end product must comply with all safety aspects of the relevant requirements of the European Safety of Machinery Directive 98/37/EC as amended, and with those of the most recent versions of standards EN60204-1 and EN292-2 at the least.

  • Page 9: Chapter 2: Introduction

    Power to the Cello is provided by a 10 to 195 VDC source. A “smart” control-supply algorithm enables the Cello to operate with the power supply only, with no need for an auxiliary 24 Volt supply.

  • Page 10: Position Control

    PT and PVT motion modes Dual (position/velocity) loop Fast output compare (OC) 2.2.5 Communication Options Depending on the application, Cello users can select from two communication options: RS-232 serial communication CANopen for fast communication in a multi-axis distributed environment 2.2.6 Feedback Options Incremental Encoder –...

  • Page 11: Fault Protection

    Introduction MAN-CELIG (Ver. 1.5) 2.2.7 Fault Protection The Cello includes built-in protection against possible fault conditions, including: Software error handling Status reporting for a large number of possible fault conditions Protection against conditions such as excessive temperature, under/over voltage, loss of commutation signal, short circuits between the motor...

  • Page 12: How To Use This Guide

    MAN-CELIG (Ver. 1.5) How to Use this Guide In order to install and operate your Elmo Cello servo drive, 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...

  • Page 13: Chapter 3: Installation

    MAN-CELIG (Ver. 1.5) Chapter 3: Installation Before You Begin 3.1.1 Site Requirements You can guarantee the safe operation of the Cello by ensuring that it is installed in an appropriate environment. Feature Value 0 °C to 40 °C (32 °F to 104 °F)
  • Page 14 Cello Installation Guide Installation MAN-CELIG (Ver. 1.5) Described in Component Connector Section Diagram Main Feedback Cable 3.4.5 FEEDBACK A Auxiliary Feedback Cable FEEDBACK B (if needed) Digital I/O Cable GENERAL I/O 3.4.8.1 (if needed) Digital Inputs and GENERAL I/O Analog Inputs Cable 3.4.8.2...

  • Page 15: Unpacking The Drive Components

    Operating Voltage and/or Halls R = Resolver I = Interpolated Analog Encoder T = Tachometer & Potentiometer Absolute Encoder 4. Verify that the Cello type is the one that you ordered, and ensure that the voltage meets your specific requirements.

  • Page 16: Mounting The Cello

    Figure 3-1: Mounting the Cello Connecting the Cables 3.4.1 Wiring the Cello Once the Cello is mounted, you are ready to wire the device. Proper wiring, grounding and shielding are essential for ensuring safe, immune and optimal servo performance of the Cello.
  • Page 17 Failing to meet this requirement can result in drive/controller/host failure. After completing the wiring, carefully inspect all wires to ensure tightness, good solder joints and general safety. The following connectors are used for wiring the Cello. Type Function Port...
  • Page 18 Cello Installation Guide Installation MAN-CELIG (Ver. 1.5) Type Function Port Connector Location 8-pin RJ-45 CANopen 8-pin RJ-45 CANopen 15-pin D-Sub Feedback B Feedback B (high-density) RS-232 CANopen Feedback B 8-pin RJ-45 RS-232 RS-232 Table 3-3: Connectors on the “Top” of the Cello...
  • Page 19 Cello Installation Guide Installation MAN-CELIG (Ver. 1.5) Figure 3-2: Cello Detailed Connection Diagram...

  • Page 20: Connecting The Power Cables

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.5) 3.4.2 Connecting the Power Cables The main power connector located at the bottom of the Cello, as follows: Pin Function Cable Positions VP+ Pos. Power input Power Power return Power Protective earth Power...

  • Page 21: Connecting The Main Power Cable

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

  • Page 22: Connecting The Optional Back-Up Supply Cable (24V)

    To connect the back-up supply to the 24v port on the bottom of the Cello, use the 2-pin power plug provided with the Cello. Remember, you are working with DC power; be sure to exercise caution.

  • Page 23: Feedback And Control Cable Assemblies

    Figure 3-6: Feedback and Control Cable Assemblies Note: All D-sub type connectors, used with the Cello, should be assembled in this way. 3.4.5 Main Feedback Cable (FEEDBACK A) The main feedback cable is used to transfer feedback data from the motor to the drive.
  • Page 24 3-12 MAN-CELIG (Ver. 1.5) FEEDBACK A on the “front” of the Cello has a 15-pin D-sub socket. Connect the Main Feedback cable from the motor to FEEDBACK A using a 15-pin, D-Sub plug with a metal housing. When assembling the Main Feedback cable, follow the instructions in Section 3.4.4 (Feedback and Control Cable Assemblies).
  • Page 25 Cello Installation Guide Installation 3-13 MAN-CELIG (Ver. 1.5) Absolute Encoders XX/YYYQ Signal Heidenhain Stegmann Hall C Hall C Hall A Hall A SUPRET Supply return Supply return EnDat (Heidenhain) Encoder +5 supply Halls supply +5V Sine A complement Sine A...
  • Page 26 Cello Installation Guide Installation 3-14 MAN-CELIG (Ver. 1.5) Figure 3-7: Main Feedback- Incremental Encoder Connection Diagram...
  • Page 27 Cello Installation Guide Installation 3-15 MAN-CELIG (Ver. 1.5) Figure 3-8: Main Feedback – Interpolated Analog Encoder Connection Diagram Figure 3-9: Main Feedback – Resolver Connection Diagram...
  • Page 28 Cello Installation Guide Installation 3-16 MAN-CELIG (Ver. 1.5) Cello Figure 3-10: Main Feedback – Tachometer Feedback with Digital Hall Sensor Connection Diagram for Brushless Motors Cello Up to 20v Max Feedback Input (use with applications having a Tacho voltage below 20v)
  • Page 29 Cello Installation Guide Installation 3-17 MAN-CELIG (Ver. 1.5) Cello Figure 3-12: Main Feedback – Potentiometer Feedback with Digital Hall Sensor Connection Diagram for Brushless Motors Cello Figure 3-13: Main Feedback – Potentiometer Feedback Connection Diagram for Brush Motors and Voice Coils...
  • Page 30 Cello Installation Guide Installation 3-18 MAN-CELIG (Ver. 1.5) Figure 3-14: Main Feedback – Stegmann Feedback Connection Diagram...
  • Page 31 Cello Installation Guide Installation 3-19 MAN-CELIG (Ver. 1.5) Figure 3-15: Main Feedback – Heidenhain Feedback Connection Diagram...

  • Page 32: Main And Auxiliary Feedback Combinations

    The Main Feedback is always used in motion control devices whereas Auxiliary Feedback is often, but not always used. The Auxiliary Feedback connector on the Cello, “FEEDBACK B” has two ports, Port B1 and Port B2. When used in combination with the Main Feedback port, “FEEDBACK A”, the ports can be set, by software, as follows:...
  • Page 33 Cello Installation Guide Installation 3-21 MAN-CELIG (Ver. 1.5) FEEDBACK B Ports B1 and B2 FEED- YA[4] = 4 YA[4] = 2 YA[4] = 0 BACK A - output Differential or Differential Single-ended Potentiometer Pulse & Position Single-ended Direction Data Auxiliary...

  • Page 34: Auxiliary Feedback (Feedback B)

    Table 3-7: Main Encoder Buffered Outputs or Emulated Encoder Outputs on FEEDBACK B - Pin Assignments FEEDBACK B on the “top” of the Cello has a 15-pin high density D-sub socket. Connect the Auxiliary Feedback cable, from the controller or other device, to FEEDBACK B using a 15-pin, high density D-Sub plug with a metal housing.
  • Page 35 Cello Installation Guide Installation 3-23 MAN-CELIG (Ver. 1.5) Figure 3-16: Main Encoder Buffered Output or Emulated Encoder Output on FEEDBACK B - Connection Diagram...

  • Page 36: Differential Auxiliary Encoder Input Option On Feedback B (Ya[4]=2)

    3.4.7.2 Differential Auxiliary Encoder Input Option on FEEDBACK B (YA[4]=2) The Cello can be used as a slave by receiving the position of the master encoder data (on Port B1) in Follower or ECAM mode. In this mode Port B2 provides differential buffered auxiliary outputs for the next slave axis in follower or ECAM mode.
  • Page 37 Cello Installation Guide Installation 3-25 MAN-CELIG (Ver. 1.5) Figure 3-17: Differential Auxiliary Encoder Input Option on FEEDBACK B - Connection Diagram...
  • Page 38 3.4.7.3 Single-ended Auxiliary Input Option on FEEDBACK B (YA[4]=2) The Cello can be used as a slave by receiving the position data (on Port B1) of the master encoder in Follower or ECAM mode. In this mode Port B2 provides differential buffered auxiliary outputs for the next slave axis in Follower or ECAM mode.
  • Page 39 Cello Installation Guide Installation 3-27 MAN-CELIG (Ver. 1.5) Figure 3-18: Single-ended Auxiliary Input Option on FEEDBACK B - Connection Diagram...

  • Page 40: Pulse-And-Direction Input Option On Feedback B

    15 Pin D-Sub Socket Table 3-10: Pulse-and-Direction Auxiliary Encoder Pin Assignment on FEEDBACK B FEEDBACK B on the “top” of the Cello has a 15-pin high density D-sub socket. Connect the Auxiliary Feedback cable from the Pulse and Direction Controller to FEEDBACK B using a 15-pin, high density D-Sub plug with a metal housing.
  • Page 41 Cello Installation Guide Installation 3-29 MAN-CELIG (Ver. 1.5) Figure 3-19: Pulse-and-Direction Input Option on FEEDBACK B - Connection Diagram...
  • Page 42 Cello Installation Guide Installation 3-30 MAN-CELIG (Ver. 1.5) Below are the signals on the Auxiliary Feedback ports when they are set up to run as differential pulse-and-direction input: Port Signal Function Pin Position PULS/CHA Pulse/Auxiliary channel A high input PULS-/CHA- Pulse-/Auxiliary channel A low input...
  • Page 43 Cello Installation Guide Installation 3-31 MAN-CELIG (Ver. 1.5) Figure 3-20: Differential Pulse-and-Direction Input Option on FEEDBACK B - Connection Diagram...

  • Page 44: I/O Cables

    Cello Installation Guide Installation 3-32 MAN-CELIG (Ver. 1.5) 3.4.8 I/O Cables The Cello has two I /O ports, J1 a nd J2. J1 i s a ge neral I O which can be used to connect 6 digital inputs and 5 digital output s.
  • Page 45 Cello Installation Guide Installation 3-33 MAN-CELIG (Ver. 1.5) Figure 3-21: General J1 I/O Connection Diagram...

  • Page 46: General Input Port (J2)

    Cello Installation Guide Installation 3-34 MAN-CELIG (Ver. 1.5) 3.4.8.2 General Input Port (J2) Port J2 has a 15-pin high density D-Sub socket. When assembling this I/O cable, follow the instructions in Section 3.4.4 (Feedback and Control Cable Assemblies) using a 15-pin high density metal case D-sub male connector (plug).
  • Page 47 Cello Installation Guide Installation 3-35 MAN-CELIG (Ver. 1.5) high speed input Figure 3-22: General Input J2 Connection Diagram...

  • Page 48: Communication Cables

    CANopen RS-232 communication requires a standard, commercial 3-core null-modem cable connected from the Cello to a serial interface on the PC. The interface is selected and set up in the Composer software. In order to benefit from CANopen communication, the user must have an understanding of the basic programming and timing issues of a CANopen network.

  • Page 49: Canopen Communication

    Cello Installation Guide Installation 3-37 MAN-CELIG (Ver. 1.5) Figure 3-23: RS-232 Connection Diagram 3.4.9.2 CANopen Communication Notes for connecting the CANopen communication cable: Use 26 or 28 AWG twisted pair shielded cables. For best results, the shield should have aluminum foil and covered by copper braid with a drain wire Connect the shield to the ground of the host (PC).
  • Page 50 Cello Installation Guide Installation 3-38 MAN-CELIG (Ver. 1.5) Caution: When installing the CANopen communications, ensure that each servo drive is allocated a unique ID. Otherwise, the CANopen network may hang. Figure 3-24: CANopen Connection Diagram...

  • Page 51: Powering Up

    3-39 MAN-CELIG (Ver. 1.5) Powering Up After the Cello has been mounted, check that the cables are intact. The Cello servo drive is then ready to be powered up. Caution: Before applying power, ensure that the DC supply is within the range specified for your specific type of Cello and that the proper plus-minus connections are in order.

  • Page 52: Appendix: Technical Specifications

    Automatic Correction of amplitude mismatch, phase mismatch, signals offset Encoder outputs, buffered, differential. • Resolver Programmable 10~15 bit resolution Up to 512 revolutions per second (RPS) Encoder outputs, buffered, differential • Elmo drives provide supply voltage for all the feedback options • Tachometer, Potentiometer...

  • Page 53: Input/Output

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.5) A.1.6 Input/Output • Analog Inputs – up to 14-bit resolution • Programmable digital inputs, optically isolated Inhibit/Enable motion Software and analog reference stop Motion limit switches Begin on input Abort motion General-purpose Homing •...

  • Page 54: Cello Dimensions

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.5) A.2 Cello Dimensions...

  • Page 55: Power Ratings

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.5) A.3 Power Ratings Feature Units Minimum supply voltage Nominal supply voltage Maximum supply voltage Maximum continuous 240 480 720 1000 1440 360 960 1600 2400 3400 1700 2400 1200 power output Efficiency at >...

  • Page 56: Cello Connections

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.5) A.5 Cello Connections The following connectors are used for wiring the Cello. Maker & Part Pins Type Mating Connector Port 5.00 mm Pitch Phoenix Header Phoenix Plug VP+, PR Header and MSTBA 2.5...

  • Page 57: Backup Supply (Optional

    Auxiliary power supply DC source only Auxiliary supply input voltage 24 V +20% Auxiliary supply input power 10 W Note: The Cello can operate without a 24 Volt back-up power supply. Control Specifications A.6.1 Current Loop Feature Details Controller type...

  • Page 58: Velocity Loop

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.5) A.6.2 Velocity Loop Feature Details Controller type Velocity control Fully digital Programmable PI and FFW control filters On-the-fly gain scheduling Automatic, manual and advanced manual tuning Velocity and position feedback Incremental Encoder...

  • Page 59: Feedbacks

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.5) A.7 Feedbacks A.7.1 Feedback Supply Voltage Feature Details Main encoder supply voltage 5 V +5% @ 200 mA maximum Auxiliary encoder supply voltage 5 V +5% @ 200 mA maximum A.7.2 Incremental Encoder Input...

  • Page 60: Digital Halls

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.5) A.7.3 Digital Halls Feature Details Halls inputs Single ended inputs Built in hysteresis for noise immunity. Input voltage Nominal operating range: 0 V < V < 5 V In_Hall Maximum absolute: -1 V < V <...

  • Page 61: Resolver

    Programmable: 10 ~ 15 bits Maximum electrical frequency 512 revolutions/sec (RPS) Resolver transfer ratio Reference frequency 1/Ts (Ts = sample time in seconds) Reference voltage Supplied by the Cello Reference current up to ±50 mA A.7.6 Tachometer* Feature Details Differential...

  • Page 62: Potentiometer

    A.7.7 Potentiometer Feature Details Single-ended Potentiometer Format Operating Voltage Range 0 ~ 5 V supplied by the Cello Potentiometer Resistance 100 Ω ~ 1 kΩ … above this range, linearity is affected detrimentally Input Resistance 100 kΩ Resolution 14 Bit A.7.8...

  • Page 63: I/Os

    Cello Installation Guide Technical Specifications A-12 MAN-CELIG (Ver. 1.5) A.8 I/Os The Cello has: 10 Digital Inputs 5 Digital Outputs 2 Analog Inputs A.8.1 Digital Input Interfaces Feature Details Connector Location Optically isolated Type of input Single ended PLC level −...

  • Page 64: Digital Output Interface

    Cello Installation Guide Technical Specifications A-13 MAN-CELIG (Ver. 1.5) A.8.2 Digital Output Interface Feature Details Connector Location Type of output Optically isolated Open collector and open emitter Maximum supply output 30 V General (Vcc) Purpose Max. output current Iout (max) ≤ 15 mA...

  • Page 65: Communications

    Cello Installation Guide Technical Specifications A-14 MAN-CELIG (Ver. 1.5) A.9 Communications Specification Details Connector Location Signals: RS-232 RxD , TxD , Gnd CANopen Full duplex, serial communication for setup port and control. CANopen port Baud Rate of 9,600 ~ 115,200 bit/sec.

  • Page 66: Standards Compliance

    Cello Installation Guide Technical Specifications A-15 MAN-CELIG (Ver. 1.5) A.12 Standards Compliance A.12.1 Quality Assurance Specification Description Quality Management ISO 9001:2008 A.12.2 Design Specification Description Reliability prediction of electronic equipment MIL-HDBK- 217F (rating, de-rating, stress, etc.) IPC-D-275 Reliability prediction of electronic equipment IPC-SM-782 (rating, de-rating, stress, etc.)

  • Page 67: Pcb

    A.12.8 WEEE* Specification Description In compliance with 2002/96/EC Waste Electrical and Electronic Equipment regulations * Please send out-of-service Elmo drives to the nearest Elmo sales office. A.12.9 RoHS Specification Description In compliance with 2002/95/EC Restrictions on Application of Hazardous (effective July 2006)

  • Page 68: Index

    Cello Installation Guide MAN-CELIG (Ver. 1.5) Index Composer · 2-1, 3-39 Conformance · 1-3, A-15 Connecting Auxiliary power cable · 3-10 Advanced Filters and Gain Scheduling · Control cables · 3-11 Feedback cables · 3-11 Advanced position control · 2-2 Main power cable ·...
  • Page 69 Power cables · 3-8 CANopen cables · 3-37 Power Ratings · A-4 Main feedback cables · 3-11, 3-34 Powering up the Cello · 3-39 Main power cables · 3-9 Pulse Width Modulation · A-14 Motor cables · 3-8 Pulse-and-direction input · 3-28 RS-232 cable ·...
  • Page 70 Velocity Loop · A-7 Workmanship · A-15 System architecture · 2-3 Warranty · 1-3 WEEE · A-16 Tachometer · A-10 Wiring the Cello · 3-4 Tachometer · 3-12 Workmanship · A-15 Tachometer Feedback · 3-16 Technical Specifications · A-1 Temperature · 3-1...

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