Elmo SimplIQ Series Installation Manual
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Elmo SimplIQ Series Installation Manual

Digital servo drive
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Cello
Digital Servo Drive
Installation Guide
July 2012 (Ver. 1.6)
www.elmomc.com

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  • Page 1 Cello Digital Servo Drive Installation Guide July 2012 (Ver. 1.6) 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 Details Initial Release (April 2008), updated Power Ratings table in Chapter 4: (August 2008), added Section 3.4.7.4: Differential Pulse-and-Direction Input (March 2010) MTCR 07-009-56: Added note to Section 3.4.8.2 (July 2012), formatted according to new template, updated Catalog Number...
  • Page 4 Germany Tel: +49 (0) 7721-944 7120 • Fax: +49 (0) 7721-944 7130 • info-de@elmomc.com China Elmo Motion Control Technology (Shanghai) Co. Ltd. Room 1414, Huawen Plaza, No. 999 Zhongshan West Road, Shanghai (200051) China Tel: +86-21-32516651 • Fax: +86-21-32516652 •...

  • Page 5: Table Of Contents

    Cello Installation Guide MAN-CELIG (Ver. 1.6) Table of Contents Chapter 1: Safety Information ..................7 1.1. Warnings ........................8 1.2. Cautions ........................8 1.3. Directives and Standards ....................9 1.4. CE Marking Conformance ...................9 1.5. Warranty Information ....................9 Chapter 2: Introduction ..................... 10 2.1.
  • Page 6 Cello Installation Guide Table of Contents MAN-CELIG (Ver. 1.6) 3.4.8. I/O Cables ....................46 3.4.8.1. General I/O Port (J1) ..............46 3.4.8.2. General Input Port (J2) ............48 3.4.9. Communication Cables ................50 3.4.9.1. RS-232 Communication ............50 3.4.9.2. CANopen Communication ............51 3.5.

  • Page 7: Chapter 1: Safety Information

    Cello Installation Guide MAN-CELIG (Ver. 1.6) Chapter 1: Safety I nform ation 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 8: Warnings

    Cello Installation Guide Safety Information MAN-CELIG (Ver. 1.6) 1.1. Warnings • To avoid electric arcing and hazards to personnel and electrical contacts, never connect/disconnect the servo drive while the power source is on. • Power cables can carry a high voltage, even when the motor is not in motion. Disconnect the Cello from all voltage sources before it is opened for servicing.

  • Page 9: Directives And Standards

    All Elmo drives are warranted for a period of 12 months from the time of installation, or 18 months from time of shipment, whichever comes first. No other warranties, expressed or implied —...

  • Page 10: Chapter 2: Introduction

    The Cello can operate as a stand-alone device or as part of a multi-axis network in a distributed configuration. The Cello drive is set up and tuned using Elmo’s Composer software. This Windows-based application enables users to quickly and simply configure the servo drive for optimal use with their motor.

  • Page 11: Velocity Control

    Cello Installation Guide Introduction MAN-CELIG (Ver. 1.6) 2.2.2. Velocity Control • Fully digital • Programmable PI and FFW (feed forward) control filters • Sample rate two times current loop sample time • “On-the-fly” gain scheduling • Automatic, manual and advanced manual tuning and determination of optimal gain and phase margins 2.2.3.

  • Page 12: Feedback Options

    0 to 5 V voltage range  Resistance: 100 Ω to 1000 Ω  • Elmo drives provide supply voltage for all the feedback options 2.2.7. Fault Protection The Cello includes built-in protection against possible fault conditions, including: • Software error handling •...

  • Page 13: System Architecture

    2.4. 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 provide you with installation instructions as follows: •...
  • Page 14 • The Composer Software Manual, which includes explanations of all the software tools that are part of Elmo’s Composer software environment. The SimplIQ Command Reference Manual, which describes, in detail, each software • command used to manipulate the Cello motion controller.

  • Page 15: Chapter 3: Installation

    Cello Installation Guide MAN-CELIG (Ver. 1.6) Chapter 3: I nstallation The Cello must be installed in a suitable environment and properly connected to its voltage supplies and the motor. 3.1. 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.
  • Page 16 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Component Connector Described in Section Drawing Main Feedback Cable FEEDBACK A 3.4.5 Auxiliary Feedback FEEDBACK B 3.4.7 0 Cable (if needed) Digital I/O Cable GENERAL I/O 3.4.8.1 (if needed) Digital Inputs and GENERAL I/O 3.4.8.2 Analog Inputs Cable (if needed)

  • Page 17: Unpacking The Drive Components

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 3.2. Unpacking the Drive Components Before you begin working with the Cello system, verify that you have all of its components, as follows: • The Cello servo drive • The Composer software and software manual The Cello is shipped in a cardboard box with Styrofoam protection.

  • Page 18: Mounting The Cello

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 3.3. Mounting the Cello The Cello has been designed for two standard mounting options: • Wall Mount along the back (can also be mounted horizontally on a metal surface) • Book Shelf along the side M4 round head screws, one through each opening in the heat sink, are used to mount the Cello (see the diagram below).

  • Page 19: Connecting The Cables

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 3.4. Connecting the Cables The Cello has ten connectors. 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. Caution: Follow these instructions to ensure safe and proper wiring: •...
  • Page 20 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) The following connectors are used for wiring the Cello. Type Function Port Connector Location 5-Pin Phoenix Power VP+, PR two pins) (provided) 5-Pin Phoenix Motor M1, M2, M3 (last 3 pins) (provided) Optional Ground Power &...
  • Page 21 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Figure 4: Cello Detailed Connection Diagram www.elmomc.com...

  • Page 22: Connecting The Power Cables

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 3.4.2. Connecting the Power Cables The main power connector, which is located on the bottom of the Cello, includes the following pins: Pin Function Cable Pin Positions VP+ Pos. Power input Power Power return Power Protective earth Power...

  • Page 23: Connecting The Main Power Cable

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Figure 5: AC Motor Power Connection Diagram 3.4.2.2. Connecting the Main Power Cable Connect the main power supply cable to the VP+ and PR terminals of the main power connector. Connect the Protective Earth wire to the PE terminal on the Cello’s heat sink. Notes for connecting the DC power supply: Be sure to isolate the source of the DC power supply.

  • Page 24: Connecting The Optional Backup Supply Cable (24V)

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 3.4.3. Connecting the Optional Backup Supply Cable (24v) 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 25: Feedback And Control Cable Assemblies

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) “Smart” Control Supply Options: • Internal DC-to-DC converter that allows operation from DC power (no need for an auxiliary external 24 VDC supply for normal operation) • 24 VDC supply for backing up the control parameters if DC power is shut off 3.4.4.
  • Page 26 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 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 27 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) CEL-XX/YYYQ Absolute Encoders 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 Sine A Sine A complement DATA- Data complement...
  • Page 28 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Figure 9: Main Feedback- Incremental Encoder Connection Diagram www.elmomc.com...
  • Page 29 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Figure 10: Main Feedback – Interpolated Analog (Sine/Cosine) Encoder Connection Diagram Figure 11: Main Feedback – Resolver Connection Diagram www.elmomc.com...
  • Page 30 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Cello Figure 12: 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) only one tachometer port is available at a time Up to 50v Max Feedback Input (use with applications having a...
  • Page 31 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Cello Figure 14: Main Feedback – Potentiometer Feedback with Digital Hall Sensor Connection Diagram for Brushless Motors Cello Figure 15: Main Feedback – Potentiometer Feedback Connection Diagram for Brush Motors and Voice Coils www.elmomc.com...
  • Page 32 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Figure 16: Main Feedback – Stegmann Feedback Connection Diagram www.elmomc.com...
  • Page 33 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Figure 17: Main Feedback – Heidenhain Feedback Connection Diagram www.elmomc.com...

  • Page 34: Main And Auxiliary Feedback Combinations

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 3.4.6. 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 (pins 1 to 5 and 10) and Port B2 (pins 6, 7 and 11 to 14).

  • Page 35: Auxiliary Feedback (Feedback B)

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) FEEDBACK B Ports B1 and B2 FEEDBACK A Software YA[4] = 4 YA[4] = 2 YA[4] = 0 Setting Potentio- FEEDBACK A input: FEEDBACK A input: Incremental FEEDBACK A input: Incremental Potentiometer Encoder or Analog Encoder or Encoder or Analog Encoder or meter Resolver or Tachometer or...
  • Page 36 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Below are the signals on the Auxiliary Feedback ports when set up to run as a buffered outputs or emulated outputs of the main encoder (on FEEDBACK A): Port Signal Function Pin Positions Auxiliary channel A high output CHA-...
  • Page 37 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 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. When assembling the Auxiliary Feedback cable, follow the instructions in Section 3.4.4 (Feedback and Control Cable Assemblies).

  • Page 38: Differential Auxiliary Encoder Input Option On Feedback B (Ya[4]=2)

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 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 39 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Figure 19: Differential Auxiliary Encoder Input Option on FEEDBACK B - Connection Diagram www.elmomc.com...

  • Page 40: Single-Ended Auxiliary Input Option On Feedback B

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 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 41 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Figure 20: Single-Ended Auxiliary Input Option on FEEDBACK B - Connection Diagram www.elmomc.com...

  • Page 42: Pulse-And-Direction Input Option On Feedback B (Ya[4]=0)

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 3.4.7.4. Pulse-and-Direction Input Option on FEEDBACK B (YA[4]=0) This mode is used for input of differential or single-ended pulse-and-direction position commands on Port B1. In this mode Port B2 provides differential buffered pulse-and-direction outputs for another axis.
  • Page 43 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Figure 21: Pulse-and-Direction Input Option on FEEDBACK B - Connection Diagram www.elmomc.com...
  • Page 44 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 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 Positions Pulse/Auxiliary channel A high input PULS/CHA Pulse-/Auxiliary channel A low input PULS-/CHA- Direction/Auxiliary channel B high input DIR/CHB...
  • Page 45 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Figure 22: Differential Pulse-and-Direction Input Option on FEEDBACK B - Connection Diagram www.elmomc.com...

  • Page 46: I/O Cables

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 3.4.8. I/O Cables The Cello has two I/O ports, J1 and J2. J1 is a general I/O which can be used to connect 6 digital inputs and 5 digital outputs. J2 is an input port for connecting up to 4 separate digital inputs and 2 analog inputs: J1 Port J2 Port...
  • Page 47 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Figure 23: General J1 I/O Connection Diagram www.elmomc.com...

  • Page 48: General Input Port (J2)

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 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 49 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) high speed input Figure 24: General Input J2 Connection Diagram www.elmomc.com...

  • Page 50: Communication Cables

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) 3.4.9. Communication Cables The communication cables use an 8-pin RJ-45 plug that connect to the RS-232 and CANopen ports on the “top” of the Cello. The communication interface may differ according to the user’s hardware. The Cello can communicate using the following options: RS-232, full duplex CANopen...

  • Page 51: Canopen Communication

    Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Figure 25: 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 52 Cello Installation Guide Installation MAN-CELIG (Ver. 1.6) Caution: When installing the CANopen communications, ensure that each servo drive is allocated a unique ID. Otherwise, the CANopen network may hang. Figure 26: CANopen Connection Diagram www.elmomc.com...

  • Page 53: Powering Up

    After the Cello has been connected and mounted, the system must be set up and initialized. This is accomplished using the Composer, Elmo’s Windows-based software application. Install the application and then perform setup and initialization according to the directions in the Composer Software Manual.

  • Page 54: Chapter 4: Technical Specifications

    Cello Installation Guide MAN-CELIG (Ver. 1.6) Chapter 4: Technical Specifications This chapter provides detailed technical information regarding the Cello. This includes its dimensions, power ratings, the environmental conditions under which it can be used, the standards to which it complies and other specifications. 4.1.

  • Page 55: Feedback Options

    Programmable 10 to 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 4.1.6. Input/Output • Analog Inputs – up to 14-bit resolution •...

  • Page 56: Built-In Protection

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.6) 4.1.7. Built-In Protection • Software error handling • Abort (hard stops and soft stops) • Status reporting • Protection against Shorts between motor power outputs  Shorts between motor power outputs and power input/return ...

  • Page 57: Cello Dimensions

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.6) 4.2. Cello Dimensions www.elmomc.com...

  • Page 58: Power Ratings

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.6) 4.3. Power Ratings Feature Units Minimum supply voltage Nominal supply voltage Maximum supply voltage Maximum continuous 240 480 720 1000 1440 260 800 1200 1700 2400 360 960 1600 2400 3400 power output Efficiency at >...

  • Page 59: Cello Connections

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.6) 4.5. Cello Connections The following connectors are used for wiring the Cello. Pins Type Maker & Part No. Mating Connector Port 5.00 mm Pitch Phoenix Header Phoenix Plug (supplied) VP+, PR Header and Plug MSTBA 2.5 HC/5-G MSTBT 2.5 HC/5-ST M1, M2, M3...

  • Page 60: Backup Supply (Optional)

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.6) 4.5.1. Backup Supply (Optional) Feature Details DC source only Auxiliary power supply Auxiliary supply input voltage 24 V ±20% Auxiliary supply input power 10 W Note: The Cello can operate without a 24 Volt backup power supply. 4.6.

  • Page 61: Velocity Loop

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.6) 4.6.2. 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 options Digital Halls Interpolated Analog (Sine/Cosine) Encoder (optional)

  • Page 62: Feedbacks

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.6) 4.7. Feedbacks The Cello can receive and process feedback input from diverse types of devices. 4.7.1. 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 4.7.2.

  • Page 63: Digital Halls

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.6) 4.7.3. 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 64: Resolver

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.6) 4.7.5. Resolver Feature Details Resolver format Sine/Cosine Differential Input resistance Differential 2.49 kΩ Resolution Programmable: 10 to 15 bits Maximum electrical frequency (RPS) 512 revolutions/sec Resolver transfer ratio Reference frequency 1/Ts (Ts = sample time in seconds) Reference voltage Supplied by the Cello Reference current...

  • Page 65: Potentiometer

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.6) 4.7.7. Potentiometer Feature Details Potentiometer Format Single-ended Operating Voltage Range 0 to 5 V supplied by the Cello Potentiometer Resistance 100 Ω to 1 kΩ … above this range, linearity is affected detrimentally Input Resistance 100 kΩ...

  • Page 66: Digital Input Interfaces

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.6) 4.8.1. Digital Input Interfaces Feature Details Type of input Optically isolated Single ended PLC level Input current = 2.2 mA for V = 12 V Input current for high speed inputs = 4.4 mA for V = 12 V High-level input voltage 12 V <...

  • Page 67: Digital Output Interface

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.6) 4.8.2. Digital Output Interface Feature Details Type of output Optically isolated Open collector and open emitter Maximum supply output (VCC) 30 V Max. output current (max) ≤ 15 mA (max) (V = Low) VOL at maximum output voltage (low (on) ≤...

  • Page 68: Analog Input

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.6) 4.8.3. Analog Input Feature Details Maximum operating differential voltage ± 10 V Maximum absolute differential input voltage ± 16 V Differential input resistance 3 kΩ Analog input command resolution 14-bit 4.9. Communications Specification Details Connector Location...

  • Page 69: 4.12. Compliance With Standards

    Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.6) 4.12. Compliance with Standards Specification Details Quality Assurance ISO 9001:2008 Quality Management Design Approved IEC/EN 61800-5-1, Safety Printed wiring for electronic equipment (clearance, creepage, spacing, conductors sizing, etc.) MIL-HDBK- 217F Reliability prediction of electronic equipment (rating, de-rating, stress, etc.) UL 60950 Printed wiring for electronic equipment...
  • Page 70 In compliance with 2002/96/EC Waste Electrical and Electronic Equipment regulations (WEEE) Note: Out-of-service Elmo drives should be sent to the nearest Elmo sales office. In compliance with 2002/95/EC Restrictions on Application of Hazardous (effective July 2006) Substances in Electric and Electronic Equipment (RoHS) www.elmomc.com...

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