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Elmo 95VDC Installation Manual

Duo integrated solution
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Duo
Integrated Solution

Installation Guide

June 2007 (Ver. 1.0)

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Summary of Contents for Elmo 95VDC

  • Page 1: Installation Guide

    Integrated Solution Installation Guide June 2007 (Ver. 1.0)

  • Page 2: Revision History

    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: Table Of Contents

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) Contents Chapter 1: Safety Information ... 1-1 1.1 Warnings ... 1-2 1.2 Cautions... 1-2 1.3 Directives and Standards... 1-3 1.4 CE Mark Conformance... 1-3 1.5 Warranty Information ... 1-3 Chapter 2: Introduction... 2-1 2.1 Product Description ... 2-1 2.2 Product Features...
  • Page 4 Duo Installation Guide MAN-DUOIG (Ver. 1.0) 3.11.2 Digital Output... 3-29 3.11.3 Analog Input ... 3-29 3.12 Communications... 3-30 3.12.1 RS232 Communication... 3-30 3.12.2 CANopen Communication ... 3-31 3.13 Powering Up ... 3-33 3.14 Initializing the System... 3-33 Appendix A: Technical Specifications ...A-1 A.1 Features...
  • Page 5 Duo Installation Guide MAN-DUOIG (Ver. 1.0) B.5 I/O (CBL-HDRIO-001)... B-5 B.6 Communication Cables... B-6 B.6.1 RS-232 Option (CBL-RJ452321)... B-6 B.6.2 CAN Open (CBL-RJ45CAN1) ... B-7 B.7 Guidelines for Making Your Own Cables... B-8 B.7.1 Recommended Wire Cross Sections... B-8 Contents...

  • Page 6: Chapter 1: Safety Information

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) Chapter 1: Safety Information In order to achieve the optimum, safe operation of the Duo, 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 Duo and accompanying equipment.

  • Page 7: Warnings

    When connecting the Duo to an approved 12 ~ 95VDC (8.5 ~ 67VAC) auxiliary power supply, connect it through a line that is isolated from hazardous live voltages using reinforced or double insulation in accordance with approved safety standards.

  • Page 8: 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.

  • Page 9: Chapter 2: Introduction

    Power to the various Duo models is provided by a 0 - 95VDC source. A “smart” control- supply algorithm enables the Duo to operate with only one power supply and there is no need for an auxiliary power supply for the logic.

  • Page 10: Chapter 2: Introduction

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) Product Features 2.2.1 Current Control Fully digital Sinusoidal commutation with vector control or trapezoidal commutation with encoder and/or digital Hall sensors 12-bit current loop resolution Automatic gain scheduling, to compensate for variations in the DC bus power supply 2.2.2 Velocity Control...

  • Page 11: Chapter 3: Installation

    • Recovery from loss of commutation signals and from communication errors How to Use this Guide In order to install and operate your Elmo Duo, you will use this manual in conjunction with a set of Elmo documentation. Installation is your first step; after carefully reading...
  • Page 12 Cable Kit 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 Whistle motion controllers...

  • Page 13: Chapter 3: Installation

    Duo User Guide MAN-DUOUG (Ver. 1.0) Chapter 3: Installation Site Requirements You can guarantee the safe operation of the Duo by ensuring that it is installed in an appropriate environment. Feature Ambient operating temperature Maximum operating altitude Maximum relative humidity Operating area atmosphere Models for extended environmental conditions are available.

  • Page 14: Mounting The Duo

    Duo User Guide MAN-DUOUG (Ver. 1.0) The part number at the top gives the type designation as follows: DUO- Axis 1 Version : Blank = Standard A = Advanced Axis 1 Continuous Current(Amps) Axis 2 Version : Blank = Standard A = Advanced Axis 2 Continuous Current(Amps)

  • Page 15: Connecting The Cables

    Duo User Guide MAN-DUOUG (Ver. 1.0) Connecting the Cables 3.4.1 Wiring the Duo Once the Duo 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 Duo. Follow these instructions to ensure safe and proper wiring Use twisted pair shielded cables for control, Feedback and communication connections.
  • Page 16 Duo User Guide MAN-DUOUG (Ver. 1.0) Type Function Main Feedback Feedback Auxiliary Auxiliary Feedback Feedback Table 3-2: Connectors on the “Front” of the Duo Type Function CANopen CANopen IN CANopen CANopen OUT RS232 RS232-1 RS232-2 Table 3-3: Connectors on the “Top” of the Duo Connector Location Auxiliary Main...

  • Page 17: Duo Connectors Type

    Duo User Guide MAN-DUOUG (Ver. 1.0) Duo Connectors type Type Qty Conn. Main Power Motor Power Main Feedback Auxiliary Feedback CANopen Comm. RS232 Comm. Connector Location RS232 Axis 2 RS232 Axis 1 On Board Connector Phoenix 5-pin Header P/N:MSTBA 2.5HC/5-G Phoenix 4-pin Header P/N:MSTBA 2.5/4G-5.08 12-pin Molex Header P/N:90130-3212 14-pin Molex Header P/N:90130-3214...

  • Page 18: Hardware Requirements

    Duo User Guide MAN-DUOUG (Ver. 1.0) Hardware Requirements The components that you will need to install your Duo are: Component Mating Connector Conn. Phoenix 5-pin Plug Main Power P/N:MSTBT 2.5HC/5-ST Phoenix 4-pin Plug Motor P/N:MSTBT 2.5/4-ST-5.08 Power 12-pin Molex Plug Main P/N:90142-0012 Feedback...

  • Page 19: Duo Block Diagram

    Duo User Guide MAN-DUOUG (Ver. 1.0) Duo Block Diagram Figure 3-2: Duo Block Diagram...

  • Page 20: The Main Power And Motor Power Connectors

    Duo User Guide MAN-DUOUG (Ver. 1.0) The Main Power and Motor Power Connectors Pin Function Protective earth Power return Aux. Supply Input Return VP+ Pos. Power input Aux. Supply Input M3 Motor phase M2 Motor phase M1 Motor phase Protective earth Table 3-6: Connectors for Main Power and Motors 3.8.1 Connecting Motor Power...

  • Page 21: Connecting Main Power

    Duo User Guide MAN-DUOUG (Ver. 1.0) 3.8.2 Connecting Main Power Connect the DC power supply cable to the VP+ and PR terminals of the Main power connector. Notes for connecting the DC power supply: The source of the 0 ~ 95 VDC Power Supply must be isolated. For the greatest immunity, it is highly recommended to use twisted and shielded cables for the DC power supply cable.

  • Page 22: Low Power Auxiliary Supply (Optional)

    Duo User Guide MAN-DUOUG (Ver. 1.0) 3.8.3 Low power Auxiliary Supply (optional) Notes for 12 ~ 95 VDC Auxiliary Supply connections: The source of the 12 ~ 95 VDC Auxiliary Supply must be isolated from the Main. For safety reasons, connect the return (common) of the closest ground near the Auxiliary Supply source.
  • Page 23 Duo User Guide 3-11 MAN-DUOUG (Ver. 1.0) Figure 3-6: Shared Supply Connection Diagram...

  • Page 24: Main Feedback

    Duo User Guide MAN-DUOUG (Ver. 1.0) Main Feedback The Main Feedback port is used to transfer Feedback data from the motor to the drive. The Duo accepts the following as a Main Feedback mechanism: Incremental encoder only Incremental encoder with digital hall sensors Digital hall sensors only Incremental analog (sine/cosine)
  • Page 25 Duo User Guide 3-13 MAN-DUOUG (Ver. 1.0) Figure 3-7: Main Feedback- Incremental Encoder With Digital Halls Sensors Connection Diagram Figure 3-8: Main Feedback- Incremental Encoder Only Connection Diagram...
  • Page 26 Duo User Guide 3-14 MAN-DUOUG (Ver. 1.0) Figure 3-9: Main Feedback – Interpolated Analog Encoder Connection Diagram Figure 3-10: Main Feedback– Resolver Connection Diagram...
  • Page 27 Duo User Guide 3-15 MAN-DUOUG (Ver. 1.0) Figure 3-11: Main Feedback – Tachometer Feedback with Digital Hall Sensor Connection Diagram for Brushless Motors Figure 3-12: Main Feedback – Tachometer Feedback Connection Diagram for Brush Motors...
  • Page 28 Duo User Guide 3-16 MAN-DUOUG (Ver. 1.0) Figure 3-13: Main Feedback – Potentiometer Feedback with Digital Hall Sensor Connection Diagram for Brushless Motors Figure 3-14: Main Feedback – Potentiometer Feedback Connection Diagram for Brush Motors and Voice Coils...

  • Page 29: Main Feedback

    Duo User Guide MAN-DUOUG (Ver. 1.0) 3.10 Auxiliary Feedback (bi-directional) When using one of the Auxiliary Feedback options, the relevant functionality of the Auxiliary Feedback's ports are software selected for that option. Refer to the SimplIQ Command Reference Manual for detailed information about Auxiliary Feedback setup. The Auxiliary Feedback connector has two ports –...

  • Page 30: Main And Auxiliary Feedback Combinations

    Duo User Guide MAN-DUOUG (Ver. 1.0) 3.10.1 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 has two ports (B1 and B2). When used in combination with Main Feedback, the Auxiliary Feedback can be set, by software, as follows: Main...
  • Page 31 Duo User Guide MAN-DUOUG (Ver. 1.0) Auxiliary Feedback: Input Main (Auxiliary Feedback: input) Feedback Incremental Encoder Input Interpolated Analog (Sin/Cos) Encoder Input Feedback: Incremental Resolver Input Tachometer Potentiometer Potentiometer Tachometer Input Any application where two Feedbacks are used by the drive. The Auxiliary Feedback port serves as an input for the Auxiliary incremental encoder.

  • Page 32: Auxiliary Feedback - Emulated, Differential Buffered Encoder Output Option (Ya[4]=4)

    Duo User Guide MAN-DUOUG (Ver. 1.0) 3.10.2 Auxiliary Feedback – Emulated, Differential Buffered Encoder Output Option (YA[4]=4) The Auxiliary Feedback's B2 port can provide emulated encoder signals to other controllers or drives. This option can be used when: A Resolver or Analog Encoder is used as a Main Feedback device. The Whistle is used as a current amplifier to provide position data to the position controller.
  • Page 33 Duo User Guide 3-21 MAN-DUOUG (Ver. 1.0) Figure 3-15: Emulated Encoder Outputs of the Resolver or Analog Encoder - Connection Diagram...

  • Page 34: Auxiliary Feedback - Differential Encoder Input Option (Ya[4]=2)

    Duo User Guide MAN-DUOUG (Ver. 1.0) 3.10.3 Auxiliary Feedback - Differential Encoder Input Option (YA[4]=2) The Whistle 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 of B1 for the next slave axis in Follower or ECAM mode.
  • Page 35 Duo User Guide 3-23 MAN-DUOUG (Ver. 1.0) Figure 3-6: Differential Auxiliary Input Option - Block Diagram...
  • Page 36 Duo User Guide 3-24 MAN-DUOUG (Ver. 1.0) Figure 3-16: Differential Auxiliary Input Option on Auxiliary Feedback - Connection Diagram...

  • Page 37: Auxiliary Feedback - Differential Pulse-And-Direction Input Option

    Duo User Guide MAN-DUOUG (Ver. 1.0) 3.10.4 Auxiliary Feedback – Differential Pulse-and-Direction Input Option (YA[4]=0) This mode is used for input of differential pulse-and-direction position commands on Port B1. In this mode Port B2 provides differential buffered pulse-and-direction outputs of B1 for another axis.
  • Page 38 Duo User Guide 3-26 MAN-DUOUG (Ver. 1.0) Figure 3-17: Pulse-and-Direction Input Option on Auxiliary Feedback - Connection Diagram...

  • Page 39: I/O

    Duo User Guide MAN-DUOUG (Ver. 1.0) 3.11 Each Whistle on the Duo has 6 digital inputs, 2 digital outputs and a single analog input. The I/O port has a 14-pin Molex Header plug with the following pin-outs. Signal Function OUT1 Programmable Digital output 1 OUTRET1 Programmable Digital output 1 return...

  • Page 40: Digital Input

    Duo User Guide MAN-DUOUG (Ver. 1.0) 3.11.1 Digital Input The Default Digital Input level Signal is set to 24v (PLC). Note: 5v is also available (TTL). Figure 3-18: Digital Input Connection Diagram 3-28...

  • Page 41: Digital Output

    Duo User Guide MAN-DUOUG (Ver. 1.0) 3.11.2 Digital Output Figure 3-19: Digital Output Connection Diagram 3.11.3 Analog Input Figure 3-20: Analog Input with Single-ended Source 3-29...

  • Page 42: Communications

    Duo User Guide MAN-DUOUG (Ver. 1.0) 3.12 Communications The communication cables use an 8-pin RJ-45 plug that connect to the RS232 and CANopen ports on the Duo. The communication interface may differ according to the user’s hardware. The Duo can communicate using the following options: 1.

  • Page 43: Canopen Communication

    Duo User Guide MAN-DUOUG (Ver. 1.0) 3.12.2 CANopen Communication Notes for connecting the CANopen communication cable: Use 26 or 28 AWG twisted pair shielded cables. should have aluminum foil and be covered by copper braid with a drain wire Connect the shield to the ground of the host (PC). Usually, this connection is soldered internally inside the connector at the PC end.
  • Page 44 Duo User Guide MAN-DUOUG (Ver. 1.0) Figure 3-22: CANopen Network Connection Diagram 3-32 Caution: When installing CANopen communications, ensure that each servo drive is allocated a unique ID. Otherwise, the CANopen network may hang.

  • Page 45: Powering Up

    After the Duo 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 46: Appendix A: Technical Specifications

    Sin / Cos Sin / Cos+Digital Halls Analog Halls Tacho Potentiometer • Communication Simultaneous operation of RS-232 and CANopen DS 402 User programming • User Programming Third-generation programming environment (language and Elmo Studio) • Encoder Inputs • Event capturing inputs...
  • Page 47 Duo Installation Guide MAN-DUOIG (Ver. 1.0) • Event triggered programming structure • Analog inputs 1 differential inputs with 12-bit resolution • Enable input, limit switches and emergency stop handling • Smart multi-purpose inputs Programmable as Enable, Forward and Reverse Limit Switches, Home, Capture •...

  • Page 48: Built-In Protection

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) Built-In Protection • Software error handling Software-based • Status reporting Available for a large number of fault conditions • Protection against: Short circuit between motor power outputs Short circuit between each motor power output and DC bus return Failure of internal power supply Heatsink over-temperature Under/over voltage...

  • Page 49: Duo Dimensions

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) Duo Dimensions...

  • Page 50: Power Ratings

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) Power Ratings Feature Unit Minimum supply voltage Nominal supply voltage Maximum supply voltage Max. output power from the drive without heatsink Efficiency at rate power Output Voltage DC and Trapezoidal Commutation Continuous Current Limit (Ic) Sinusoidal Commutation Continuous RMS Current Limit (Ic)

  • Page 51: A.5.1 Current Loop

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) Control Specifications A.5.1 Current Loop Feature Controller type Current sampling time Current loop bandwidth Compensation for bus voltage variations Motor types Current control Current loop step response (including settling time) Current rise time Details Vector, digital 70 - 100 μsec 1400 - 2500 Hz...

  • Page 52: A.5.2 Velocity Loop

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) A.5.2 Velocity Loop Feature Controller type Speed sampling time Velocity loop bandwidth Velocity control Velocity and position feedback options Velocity command options A.5.3 Position Loop Feature Controller type Position sampling time Analog input command resolution PWM resolution PWM switching frequency on...

  • Page 53: A.6.2 Feedback Supply Voltage

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) Feedbacks A.6.1 Incremental Encoder Feature Encoder format Interface: Input resistance: Maximum incremental encoder frequency: Minimum quadrature input period (P Minimum quadrature input high/low period (P Minimum quadrature phase period (P Maximum encoder input voltage range A.6.2 Feedback Supply Voltage...

  • Page 54: A.6.3 Digital Halls

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) A.6.3 Digital Halls Feature Halls inputs Input voltage Input current Maximum frequency A.6.4 Interpolated Analog Encoder (Sine/Cosine) Feature Analog encoder format Analog input signal level Input resistance Maximum analog signal frequency Interpolation multipliers Maximum “counts” frequency Automatic errors correction Details HA, HB, HC.

  • Page 55: A.6.6 Tachometer*

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) A.6.5 Resolver Feature Resolver format Input resistance Resolution Maximum electrical frequency (RPS) Resolver transfer ratio Reference frequency Reference voltage Reference current A.6.6 Tachometer* Feature Tachometer format Maximum operating differential voltage for TAC1+, TAC1- Maximum absolute differential input voltage for TAC1+, TAC1- Maximum operating differential voltage for TAC2+, TAC2-...

  • Page 56: A.6.8 Auxiliary Feedback Port (Output Mode Ya[4]= 4)

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) A.6.7 Potentiometer Feature Potentiometer Format Operating Voltage Range Potentiometer Resistance Input Resistance Resolution A.6.8 Auxiliary Feedback Port (output mode YA[4]= 4) Feature Emulated output Output current capability Available as options Maximum frequency Edge separation between A & B Index (marker): Figure A-1: Auxiliary Feedback - Encoder Phase Diagram Details...

  • Page 57: Auxiliary Feedback Port (Input Mode

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) A.6.9 Auxiliary Feedback Port (input mode YA[4]= 2, 0) Feature Encoder input, pulse and direction input Output current capability Encoder/Hall supply voltage Maximum encoder supply current Available as options Edge separation between A & B Index (marker): Figure A-2: Auxiliary Feedback - Encoder Phase Diagram Details...

  • Page 58: I/Os

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) I/Os A.7.1 Digital Input Interface – 6 Digital Inputs Feature Details Optically isolated Type of input All six inputs share one signal return line Input current Iin = 6.5 mA @ Vin = 24 V for all inputs 24 V Input voltage...

  • Page 59: A.7.3 Analog Inputs – 1 Analog Input

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) A.7.2 Digital Output Interface – 2 Digital Outputs Feature Type of output Maximum supply output (Vcc) Max. output current Iout (max) (Vout = Low) VOL at maximum output voltage (low level) Executable time A.7.3 Analog Inputs –...

  • Page 60: A.10 Compliance Standards

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) Mechanical Specifications Feature Mounting Overall dimensions Weight Environmental Conditions Feature Operating ambient temperature Storage temperature Humidity Maximum Operating Altitude Protection level A.10 Compliance Standards Specification ISO9001 A.10.1 Design Specification MIL-HDBK- 217F IPC-D-275 IPC-SM-782 IPC-CM-770 UL508c UL840 In compliance with VDE0160 -7...

  • Page 61: Safety

    Duo Installation Guide MAN-DUOIG (Ver. 1.0) A.10.2 Safety Specification Recognized UL508c In compliance with UL840 In compliance with UL60950 In compliance with EN60204-1 A.10.3 EMC Specification In compliance with IEC 1800-3, Part 3: 1996 (Adjustable speed electrical power-drive systems - EMC products standard, including specific test methods) Details...

  • Page 62: Appendix B: Cables (Optional)

    Duo Installation Guide Appendix B: Cables (Optional) Cable Photos Main Feedback: CBL- HDRFB-001 Auxiliary Feedback: CBL- HDRAUX-001 I/O: CBL- HDRIO-001 RS-232 Com.: CBL-RJ452321 CAN Com.: CBL-RJ45CAN1...

  • Page 63: Cable Kit

    MAN-DUO (Ver. 1.0) Cable Kit The cables are all 2m in length. Each set contains the cables listed below. Additional cable kit and/or individual cables (in multiples of 10 each) are available from Elmo. Cable Application Main Feedback Auxiliary Feedback...

  • Page 64: Main Feedback Cable (Cbl-Hdrfb-001

    Duo Installation Guide MAN-DUO (Ver. 1.0) Main Feedback Cable (CBL-HDRFB-001) The Main Feedback cable (CBL-HDRFB-001) is made of a 24-AWG shielded cable with a 12-pin Molex Header socket. It connects to the Main Feedback port on the Duo. It is open on its other side so that it can be connected to customer-specific motor connector.

  • Page 65: Auxiliary Feedback (Cbl-Hdraux-001

    Duo Installation Guide MAN-DUO (Ver. 1.0) Auxiliary Feedback (CBL-HDRAUX-001) The Auxiliary Feedback cable (CBL-HDRAUX-001) is made of a 24-AWG shielded cable with a 16-pin Molex Header socket. It connects to the Auxiliary Feedback port on the Duo. Color Brown White Cyan Orange Purple...

  • Page 66: B.5 I/O (Cbl-Hdrio-001)

    Duo Installation Guide MAN-DUO (Ver. 1.0) I/O (CBL-HDRIO-001) The I/O cable (CBL-HDRIO-001) is made of a 24-AWG shielded cable with a 14-pin Molex Header socket. It connects to the I/O port on the Duo. Color Orange Cyan Black Purple Brown White Green Yellow...

  • Page 67: B.6.1 Rs-232 Option (Cbl-Rj452321)

    Duo Installation Guide MAN-DUO (Ver. 1.0) Communication Cables The communication cables use 26-AWG twisted pair shielded cable. They are connected using an 8-pin RJ-45 plug. Elmo drives can communicate using the following options: RS-232 full duplex CANopen B.6.1 RS-232 Option (CBL-RJ452321)

  • Page 68: B.6.2 Can Open (Cbl-Rj45Can1)

    Duo Installation Guide MAN-DUO (Ver. 1.0) B.6.2 CAN Open (CBL-RJ45CAN1) RJ45 D-type Female Color Pin No. Green Yellow White — — — — body Drain Wire body The shields of the RJ-45 and D-type plugs are connected to each other through the cable braid.

  • Page 69: B.7.1 Recommended Wire Cross Sections

    Guidelines for Making Your Own Cables Proper wiring, grounding and shielding are essential for ensuring safe, immune and optimal servo performance of the Duo. If you do not plan to use cables provided by Elmo, follow the instructions below carefully.

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