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Elmo ExtrIQ line Installation Manual

Digital servo drive
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Falcon

Digital Servo Drive

Installation Guide

July 2012 (Ver. 1.5)
www.elmomc.com

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  • Page 1: Digital Servo Drive

    Falcon Digital Servo Drive Installation Guide July 2012 (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 registered trademarks of Elmo Motion Control Ltd. • Information in this document is subject to change without notice.

  • Page 3: Revision History

    Revision History Version Details Initial Release August 2008 Added 3.4.7.4: Differential Pulse-and-Direction Input September MTCR 00-100-29: Added Table 7, Figure 16 and Figure 17 2008 March 2010 MTCR 07-009-56: Added note to 3.4.8.2 July 2011 Formatted according to the new template...
  • 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

    Falcon Installation Guide MAN-FALIG (Ver. 1.5) 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 ..................... 10 1.5. Warranty Information ....................10 Chapter 2: Introduction ....................

  • Page 6: Table Of Contents

    Falcon Installation Guide Table of Contents MAN-FALIG (Ver. 1.5) 3.4.7.4. Pulse-and-Direction Input Option on FEEDBACK B (YA[4]=0) ..43 3.4.8. I/O Cables ...................... 47 3.4.8.1. General I/O Port (J1) ..............47 3.4.8.2. General Input Port (J2) ..............49 3.4.9. Communication Cables .................. 51 3.4.9.1.

  • Page 7: Chapter 1: Safety Information

    Falcon Installation Guide MAN-FALIG (Ver. 1.5) Chapter 1: Safety I nform ation In order to achieve the optimum, safe operation of the Falcon 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 Falcon and accompanying equipment.

  • Page 8: Warnings

    Falcon Installation Guide Safety Information MAN-FALIG (Ver. 1.5) 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 Falcon from all voltage sources before it is opened for servicing.

  • Page 9: Directives And Standards

    Quality Management The Falcon servo drive has been developed, produced, tested and documented in accordance with the relevant standards. Elmo Motion Control is not responsible for any deviation from the configuration and installation described in this documentation. Furthermore, Elmo is not responsible for the performance of new measurements or ensuring that regulatory requirements are met.

  • Page 10: Ce Marking Conformance

    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 11: Chapter 2: Introduction

    Ex trI Q 2.1. Product Family Elmo Motion Control’s ExtrIQ product family is a set of durable motion control products for applications operating under extreme environmental conditions. The products are capable of withstanding the following extreme conditions: Feature...

  • Page 12: Drive Description

    • MIL-HDBK-217 – Reliability Prediction of Electronic Equipment • ISO-9001:2008 Based on Elmo Motion Control's innovative ExtrIQ core technology, they support a wide range of motor feedback options, programming capabilities and communication protocols. 2.2. Drive Description The Falcon is a series of highly durable and intelligent servo drives. Designed for OEMs, the Falcon is part of the Elmo’s ExtrIQ product line designed to endure extended environmental...

  • Page 13: Product Features

    Falcon Installation Guide Introduction MAN-FALIG (Ver. 1.5) 2.3. Product Features 2.3.1. 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 2.3.2.

  • Page 14: Feedback Options

    0 V to 5 V voltage range  Resistance: 100 Ω to 1000 Ω  • Elmo drives provide supply voltage for all the feedback options. 2.3.6. Fault Protection The Falcon includes built-in protection against possible fault conditions, including: •...

  • Page 15: System Architecture

    2.5. How to Use this Guide In order to install and operate your Elmo Falcon 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...
  • Page 16 • 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 Falcon motion controller.

  • Page 17: Chapter 3: Installation

    Falcon Installation Guide MAN-FALIG (Ver. 1.5) Chapter 3: I nstallation The Falcon 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 Falcon by ensuring that it is installed in an appropriate environment.
  • Page 18 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Component Wire Described Drawing in Section Backup Supply 24 V- 3.4.3 Cable (if red/black needed) Main FEEDBACK A 3.4.5 Feedback Cable Auxiliary FEEDBACK B 3.4.7 Feedback Cable (if needed) Digital I/O GENERAL 3.4.8.1 Cable (if needed) Digital Inputs...

  • Page 19: Unpacking The Drive Components

    Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Component Wire Described Drawing in Section CANopen CAN (in) 3.4.9.2 Communicatio CAN (out) n cable(s) (if needed) PC for drive setup and tuning Motor data sheet or manual 3.2. Unpacking the Drive Components Before you begin working with the Falcon system, verify that you have all of its components, as follows: •...

  • Page 20: Mounting The Falcon

    Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) The P/N number at the top gives the type designation as follows: FAL- XX/YYY Continuous Current Feedback: (Amps) Blank = Incremental Maximum DC Encoder Operating Voltage and/or Halls R = Resolver I = Interpolated Analog Encoder T = Tachometer &...

  • Page 21: Connecting The Cables

    Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) 3.4. Connecting the Cables The Falcon has ten connectors. 3.4.1. Wiring the Falcon Once the Falcon 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 Falcon. Caution: Follow these instructions to ensure safe and proper wiring: •...
  • Page 22 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) The following connectors are used for wiring the Falcon. Type Function Port Connector Location 5-Pin Phoenix (first 2 Power VP+, PR pins) (provided) 5-Pin Phoenix (last 3 Motor M1, M2, M3 pins) (provided) 3 ground screws Ground PE, PE, PE...
  • Page 23 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Figure 4: Falcon Detailed Connection Diagram www.elmomc.com...

  • Page 24: Connecting The Power Cables

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

  • Page 25: Connecting The Main Power Cable

    Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) 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 Falcon’s heatsink. Notes for connecting the DC power supply: •...

  • Page 26: Connecting The Optional Backup Supply Cable (24V)

    Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) 3.4.3. Connecting the Optional Backup Supply Cable (24v) Power to the Falcon is provided by a 10 to 195 VDC source. A “smart” control-supply algorithm enables the Falcon to operate with the power supply only, with no need for an auxiliary 24 volt supply.

  • Page 27: Feedback And Control Cable Assemblies

    Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) “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 (13 V min to 40 V max) supply for backing up the control parameters if DC power is shut off.
  • Page 28 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) FEEDBACK A on the “front” of the Falcon 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 29 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Absolute Encoders FAL-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 Sine A Sine A complement DATA- Data complement...
  • Page 30 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Figure 10: Main Feedback – Interpolated Analog (Sine/Cosine) Encoder Connection Diagram Figure 11: Main Feedback – Resolver Connection Diagram www.elmomc.com...
  • Page 31 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Figure 12: Main Feedback – Tachometer Feedback with Digital Hall Sensor Connection Diagram for Brushless Motors Figure 13: Main Feedback – Tachometer Feedback Connection Diagram for Brush Motors www.elmomc.com...
  • Page 32 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Figure 14: Main Feedback – Potentiometer Feedback with Digital Hall Sensor Connection Diagram for Brushless Motors Figure 15: Main Feedback – Potentiometer Feedback Connection Diagram for Brush Motors and Voice Coils www.elmomc.com...
  • Page 33 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Figure 16: Main Feedback – Stegmann Feedback Connection Diagram www.elmomc.com...
  • Page 34 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Figure 17: Main Feedback – Heidenhain Feedback Connection Diagram www.elmomc.com...

  • Page 35: Main And Auxiliary Feedback Combinations

    Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) 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 Falcon, “FEEDBACK B” has two ports, Port B1 and Port B2.

  • Page 36: Auxiliary Feedback (Feedback B)

    Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) FEEDBACK A FEEDBACK B Ports B1 and B2 Software YA[4] = 4 YA[4] = 2 YA[4] = 0 Setting Potentiometer - output Potentiometer Input Differential Differential or Position Single-ended Data Emulated Pulse & Single-ended in Incremental Direction...
  • Page 37 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) 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 Auxiliary channel A low output CHA-...
  • Page 38 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Figure 18: Main Encoder Buffered Output or Emulated Encoder Output on FEEDBACK B - Connection Diagram www.elmomc.com...

  • Page 39: Differential Auxiliary Encoder Input Option On Feedback B (Ya[4]=2)

    Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) 3.4.7.2. Differential Auxiliary Encoder Input Option on FEEDBACK B (YA[4]=2) The Falcon 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 40 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Figure 19: Differential Auxiliary Encoder Input Option on FEEDBACK B – Connection Diagram www.elmomc.com...

  • Page 41: Single-Ended Auxiliary Input Option On Feedback B (Ya[4]=2)

    Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) 3.4.7.3. Single-Ended Auxiliary Input Option on FEEDBACK B (YA[4]=2) The Falcon 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 42 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Figure 20: Single-Ended Auxiliary Input Option on FEEDBACK B – Connection Diagram www.elmomc.com...

  • Page 43: Pulse-And-Direction Input Option On Feedback B (Ya[4]=0)

    Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) 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 44 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Figure 21: Pulse-and-Direction Input Option on FEEDBACK B – Connection Diagram www.elmomc.com...
  • Page 45 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Below are the signals on the Auxiliary Feedback ports when set up to run as a 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 46 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Figure 22: Differential Pulse-and-Direction Input Option on FEEDBACK B – Connection Diagram www.elmomc.com...

  • Page 47: I/O Cables

    Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) 3.4.8. I/O Cables The Falcon 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 (Sine/Cosine) inputs: J1 Port J2 Port...
  • Page 48 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Figure 23: General J1 I/O Connection Diagram www.elmomc.com...

  • Page 49: General Input Port (J2)

    Falcon Installation Guide Installation MAN-FALIG (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 50 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Figure 24: General Input J2 Connection Diagram www.elmomc.com...

  • Page 51: Communication Cables

    Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) 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 Falcon. The communication interface may differ according to the user’s hardware. The Falcon can communicate using the following options: a.

  • Page 52: Canopen Communication

    Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) 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 •...
  • Page 53 Falcon Installation Guide Installation MAN-FALIG (Ver. 1.5) Caution: When installing 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 54: Powering Up

    After the Falcon 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 55: Chapter 4: Technical Specifications

    Falcon Installation Guide MAN-FALIG (Ver. 1.5) Chapter 4: Technical Specifications This chapter provides detailed technical information regarding the Falcon. 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 56: 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 57: Built-In Protection

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) 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 58: Falcon Dimensions

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) 4.2. Falcon Dimensions www.elmomc.com...

  • Page 59: Power Ratings

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) 4.3. Power Ratings Feature Units 15/60 30/60 15/100 30/100 15/200 Minimum supply voltage Nominal supply voltage Maximum supply voltage Maximum continuous power 1440 1200 2400 2400 output Efficiency at > 97 rated power (at nominal conditions) Maximum output voltage 97% of DC bus voltage at f=22 kHz...

  • Page 60: Environmental Conditions

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) 4.4. Environmental Conditions Feature Operation Conditions Range Ambient Non-operating conditions -50 °C to +100 °C (-58 °F to 212 °F) Temperature Operating conditions -40 °C to +70 °C (-40 °F to 160 °F) Range Temperature Non-operating conditions...

  • Page 61: Backup Supply (Optional)

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) Pins Type Port Connector Location D-Sub Socket FEEDBACK A High Density D-Sub Plug High Density D-Sub Socket J2: I/O J1: I/O Feedback A Table 18: Connectors on the Front of the Falcon Pins Type Port Connector Location...

  • Page 62: Control Specifications

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) 4.6. Control Specifications 4.6.1. Current Loop Feature Details Controller type Vector, digital Compensation for bus voltage “On-the-fly” gain scheduling variations Motor types • AC brushless (sinusoidal) • DC brushless (trapezoidal) • DC brush •...

  • Page 63: Velocity Loop

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) 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 •...

  • Page 64: Feedbacks

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) 4.7. Feedbacks The Falcon 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 65: Digital Halls

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) 4.7.3. Digital Halls Feature Details Halls inputs • H • 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 <...

  • Page 66: Resolver

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) 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 Falcon...

  • Page 67: Potentiometer

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) 4.7.7. Potentiometer Feature Details Potentiometer Format Single-ended Operating Voltage Range 0 V to 5 V supplied by the Falcon Potentiometer Resistance 100 Ω to 1 kΩ … above this range, linearity is affected detrimentally Input Resistance 100 kΩ...

  • Page 68: I/Os

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) 4.8. I/Os The Falcon has: • 10 Digital Inputs • 5 Digital Outputs • 2 Analog Input 4.8.1. Digital Input Interfaces Feature Details Type of input • Optically isolated • Single ended •...

  • Page 69: Digital Output Interface

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) Feature Details Connector location J2: General J1: General purpose I/O purpose I/O Rin = 2.5K General input return Figure 28: Digital Input Schematic 4.8.2. Digital Output Interface Feature Details Connector Location Type of output •...

  • Page 70: Analog Input

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) Feature Details Connector Location Executable time If output is set to one of the built-in functions — Home flag, Brake or AOK — execution is immediate upon detection: 0 < T < 4 x TS If output is set to General output and is executed from a program, the typical time is approximately 0.5...

  • Page 71: Communications

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) 4.9. Communications Specification Details Connector Location Signals: RS-232 • RxD , TxD , GND • Full duplex, serial communication for CANopen setup and control. port • Baud Rate of 9,600 to 115,200 CANopen port bit/sec.

  • Page 72: 4.12. Compliance With Standards

    Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.5) 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.) •...
  • Page 73 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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