Falcon Digital Servo Drive Installation Guide July 2014 (Ver. 1.502) www.elmomc.
Notice 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 Falcon servo drive in its installation. • The text and graphics included in this manual are for the purpose of illustration and reference only. The specifications on which they are based are subject to change without notice.
Revision History Version Details 1.0 Initial release 1.2 Aug 2008 Added 3.4.7.4: Differential Pulse-and-Direction Input 1.3 Sep 2008 MTCR 00-100-29: Added Table 7, Figure 16 and Figure 17 1.4 Mar 2010 MTCR 07-009-56: Added note to 3.4.8.2 1.5 July 2011 Formatted according to the new template 1.501 Feb 2013 Added a caution and recommendation on the type of cleaning solution to use for the Elmo unit. 1.
Elmo Worldwide Head Office Elmo Motion Control Ltd. 60 Amal St., P.O. Box 3078, Petach Tikva 49516 Israel Tel: +972 (3) 929-2300 • Fax: +972 (3) 929-2322 • info-il@elmomc.com North America Elmo Motion Control Inc. 42 Technology Way, Nashua, NH 03060 USA Tel: +1 (603) 821-9979 • Fax: +1 (603) 821-9943 • info-us@elmomc.com Europe Elmo Motion Control GmbH Hermann-Schwer-Strasse 3, 78048 VS-Villingen Germany Tel: +49 (0) 7721-944 7120 • Fax: +49 (0) 7721-944 7130 • info-de@elmomc.
Falcon Installation Guide MAN-FALIG (Ver. 1.502) Table of Contents Chapter 1: 1.1. 1.2. 1.3. 1.4. 1.5. Warnings......................................................................................................................... 8 Cautions .......................................................................................................................... 8 Directives and Standards ................................................................................................
Falcon Installation Guide Table of Contents MAN-FALIG (Ver. 1.502) 3.5. 3.6. 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.
Falcon Installation Guide 7 MAN-FALIG (Ver. 1.502) 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. Please read this chapter carefully before you begin the installation process.
Falcon Installation Guide Safety Information MAN-FALIG (Ver. 1.502) 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.
Safety Information Falcon Installation Guide MAN-FALIG (Ver. 1.502) 1.3.
Falcon Installation Guide Safety Information MAN-FALIG (Ver. 1.502) 1.4. CE Marking Conformance The Falcon 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 EN 60204-1 and EN 292-2 at the least.
Falcon Installation Guide 11 MAN-FALIG (Ver. 1.502) Chapter 2: I ntroduction This installation guide describes the Falcon servo drive and the steps for its wiring, installation and powering up. Following these guidelines ensures maximum functionality of the drive and the system to which it is connected. 2.1. Ex trI Q Product Family Elmo Motion Control’s ExtrIQ product family is a set of durable motion control products for applications operating under extreme environmental conditions.
Falcon Installation Guide Introduction MAN-FALIG (Ver. 1.502) ExtrIQ products have a high power density in the range from 50 W to 18,000 W and a current carrying capacity of up to 140 A (280 A peak).
Falcon Installation Guide Introduction MAN-FALIG (Ver. 1.502) 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.
Introduction Falcon Installation Guide MAN-FALIG (Ver. 1.502) 2.3.5.
Introduction Falcon Installation Guide MAN-FALIG (Ver. 1.502) 2.4. System Architecture Tachometer Communication RS 232 and CANopen or Potentiometer or Analog Encoder or Resolver or Incremental Encoder Controller I/Os Protection PWM Auxiliary Power Supply Current Feedback Power Stage 24 VDC Auxiliary Encoder Incremental Encoder Buffered Output or Emulated Output Figure 1: Falcon System Block Diagram 2.5.
Falcon Installation Guide Introduction MAN-FALIG (Ver. 1.502) Figure 2: Elmo Documentation Hierarchy As depicted in the previous figure, this installation guide is an integral part of the Falcon documentation set, comprising: • 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.
Falcon Installation Guide 17 MAN-FALIG (Ver. 1.502) 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.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) Component Wire Described in Section 24 Vred/black 3.4.3 Main Feedback Cable FEEDBACK A 3.4.5 Auxiliary Feedback Cable (if needed) FEEDBACK B 3.4.7 Digital I/O Cable (if needed) GENERAL I/O J1 3.4.8.1 Digital Inputs and Analog Inputs Cable (if needed) GENERAL I/O J2 3.4.8.2 RS232 Communicatio n Cable RS-232 3.4.9.1 Backup Supply Cable (if needed) Drawing www.elmomc.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) Component CAN Communicatio n cable(s) (if needed) Wire CAN (in) CAN (out) Described in Section Drawing 3.4.9.2 PC for drive setup and tuning Motor data sheet or manual 3.2.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) The P/N number at the top gives the type designation as follows: FAL- XX/YYY R Continuous Current (Amps) Maximum DC Operating Voltage Feedback: Blank = Incremental Encoder and/or Halls R = Resolver I = Interpolated Analog Encoder T = Tachometer & Potentiometer Q = Absolute Encoder 4. Verify that the Falcon type is the one that you ordered, and ensure that the voltage meets your specific requirements. 3.3.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) 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: • Use twisted pair shielded cables for control, feedback and communication connections.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) 22 The following connectors are used for wiring the Falcon.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) Figure 4: Falcon Detailed Connection Diagram www.elmomc.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) 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.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) 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: • Be sure to isolate the source of the DC power supply.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) 3.4.3. Connecting the Optional Backup Supply Cable (24 V) 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.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) “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. 3.4.4. Feedback and Control Cable Assemblies The Falcon features easy-to-use D-Sub type connections for all Control and Feedback cables.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) 28 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).
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) Figure 10: Main Feedback – Interpolated Analog (Sine/Cosine) Encoder Connection Diagram Figure 11: Main Feedback – Resolver Connection Diagram www.elmomc.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) 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.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) 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.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) Figure 16: Main Feedback – Stegmann Feedback Connection Diagram www.elmomc.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) Figure 17: Main Feedback – Heidenhain Feedback Connection Diagram www.elmomc.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) 3.4.6. 35 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.
Installation Falcon Installation Guide 36 MAN-FALIG (Ver. 1.502) FEEDBACK A FEEDBACK B Ports B1 and B2 YA[4] = 4 Software Setting Potentiometer Input B1 - output Potentiometer Position Data Emulated in Incremental Encoder Format (signals are quadrature, differential & buffered) A - input Potentiometer Typical Applications 3.4.7.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) Figure 18: Main Encoder Buffered Output or Emulated Encoder Output on FEEDBACK B Connection Diagram www.elmomc.
Falcon Installation Guide Installation 39 MAN-FALIG (Ver. 1.502) 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.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) Figure 19: Differential Auxiliary Encoder Input Option on FEEDBACK B – Connection Diagram www.elmomc.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) 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.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) Figure 20: Single-Ended Auxiliary Input Option on FEEDBACK B – Connection Diagram www.elmomc.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) 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.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) Figure 21: Pulse-and-Direction Input Option on FEEDBACK B – Connection Diagram www.elmomc.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) Figure 22: Differential Pulse-and-Direction Input Option on FEEDBACK B – Connection Diagram www.elmomc.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) 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: I/O J1 Port J2 Port Total Digital Input 6 4 10 Digital Output 5 - 5 Analog Input - 2 2 3.4.8.1. General I/O Port (J1) Port J1 has a 15-pin high density D-Sub plug.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) Figure 23: General J1 I/O Connection Diagram www.elmomc.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) 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). Note: Analog Inputs 1 and 2 are functionally identical. However, note that the velocity and current commands can only be given on Analog Input 1.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) Figure 24: General Input J2 Connection Diagram www.elmomc.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) 3.4.9. Communication Cables The communication cables use an 8-pin RJ-45 plug that connect to the RS-232 and CAN 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. RS-232, full duplex b. CAN RS-232 communication requires a standard, commercial 3-core null-modem cable connected from the Falcon to a serial interface on the PC.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) Figure 25: RS-232 Connection Diagram 3.4.9.2. CAN Communication Notes for connecting the CAN 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). Usually, this connection is soldered internally inside the connector at the PC end.
Installation Falcon Installation Guide MAN-FALIG (Ver. 1.502) Caution: When installing CAN communications, ensure that each servo drive is allocated a unique ID. Otherwise, the CAN network may hang. Figure 26: CAN Connection Diagram www.elmomc.
Falcon Installation Guide Installation MAN-FALIG (Ver. 1.502) 3.5. Powering Up After the Falcon has been mounted, check that the cables are intact. The Falcon 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 Falcon and that the proper plus-minus connections are in order. 3.6. Initializing the System After the Falcon has been connected and mounted, the system must be set up and initialized.
Falcon Installation Guide 55 MAN-FALIG (Ver. 1.502) 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. Features The Falcon's features determine how it controls motion, as well as how it processes host commands, feedback and other input. 4.1.1.
Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.502) 4.1.5.
Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.502) 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 Failure of internal power supplies Overheating Over/Under voltage Loss of feedback Following error Current limits www.elmomc.
Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.502) 4.2. Falcon Dimensions www.elmomc.
Technical Specifications Falcon Installation Guide MAN-FALIG (Ver. 1.502) 4.3.
Technical Specifications Falcon Installation Guide MAN-FALIG (Ver. 1.502) 4.4.
Technical Specifications Falcon Installation Guide MAN-FALIG (Ver. 1.502) Pins Type Port Connector Location 15 D-Sub Socket FEEDBACK A 15 High Density D-Sub Plug J1 15 High Density D-Sub Socket J2 J2: I/O J1: I/O Feedback A Table 18: Connectors on the Front of the Falcon Pins Type Port Connector Location 8 RJ-45 CAN 8 RJ-45 CAN 15 High Density D-Sub Socket 8 RJ-45 FEEDBACK B RS-232 CAN Feedback B RS-232 Table 19: Connectors on the Top of the Falcon 4.5.1.
Technical Specifications Falcon Installation Guide MAN-FALIG (Ver. 1.502) 4.6. Control Specifications 4.6.1.
Technical Specifications Falcon Installation Guide MAN-FALIG (Ver. 1.502) 4.6.2.
Technical Specifications Falcon Installation Guide MAN-FALIG (Ver. 1.502) 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.
Technical Specifications Falcon Installation Guide MAN-FALIG (Ver. 1.502) 4.7.3. Digital Halls Feature Details Halls inputs • HA, HB, HC. • Single ended inputs • Built in hysteresis for noise immunity. Input voltage Nominal operating range: 0 V < VIn_Hall < 5 V Maximum absolute: -1 V < VIn_Hall < 15 V High level input voltage: V InHigh > 2.5 V Low level input voltage: V InLow < 1 V Input current Sink current (when input pulled to the common): 3 mA Source current: 1.
Technical Specifications Falcon Installation Guide MAN-FALIG (Ver. 1.502) 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 0.5 Reference frequency 1/Ts (Ts = sample time in seconds) Reference voltage Supplied by the Falcon Reference current up to ±50 mA 4.7.6.
Technical Specifications Falcon Installation Guide MAN-FALIG (Ver. 1.502) 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 Resolution 14 bit 4.7.8.
Technical Specifications Falcon Installation Guide MAN-FALIG (Ver. 1.502) 4.8. I/Os The Falcon has: • 10 Digital Inputs • 5 Digital Outputs • 2 Analog Input 4.8.1. Digital Input Interfaces Feature Type of input Details • Optically isolated • Single ended • PLC level Input current * Iin = 2.2 mA for Vin = 12 V Input current for high speed inputs * Iin = 4.4 mA for Vin = 12 V High-level input voltage 12 V < Vin < 30 V, 24 V typical Low-level input voltage 0 V < Vin < 6.
Technical Specifications Falcon Installation Guide MAN-FALIG (Ver. 1.502) Feature Details Connector location J2: General purpose I/O J1: General purpose I/O Rin = 2.5K General input return Figure 28: Digital Input Schematic 4.8.2. Digital Output Interface Feature Type of output Details Connector Location • Optically isolated • Open collector and open emitter Maximum supply output (VCC) 30 V Max.
Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.502) Feature Details 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 Connector Location If output is set to General output and is executed from a program, the typical time is approximately 0.5 msec. Digital Output Schematic 4.8.3.
Technical Specifications Falcon Installation Guide MAN-FALIG (Ver. 1.502) 4.9. Communications Specification Details RS-232 Signals: • RxD , TxD , GND CAN Connector Location • Full duplex, serial communication for setup and control. CAN port • Baud Rate of 9,600 to 115,200 bit/sec. CAN port CAN bus Signals: • CAN_H, CAN_L, CAN_GND • Maximum Baud Rate of 1 Mbit/sec. Version: • DS 301 V4.01 RS-232 port Device Profile (drive and motion control): • DS 402 4.10.
Technical Specifications Falcon Installation Guide MAN-FALIG (Ver. 1.502) 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.
Falcon Installation Guide Technical Specifications MAN-FALIG (Ver. 1.
