Solo Hornet Digital Servo Drive Installation Guide July 2014 (Ver. 1.003) 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 Solo Hornet 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 Date Details 1.0 Sep 2012 Initial release 1.001 Jan 2013 Updated the auxiliary voltage value Added a caution and recommendation on the type of cleaning solution to use for the Elmo unit. 1.002 Apr 2013 Small changes to Diferential RS-232 Communication 1.003 July 2014 General format update 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.
Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) Table of Contents Chapter 1: 1.1. 1.2. 1.3. 1.4. 1.5. Warnings.....................................................................................................................8 Cautions ......................................................................................................................8 Directives and Standards ............................................................................................9 CE Marking Conformance .
Solo Hornet Installation Guide Table of Contents MAN-SOLHRNIG (Ver. 1.003) 4.8.1.1. Digital Input 5 V (TTL) .............................................................. 42 4.8.1.2. Digital Input 24 V (PLC) ............................................................ 43 4.8.2. Digital Output ........................................................................................... 44 4.8.3. Analog Input ............................................................................................. 45 4.
Solo Hornet Installation Guide Table of Contents MAN-SOLHRNIG (Ver. 1.003) 5.7. 5.8. 5.9. 5.6.1. Digital Input Interfaces ............................................................................. 66 5.6.2. Digital Output Interface ............................................................................ 67 5.6.3. Analog Input ............................................................................................. 68 Communications .............................................................
Solo Hornet Installation Guide 7 MAN-SOLHRNIG (Ver. 1.003) Chapter 1: Safety I nform ation In order to achieve the optimum, safe operation of the Solo Hornet 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 Solo Hornet as well as the accompanying equipment. Please read this chapter carefully before you begin the installation process.
Solo Hornet Installation Guide Safety Information MAN-SOLHRNIG (Ver. 1.003) 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 Solo Hornet from all voltage sources before it is opened for servicing. • The Solo Hornet servo drive contains grounding conduits for electric current protection.
Safety Information Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 1.3.
Solo Hornet Installation Guide 10 MAN-SOLHRNIG (Ver. 1.003) Chapter 2: I ntroduction The Solo Hornet is an integrated solution designed to simply and efficiently connect Elmo’s Hornet servo drive directly to the application. The solution consists of the Hornet together with a convenient connection interface which either eliminates or reduces development time and resources when designing an application’s PCB board.
Solo Hornet Installation Guide Introduction MAN-SOLHRNIG (Ver. 1.003) The Solo Hornet drive is available in two models: • The standard model is a basic servo drive which operates in current, velocity and position modes including PT & PVT. It operates simultaneously via RS-232/RS-422 and CAN DS-301, DS-305, DS-402 communications and features a third-generation programming environment.
Solo Hornet Installation Guide Introduction MAN-SOLHRNIG (Ver. 1.003) 2.2.4. Advanced Position Control This relates to the Advanced model only. • Position-based and time-based ECAM mode that supports a non-linear follower mode, in which the motor tracks the master motion using an ECAM table stored in flash memory • Dual (position/velocity) loop 2.2.5.
Introduction Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 2.3. System Architecture Communication RS-232/RS-422 and CANopen Potentiometer or Tachometer or Analog Encoder or Resolver I/Os or Main 12~95 VDC Power Supply Incremental Encoder Controller Auxilliary Encoder Optional 12~95 VDC Auxiliary Supply Protection PWM Current Feedback Power Stage Motor Figure 1: Solo Hornet System Block Diagram 2.4.
Introduction Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) Figure 2: Elmo Digital Servo Drive Documentation Hierarchy As depicted in the previous figure, this installation guide is an integral part of the Solo Hornet documentation set, comprising: • The Composer Software Manual, which includes explanations of all the software tools that are part of Elmo’s Composer software environment.
Solo Hornet Installation Guide 15 MAN-SOLHRNIG (Ver. 1.003) Chapter 3: Technical I nform ation Minimum supply voltage VDC 6 7.5 12 Nominal supply voltage VDC 42 50 85 Maximum supply voltage VDC 48 59 95 Maximum continuous power output W Efficiency at rated power (at nominal conditions) % 600 800 240 480 960 200 400 1200 > 95% of DC bus voltage at f=22 kHz VDC 11 – 95 VDC (up to 2.5 VA inc.
Installation Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) Chapter 4: I nstallation The Solo Hornet must be installed in a suitable environment and properly connected to its voltage supplies and the motor. 4.1. Site Requirements You can guarantee the safe operation of the Solo Hornet drive by ensuring that it is installed in an appropriate environment.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 3. To ensure that the Solo Hornet drive you have unpacked is the appropriate type for your requirements, locate the part number sticker on the side of the Solo Hornet. The part number at the top gives the type designation as follows: 4. Verify that the Solo Hornet model is the one that you ordered, and ensure that the voltage meets your specific requirements. www.elmomc.
Installation Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 4.3. Connector Types The Solo Hornet has two connectors (in the connectors version). Pins 6 Type Port Nicomatics CM220 6HP/12 Pins Function J1 Motor Power and Main Feedback J2 I/O, Communication and Aux Feedback 2x6 2 x 15 Nicomatics CM220 2 x 15 Pins Connector Locations J1 J2 Table 1: Connector Types www.elmomc.
Installation Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 4.4. Main and Motor Power – J1 and J2 Pin (J1) Signal Function P1 VP+ Pos.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.4.1. Connecting Main Power Power to the Solo Hornet is provided by an 11 to 95 VDC source. A smart control-supply algorithm enables the Solo Hornet to operate with the power supply only, with no need for an auxiliary 24 volt supply. If backup functionality is required (for storing control parameters in case of power-outs) an additional backup supply can be connected by implementing "diode coupling" to the VL+.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.5. 4.5.1. Motor Power Connecting Motor Power Connect the M1, M2, M3 and PE pins on the Solo Hornet. The phase connection is arbitrary as the Composer will establish the proper commutation automatically during setup. However, if you plan to copy the setup to other drives, then the phase order on all copy drives must be the same. Figure 4: AC Motor Power Connection Diagram www.elmomc.
Installation Solo Hornet Installation Guide 22 MAN-SOLHRNIG (Ver. 1.003) 4.6. Main Feedback – J1 The Main Feedback port is used to transfer feedback data from the motor to the drive. In order to copy the setup to other drives, the phase order on all copy drives must be the same.
Installation Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) Incremental Encoder Interpolated Analog Encoder Resolver 23 Tachometer and Potentiometer Pin Positions Table 2: Main Feedback Pin Assignments Figure 5: Main Feedback- Incremental Encoder with Digital Hall Sensor Connection Diagram www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) Figure 6: Main Feedback – Interpolated Analog (Sine/Cosine) Encoder Connection Diagram Figure 7: Main Feedback – Interpolated Analog (Sine/Cosine) Encoder with Digital Hall Sensor Connection Diagram www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) Figure 8: Main Feedback – Resolver Connection Diagram www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) Figure 9: Main Feedback – Resolver with Digital Hall Sensor Connection Diagram www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) Figure 10: Main Feedback – Tachometer Feedback with Digital Hall Sensor Connection Diagram for Brushless Motors Figure 11: Main Feedback – Tachometer Feedback Connection Diagram for Brush Motors www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) Figure 12: Main Feedback, Potentiometer Feedback with Digital Hall Sensor Connection Diagram for Brushless Motors Figure 13: Main Feedback, Potentiometer Feedback Connection Diagram for Brush Motors and Voice Coils www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.7.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.
Installation Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 4.7.1. Auxiliary Feedback Operation Modes There are two modes of operation for the Solo Hornet: • Mode 1: Auxiliary output (Composer command: YA[4]=4) – see Section 4.7.2 For SOL-HORXXX/YYYY51 to SOL-HORXXX/YYYY52 And SOL-HORXXX/YYYY55 to SOL-HORXXX/YYYY56 Differential emulated encoder outputs are used to provide emulated encoder signals to another controller or drive.
Installation Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 4.7.2. 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 Solo Hornet has three bidirectional pins (CHA, CHB and INDEX).
Installation Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.
Installation Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.7.3. Pin (J2) Auxiliary Feedback: Emulated Encoder Output Option (YA[4]=4) Signal Function 3 PE Protective Earth 24 COMRET Common Return 5 CHA Buffered Channel A output 4 CHA- Buffered Channel A complement output 19 CHB Buffered Channel B output 20 CHB- Buffered Channel B complement output 8 INDEX Buffered Index output 9 INDEX- Buffered Index complement output Pin Positions www.elmomc.
Installation Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) Figure 14: Emulated Encoder Differential Output Diagram www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.7.4. Pin (J2) Auxiliary Feedback: Differential Encoder Input Option (YA[4]=2) Signal Function 3 PE Protective Earth 24 COMRET Common Return 5 CHA Auxiliary channel A Input 4 CHA- Auxiliary channel A complement input 19 CHB Auxiliary channel B input 20 CHB- Auxiliary channel B complement input 8 INDEX Auxiliary Index input 9 INDEX- Auxiliary Index complement Input Pin Positions www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) Figure 15: Differential Auxiliary (Controller) Encoder Input Option Diagram Figure 16: Differential Auxiliary (Incremental) Encoder Input Option Diagram www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.7.5. Pin (J2) Auxiliary Feedback: Differential Pulse-and-Direction Input Option (YA[4]=0) Signal Function 3 PE Protective Earth 24 COMRET Common Return 5 CHA Auxiliary Pulse input 4 CHA- Auxiliary Pulse complement input 19 CHB Auxiliary Direction input 20 CHB- Auxiliary Direction complement input 8 INDEX NA 9 INDEX- NA Pin Positions www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) Figure 17: Pulse-and-Direction Diagram www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.8. I/Os The Solo Hornet has four digital inputs, two digital outputs and one analog input. 4.8.1. Digital Input (J2) The digital input level signal can be 5 V (TTL).
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.8.1.1. Digital Input 5 V (TTL) Figure 18: Digital Input 5 V Connection Diagram www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.8.1.2. Digital Input 24 V (PLC) Figure 19: Digital Input 24 Connection Diagram www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.8.2. Pin (J2) Digital Output Signal Function 10 OUT1 Programmable digital output 1 11 OUTRET1 Programmable digital output return 1 12 OUT2 Programmable digital output 2 13 OUTRET2 Programmable digital output return 2 Pin Positions Table 4: Digital Output Pin Assignment Figure 20: Digital Output Connection Diagram www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.8.3. Analog Input Pin (J2) Signal Function 22 ANLIN1+ Analog input 1+ 23 ANLIN1- Analog input 1- 21 ANLRET Analog return Pin Positions Table 5: Analog Input Pin Assignments Figure 21: Analog Input with Single-Ended Source www.elmomc.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.9. Communications The communication interface may differ according to the user’s hardware. The Solo Hornet can communicate using the following options: a. RS-232, full duplex b. RS-422, Differential RS-232 c. CAN RS-232 communication requires a standard, commercial 3-core null-modem cable connected from the Solo Hornet to a serial interface on the PC. The interface is selected and set up in the Composer software.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.9.1. RS-232 Communication (J2) Notes for connecting the RS-232 communication cable: • Connect the shield to the ground of the host (PC). Usually, this connection is soldered internally inside the connector at the PC end. You can use the drain wire to facilitate connection. • The RS-232 communication port is non-isolated.
Installation Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 4.9.2. Differential RS-232 Communication (RS-422) – J2 Note for connecting the RS-232 communication cable: • This is Differential RS-232 Communication based on RS-422. Connect the shield to the ground of the Controller. Usually, this connection is soldered internally inside the connector at the PC end. You can use the drain wire to facilitate connection.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.9.3. CAN Communication (J2) Notes for connecting the CAN communication cable: • Connect the shield to the ground of the host (PC). Usually, this connection is soldered internally inside the connector at the PC end. You can use the drain wire to facilitate connection. • Make sure to have a 120-Ω resistor termination at each of the two ends of the network cable. • The Solo Hornet’s CAN ports are non-isolated.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) Figure 24: CAN Network Diagram Caution: When installing CAN communication, ensure that each servo drive is allocated a unique ID. Otherwise, the CAN network may hang. www.elmomc.
Installation Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 4.10. Powering Up After the Solo Hornet is connected to its device, it is ready to be powered up. Caution: Before applying power, ensure that the DC supply is within the specified range and that the proper plus-minus connections are in order. 4.11. Initializing the System After the Solo Hornet has been connected and mounted, the system must be set up and initialized.
Installation Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 4.12.2. Heat Dissipation Data Heat dissipation is shown in graphically below: Whistle - 60 Series Power Dissipation Solo Hornet 50V 40V 30V 20V 10.0 Power Dissipation (Watts 9.0 8.0 7.0 External Heatsink Required 6.0 5.0 4.0 Standard 40 °C Ambient Temp. Heatsink not Required 3.0 2.0 1.0 0.0 0 0. 75 1. 5 2. 25 3 3. 75 4. 5 5. 25 6 6. 75 7. 5 8. 25 9 9.
Solo Hornet Installation Guide Installation MAN-SOLHRNIG (Ver. 1.003) 4.12.3. How to Use the Charts The charts above are based upon theoretical worst-case conditions. Actual test results show 30% to 50% better power dissipation. To determine if your application needs a heat sink: 1. Allow maximum heat sink temperature to be 80 °C or less. 2. Determine the ambient operating temperature of the Solo Hornet. 3.
Solo Hornet Installation Guide 54 MAN-SOLHRNIG (Ver. 1.003) Chapter 5: Technical Specifications This chapter provides detailed technical information regarding the Solo Hornet. This includes its dimensions, power ratings, the environmental conditions under which it can be used, the standards to which it complies and other specifications. 5.1. Features The Solo Hornet's features determine how it controls motion, as well as how it processes host commands, feedback and other input. 5.1.1.
Solo Hornet Installation Guide Technical Specifications MAN-SOLHRNIG (Ver. 1.003) 5.1.5.
Solo Hornet Installation Guide Technical Specifications MAN-SOLHRNIG (Ver. 1.003) 5.1.7.
Solo Hornet Installation Guide Technical Specifications MAN-SOLHRNIG (Ver. 1.003) 5.2. Solo Hornet Dimensions www.elmomc.
Technical Specifications Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 5.3. Environmental Conditions Feature Operation Conditions Range Ambient Temperature Range Non-operating conditions -50 °C to +100 °C (-58 °F to 212 °F) Operating conditions -40 °C to +70 °C (-40 °F to 160 °F) Temperature Shock Non-operating conditions -40 °C to +70 °C (-40 °F to 160 °F) within 3 min.
Technical Specifications Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 5.4. Control Specifications 5.4.1.
Technical Specifications Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 5.4.2.
Technical Specifications Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 5.5. Feedbacks 5.5.1. Feedback Supply Voltage The Solo Hornet has two feedback ports (Main and Auxiliary). The drive supplies voltage to the main feedback device only. Feature Details Main encoder supply voltage 5 V +5% @ 200 mA maximum 5.5.2. Main Feedback Options The Solo Hornet can receive and process feedback input from diverse types of devices. 5.5.2.1.
Technical Specifications Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 5.5.2.2. Digital Halls Feature Details Halls inputs • HA, HB, HC. • Single ended inputs • Built in hysteresis of 1 V 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 Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 5.5.2.4. 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.
Technical Specifications Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 5.5.2.6. Potentiometer Feature Details Potentiometer Format Single-ended Operating Voltage Range 0 to 5 V supplied by the Solo Hornet Potentiometer Resistance 100 Ω to 1 kΩ above this range, linearity is affected detrimentally Input Resistance 100 kΩ Resolution 14 bit 5.5.3.
Technical Specifications Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 5.5.4. Auxiliary Feedback Port (input mode YA[4]= 2, 0) Feature Details Encoder input, pulse and direction input Input voltage • A, B, Index • Differential Vin Low: 0 V < VIL < 0.8 V Vin High: 2 V < VIH < 5 V Maximum absolute voltage: 0 < Vin < 5.
Technical Specifications Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 5.6. I/Os The Solo Hornet has: • 4 Digital Inputs • 2 Digital Outputs • 1 Analog Input 5.6.1. Digital Input Interfaces Feature Type of input Details • Optically isolated • All four inputs share one signal return line Input current for 5 V DI level Rin=1.43K, Iin = 2.8 mA @ Vin = 5 V Input current for 24 V DI level Rin=10.52k, Iin = 2.
Technical Specifications Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) Feature Details Rin = 1.43K General Input Return Figure 28: Digital Input Schematic 5.6.2. Digital Output Interface Feature Details Type of output • Optically isolated • Open collector and open emitter Maximum supply output (VCC) 30 V Max. output current Iout (max) (Vout = Low) Iout (max) ≤ 10 mA VOL at maximum output voltage (low level) Vout (on) ≤ 0.
Technical Specifications Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 5.6.3. Analog Input Feature Details Maximum operating differential voltage ± 10 V Maximum absolute differential input voltage ± 16 V Differential input resistance 3.74 kΩ Analog input command resolution 14-bit 5.7. Communications Specification Details RS-232 Signals: • RxD , TxD , GND • Full duplex, serial communication for setup and control. • Baud Rate of 9,600 to 57,600 bit/sec.
Technical Specifications Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.003) 5.9. 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.
Technical Specifications Solo Hornet Installation Guide MAN-SOLHRNIG (Ver. 1.
