Cello Digital Servo Drive Installation Guide July 2014 (Ver. 1.602) 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 Cello 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 1.0 Details Initial release 1.3 Apr 2008 Updated Power Ratings table in 4 1.4 Aug 2008 Added Section 3.4.7.4: Differential Pulse-and-Direction Input 1.5 Mar 2010 MTCR 07-009-56: added note to Section 3.4.8.2 1.6 July 2012 Formatted according to new template, updated Catalog Number 1.601 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., POB 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.
Cello Installation Guide MAN-CELIG (Ver. 1.602) Table of Contents 1 Safety Information .......................................................................................... 7 1.1 1.2 1.3 1.4 1.5 2 Warnings.....................................................................................................................8 Cautions ......................................................................................................................8 Directives and Standards .........................
Cello Installation Guide Table of Contents MAN-CELIG (Ver. 1.602) 3.4.8 3.5 3.6 4 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.
Cello Installation Guide 7 MAN-CELIG (Ver. 1.602) 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. Please read this chapter carefully before you begin the installation process.
Cello Installation Guide Safety Information MAN-CELIG (Ver. 1.602) 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.
Safety Information Cello Installation Guide MAN-CELIG (Ver. 1.602) 1.
Cello Installation Guide 10 MAN-CELIG (Ver. 1.602) 2 I ntroduction This installation guide describes the Cello 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.
Cello Installation Guide Introduction MAN-CELIG (Ver. 1.602) 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.
Cello Installation Guide Introduction MAN-CELIG (Ver. 1.602) 2.2.
Introduction Cello Installation Guide MAN-CELIG (Ver. 1.602) 2.3 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: Cello System Block Diagram 2.
Introduction Cello Installation Guide MAN-CELIG (Ver. 1.
Cello Installation Guide 15 MAN-CELIG (Ver. 1.602) 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.
Installation Cello Installation Guide MAN-CELIG (Ver. 1.602) Component Connector Described in Section Main Feedback Cable FEEDBACK A 3.4.5 Auxiliary Feedback Cable (if needed) FEEDBACK B 3.4.70 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 3.4.9.1 CAN (in) CAN (out) 3.4.9.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) 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. To unpack the Cello: Carefully remove the servo drive from the box and the Styrofoam. Check the drive to ensure that there is no visible damage to the instrument.
Installation Cello Installation Guide MAN-CELIG (Ver. 1.602) 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). Figure 3: Mounting the Cello www.elmomc.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) 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: Use twisted pair shielded cables for control, feedback and communication connections.
Installation Cello Installation Guide MAN-CELIG (Ver. 1.602) The following connectors are used for wiring the Cello.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) Figure 4: Cello Detailed Connection Diagram www.elmomc.
Installation Cello Installation Guide MAN-CELIG (Ver. 1.602) 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.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) 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.
Installation Cello Installation Guide MAN-CELIG (Ver. 1.602) 3.4.3 Connecting the Optional Backup Supply Cable (24 V) 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.
Installation Cello Installation Guide MAN-CELIG (Ver. 1.602) “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 Feedback and Control Cable Assemblies The Cello features easy-to-use D-Sub type connections for all Control and Feedback cables.
Installation Cello Installation Guide 26 MAN-CELIG (Ver. 1.602) 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).
Installation Cello Installation Guide MAN-CELIG (Ver. 1.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) Figure 9: Main Feedback- Incremental Encoder Connection Diagram www.elmomc.
Installation Cello Installation Guide MAN-CELIG (Ver. 1.602) Figure 10: Main Feedback – Interpolated Analog (Sine/Cosine) Encoder Connection Diagram Figure 11: Main Feedback – Resolver Connection Diagram www.elmomc.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.
Cello Installation Guide Installation 31 MAN-CELIG (Ver. 1.602) Cello CEL Figure 14: Main Feedback – Potentiometer Feedback with Digital Hall Sensor Connection Diagram for Brushless Motors Cello CEL Figure 15: Main Feedback – Potentiometer Feedback Connection Diagram for Brush Motors and Voice Coils www.elmomc.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) Figure 16: Main Feedback – Stegmann Feedback Connection Diagram www.elmomc.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) Figure 17: Main Feedback – Heidenhain Feedback Connection Diagram www.elmomc.
Installation Cello Installation Guide MAN-CELIG (Ver. 1.602) 34 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).
Installation Cello Installation Guide MAN-CELIG (Ver. 1.
Installation Cello Installation Guide 36 MAN-CELIG (Ver. 1.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) Figure 18: Main Encoder Buffered Output or Emulated Encoder Output on FEEDBACK B Connection Diagram www.elmomc.
Cello Installation Guide Installation 38 MAN-CELIG (Ver. 1.602) 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.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) Figure 19: Differential Auxiliary Encoder Input Option on FEEDBACK B Connection Diagram www.elmomc.
Installation Cello Installation Guide MAN-CELIG (Ver. 1.602) 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.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) Figure 20: Single-Ended Auxiliary Input Option on FEEDBACK B - Connection Diagram www.elmomc.
Cello Installation Guide Installation 42 MAN-CELIG (Ver. 1.602) 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.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) Figure 21: Pulse-and-Direction Input Option on FEEDBACK B - Connection Diagram www.elmomc.
Cello Installation Guide Installation 44 MAN-CELIG (Ver. 1.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) Figure 22: Differential Pulse-and-Direction Input Option on FEEDBACK B - Connection Diagram www.elmomc.
Installation Cello Installation Guide MAN-CELIG (Ver. 1.602) 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: 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.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) Figure 23: General J1 I/O Connection Diagram www.elmomc.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) 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.
Installation Cello Installation Guide MAN-CELIG (Ver. 1.602) high speed input Figure 24: General Input J2 Connection Diagram www.elmomc.
Installation Cello Installation Guide MAN-CELIG (Ver. 1.602) 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 Cello. The communication interface may differ according to the user’s hardware. The Cello can communicate using the following options: a. RS-232, full duplex CAN RS-232 communication requires a standard, commercial 3-core null-modem cable connected from the Cello to a serial interface on the PC.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) 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 Cello Installation Guide MAN-CELIG (Ver. 1.602) Caution: When installing the 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.
Cello Installation Guide Installation MAN-CELIG (Ver. 1.602) 3.5 Powering Up After the Cello has been mounted, check that the cables are intact. The Cello 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 Cello and that the proper plus-minus connections are in order. 3.6 Initializing the System After the Cello has been connected and mounted, the system must be set up and initialized.
Cello Installation Guide 54 MAN-CELIG (Ver. 1.602) 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 Features The Cello's features determine how it controls motion, as well as how it processes host commands, feedback and other input. 4.1.
Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.602) 4.1.
Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.602) Buffered and differential outputs of the main encoder with up to 5 MHz pulses Buffered and differential outputs of the auxiliary encoder Emulated output of the resolver or interpolated analog encoder Fast output compare (OC), optically isolated 4.1.
Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.602) 4.2 Cello Dimensions www.elmomc.
Technical Specifications Cello Installation Guide 58 MAN-CELIG (Ver. 1.602) Minimum supply voltage VDC 10 20 40 Nominal supply voltage VDC 50 85 170 Maximum supply voltage VDC 59 95 195 15RMS/200 15/200 10/200 6/200 2/200 30/100 15RMS/100 15/100 10/100 3/100 30/60 15/60 10/60 Units 5/60 Feature 15RMS/60 4.
Technical Specifications Cello Installation Guide MAN-CELIG (Ver. 1.602) 4.
Technical Specifications Cello Installation Guide MAN-CELIG (Ver. 1.602) 4.5 Cello Connections The following connectors are used for wiring the Cello. Pins Type 5 5.00 mm Pitch Header and Plug 3 M4 screws 2 3.81 mm Pitch Header and Plug Maker & Part No. Mating Connector Port Phoenix Header MSTBA 2.5 HC/5-G Phoenix Plug (supplied) MSTBT 2.5 HC/5-ST VP+, PR M1, M2, M3 PE, PE, PE Phoenix Header MC 1.5/2-G-3.81 Phoenix Plug (supplied) MC 1.5/2-ST-3.
Technical Specifications Cello Installation Guide MAN-CELIG (Ver. 1.602) 4.5.1 Backup Supply (Optional) Feature Details Auxiliary power supply DC source only 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 Control Specifications 4.6.
Technical Specifications Cello Installation Guide MAN-CELIG (Ver. 1.602) 4.6.
Cello Installation Guide Technical Specifications MAN-CELIG (Ver. 1.602) 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.
Technical Specifications Cello Installation Guide MAN-CELIG (Ver. 1.602) 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 Cello Installation Guide MAN-CELIG (Ver. 1.602) 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 Cello Reference current up to ±50 mA 4.7.
Technical Specifications Cello Installation Guide MAN-CELIG (Ver. 1.602) Feature Details Potentiometer Resistance 100 Ω to 1 kΩ … above this range, linearity is affected detrimentally Input Resistance 100 kΩ Resolution 14 Bit 4.7.
Technical Specifications Cello Installation Guide MAN-CELIG (Ver. 1.602) 4.8 I/Os The Cello 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 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 Cello Installation Guide MAN-CELIG (Ver. 1.602) Feature Details Connector Location J2: General purpose I/O J1: General purpose I/O General input return Figure 28: Digital Input Schematic 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 Iout (max) (Vout = Low) Iout (max) ≤ 15 mA VOL at maximum output voltage (low level) Vout (on) ≤ 0.3 V + 0.
Technical Specifications Cello Installation Guide MAN-CELIG (Ver. 1.602) Feature Details Connector Location J2: General purpose I/O J1: General purpose I/O Figure 29: Digital Output Schematic www.elmomc.
Technical Specifications Cello Installation Guide MAN-CELIG (Ver. 1.602) 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 RS-232 Signals: RxD , TxD , Gnd Connector Location Full duplex, serial communication for setup and control. Baud Rate of 9,600 to 115,200 bit/sec.
Technical Specifications Cello Installation Guide MAN-CELIG (Ver. 1.602) 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.
Technical Specifications Cello Installation Guide MAN-CELIG (Ver. 1.
