Solo Whistle Digital Servo Drive Installation Guide July 2014 (Ver. 1.503) 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 Whistle 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 June 2008 Initial Release 1.1 November Changed: Front matter, P/N explanations, sticker & schematics in 2008 Section 4.2, Figure 14, Figure 15, Figure 16, Section 3.7 and Section 3.8. Added information for auxiliary input features in Chapters 2 and 3 and in Section 4.7.4. MTCR 00-100-33: Weight of product changed to 68.4 grams in Section 4.3 1.2 February 2009 MTCR 01-009-39: Section 3.7.
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.
Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) Table of Contents Chapter 1: 1.1. 1.2. 1.3. 1.4. 1.5. Warnings......................................................................................................................... 9 Cautions .......................................................................................................................... 9 Directives and Standards ..............................................................................................
Solo Whistle Installation Guide Table of Contents MAN-SOLWHIIG (Ver. 1.503) 3.8.3. Analog Input .................................................................................................. 44 3.9. Communications ........................................................................................................... 45 3.9.1. RS-232 Communication ................................................................................. 45 3.9.2. CANopen Communication ......................................
Solo Whistle Installation Guide Table of Contents MAN-SOLWHIIG (Ver. 1.503) 4.8.2. Digital Output Interface ................................................................................. 66 4.8.3. Analog Input .................................................................................................. 67 4.9. Communications ........................................................................................................... 67 4.10. Pulse-Width Modulation (PWM) ............................
Solo Whistle Installation Guide 8 MAN-SOLWHIIG (Ver. 1.503) Chapter 1: Safety I nform ation In order to achieve the optimum, safe operation of the Solo Whistle 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 Whistle as well as the accompanying equipment. Please read this chapter carefully before you begin the installation process.
Solo Whistle Installation Guide Safety Information MAN-SOLWHIIG (Ver. 1.503) 1.1. Warnings • Power cables can carry a high voltage, even when the motor is not in motion. Disconnect the Solo Whistle from all voltage sources before it is opened for servicing. • The Solo Whistle servo drive contains grounding conduits for electric current protection. Any disruption to these conduits may cause the instrument to become hot (live) and dangerous.
Safety Information Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 1.3.
Solo Whistle Installation Guide 11 MAN-SOLWHIIG (Ver. 1.503) Chapter 2: I ntroduction The Solo Whistle is an integrated solution designed to simply and efficiently connect Elmo’s Whistle servo drive directly to the application. The solution consists of the Whistle together with a convenient connection interface which either eliminates or reduces development time and resources when designing an application’s PCB board.
Solo Whistle Installation Guide Introduction MAN-SOLWHIIG (Ver. 1.503) The Solo Whistle 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 and CANopen DS 301, DS 305, DS 402 communications and features a third-generation programming environment.
Introduction Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 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.
Solo Whistle Installation Guide Introduction MAN-SOLWHIIG (Ver. 1.503) 2.3. System Architecture Figure 1: Solo Whistle System Block Diagram 2.4. How to Use this Guide In order to install and operate your Elmo Solo Whistle servo drive, you will use this manual in conjunction with a set of Elmo documentation.
Introduction Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) Figure 2: Elmo Digital Servo Drive Documentation Hierarchy As depicted in the previous figure, this installation guide is an integral part of the Solo Whistle 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 Whistle Installation Guide 16 MAN-SOLWHIIG (Ver. 1.503) Chapter 3: I nstallation The Solo Whistle must be installed in a suitable environment and properly connected to its voltage supplies and the motor. 3.1. Site Requirements You can guarantee the safe operation of the Solo Whistle drive by ensuring that it is installed in an appropriate environment.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) The part number at the top gives the type designation as follows: 4. Verify that the Solo Whistle model is the one that you ordered, and ensure that the voltage meets your specific requirements. Note: The catalog number suffix is a number from 01 to 08, as shown above. The odd numbers are models with connectors and the even numbers are models with wires.
Installation Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 3.3. Connector Types The Solo Whistle has eight connectors (in the connectors version). Pins Type Port Function 9 3.5 mm Pitch J1 Power Connector 12 2 mm Pitch J2 I/O 8 2 mm Pitch J3 Auxiliary Feedback 12 2 mm Pitch J4 Main Feedback 3 2 mm Pitch J5 RS232 3 2 mm Pitch J6 CANIN 3 2 mm Pitch J7 CANOUT 8 3.
Installation Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 3.4.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) 3.4.1. Connecting Motor Power Connect the M1, M2, M3 and PE pins on the Solo Whistle. 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 3: AC Motor Power Connection Diagram www.elmomc.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) 3.5. Main Power – J1 Pin (J1) Signal Function 1 VL+ Auxiliary supply input 2 PR Auxiliary supply input return 3 VP+ Pos. power input 4 VP+ Pos. power input 5 PR Power return 6 PR Power return 7 PE Protective earth 8 N/C Not connected 9 N/C Not connected Pin Positions Note: When connecting several drives to several motors, all should be wired in the same motor phases and feedback sequences.
Installation Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 3.5.1. Connecting Main Power Power to the Solo Whistle is provided by a 12 to 195 VDC source. A smart control-supply algorithm enables the Solo Whistle to operate with the power supply only in up to 100 V models, with no need for an auxiliary 24 volt supply. 200 V models always require two separate power supplies.
Installation Solo Whistle Installation Guide 23 MAN-SOLWHIIG (Ver. 1.503) 3.6. Main Feedback 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.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) Figure 5: Main Feedback- Incremental Encoder with Digital Hall Sensor Connection Diagram Figure 6: Main Feedback – Interpolated Analog (Sine/Cosine) Encoder Connection Diagram www.elmomc.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) Figure 7: Main Feedback – Interpolated Analog (Sine/Cosine) Encoder with Digital Hall Sensor Connection Diagram Figure 8: Main Feedback – Resolver Connection Diagram www.elmomc.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) Figure 9: Main Feedback – Resolver with Digital Hall Sensor Connection Diagram www.elmomc.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) 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 Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) 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.
Installation Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 3.7. Auxiliary Feedback When using one of the Auxiliary Feedback options, the relevant functionality of the Auxiliary Feedback's ports are software- and hardware-selected for that option. Refer to the SimplIQ Command Reference Manual for detailed information about Auxiliary Feedback setup. 3.7.1.
Installation Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 3.7.2. 30 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 Whistle has three bidirectional pins (CHA, CHB and INDEX).
Installation Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.
Installation Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) 3.7.3. Pin (J3) Auxiliary Feedback: Emulated Encoder Output Option (YA[4]=4) Signal Function 1 PE Protective Earth 2 COMRET Common Return 3 INDEXO- Buffered Index complement output 4 INDEXO Buffered Index output 5 CHBO- Buffered Channel B complement output 6 CHBO Buffered Channel B output 7 CHAO- Buffered Channel A complement output 8 CHAO Buffered Channel A output Pin Positions www.elmomc.
Installation Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) Figure 14: Emulated Encoder Differential Output Diagram www.elmomc.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) 3.7.4. Pin (J3) Auxiliary Feedback: Differential Encoder Input Option (YA[4]=2) Signal Function 1 PE Protective Earth 2 COMRET Common Return 3 INDEX- Auxiliary Index complement Input 4 INDEX Auxiliary Index Input 5 CHB- Auxiliary channel B complement input 6 CHB Auxiliary channel B input 7 CHA- Auxiliary channel A complement input 8 CHA Auxiliary channel A input Pin Positions www.elmomc.
Installation Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) Figure 15: Differential Auxiliary Encoder Input Option Diagram Figure 16: Differential Auxiliary Encoder Input Option Diagram www.elmomc.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) 3.7.5. Pin (J3) Auxiliary Feedback: Differential Pulse-and-Direction Input Option (YA[4]=0) Signal Function 1 PE Protective Earth 2 COMRET Common Return 3 NA Do not connect this pin 4 NA Do not connect this pin 5 CHB- Auxiliary Direction complement input 6 CHB Auxiliary Direction input 7 CHA- Auxiliary Pulse complement input 8 CHA Auxiliary Pulse input Pin Positions www.elmomc.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) Figure 17: Pulse-and-Direction Diagram www.elmomc.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) 3.8. I/Os The Solo Whistle has four digital inputs, two digital outputs and one analog input. 3.8.1. Digital Input The digital input level signal can be 5 V (TTL) or 24 V (PLC).
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) 3.8.1.1. Digital Input 5 V (TTL) Figure 18: Digital Input 5 V Connection Diagram www.elmomc.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) 3.8.1.2. Digital Input 24 V (PLC) Figure 19: Digital Input 24 Connection Diagram www.elmomc.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) 3.8.2. Pin (J2) Digital Output Signal Function 8 OUT1 Programmable digital output 1 9 OUTRET1 Programmable digital output return 1 6 OUT2 Programmable digital output 2 7 OUTRET2 Programmable digital output return 2 Pin Positions Table 4: Digital Output Pin Assignment www.elmomc.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) Figure 20: Digital Output Connection Diagram www.elmomc.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) 3.8.3. Analog Input Pin (J2) Signal Function 10 ANLIN1+ Analog input 1+ 11 ANLIN1- Analog input 1- 12 ANLRET Analog return Pin Positions Table 5: Analog Input Pin Assignments Figure 21: Analog Input with Single-Ended Source www.elmomc.
Installation Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 3.9. Communications The communication interface may differ according to the user’s hardware. The Solo Whistle can communicate using the following options: a. RS-232, full duplex b. CANopen RS-232 communication requires a standard, commercial 3-core null-modem cable connected from the Solo Whistle to a serial interface on the PC. The interface is selected and set up in the Composer software.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) Figure 22: RS-232 Connection Diagram www.elmomc.
Installation Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 3.9.2. CANopen Communication Notes for connecting the CANopen 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 Whistle’s CAN ports are non-isolated.
Solo Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) Figure 23: CANopen Network Diagram Caution: When installing CANopen communication, ensure that each servo drive is allocated a unique ID. Otherwise, the CANopen network may hang. www.elmomc.
Installation Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 3.10. Powering Up After the Solo Whistle 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. 3.11. Initializing the System After the Solo Whistle has been connected and mounted, the system must be set up and initialized.
Installation Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 3.12.2. Heat Dissipation Data Heat dissipation is shown in graphically below: Solo Whistle - 60 Series Power Dissipation 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 Whistle Installation Guide Installation MAN-SOLWHIIG (Ver. 1.503) 3.12.3. 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 Whistle. 3.
Solo Whistle Installation Guide 52 MAN-SOLWHIIG (Ver. 1.503) Chapter 4: Technical Specifications This chapter provides detailed technical information regarding the Solo Whistle. 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 Solo Whistle's features determine how it controls motion, as well as how it processes host commands, feedback and other input. 4.1.1.
Solo Whistle Installation Guide Technical Specifications MAN-SOLWHIIG (Ver. 1.503) 4.1.5.
Solo Whistle Installation Guide Technical Specifications MAN-SOLWHIIG (Ver. 1.503) 4.1.7.
Solo Whistle Installation Guide Technical Specifications MAN-SOLWHIIG (Ver. 1.503) 4.2. Solo Whistle Dimensions www.elmomc.
Technical Specifications Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) Physical Specifications Feature Units Weight Dimensions 3/200 6/200 68.4 g (2.4 oz) mm (in) 58.25 x 28.5 x 46.5 (2.3" x 1.1" x 1.8") Mounting method PCB mount Minimum supply voltage VDC 6 7.
Technical Specifications Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.
Technical Specifications Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 4.5.
Technical Specifications Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 4.6.2.
Technical Specifications Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 4.7. Feedbacks 4.7.1. Feedback Supply Voltage The Solo Whistle 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 4.7.2. Main Feedback Options The Solo Whistle can receive and process feedback input from diverse types of devices. 4.7.2.1.
Technical Specifications Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 4.7.2.2. 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 Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 4.7.2.4. 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 Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 4.7.2.6. Potentiometer Feature Details Potentiometer Format Single-ended Operating Voltage Range 0 to 5 V supplied by the Solo Whistle Potentiometer Resistance 100 Ω to 1 kΩ … above this range, linearity is affected detrimentally Input Resistance 100 kΩ Resolution 14 bit 4.7.3.
Technical Specifications Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) Figure 25: Auxiliary Feedback - Encoder Phase Diagram 4.7.4. 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 Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 4.8. I/Os The Solo Whistle has: • 4 Digital Inputs • 2 Digital Outputs • 1 Analog Input 4.8.1. 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 Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) Rin = 1.43K General Input Return Figure 27: 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) ≤ 10 mA VOL at maximum output voltage (low level) Vout (on) ≤ 0.
Technical Specifications Solo Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 4.8.3. 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 4.9. 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 Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.503) 4.11. 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 Whistle Installation Guide MAN-SOLWHIIG (Ver. 1.
