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Gold DC Whistle Installation Guide

MAN-G-DCWHIIG-EC (Ver. 1.705)

||Technical Data|

www.elmomc.com

Elmo now offers a 200 VDC maximum output rating selection of Gold DC Whistle, according to the
following technical data:

Feature

Units

3/200

6/200

9/200

Minimum supply voltage

VDC

Nominal supply voltage

VDC

170

Maximum supply voltage

VDC

195

Maximum continuous power output

480

960

1450

Efficiency at rated power (at
nominal conditions)

> 99

Maximum output voltage

> 95% of DC bus voltage at f = 22 kHz

Auxiliary power supply

VDC

12 to 95 VDC

(up to 6 VA inc. 5 V/2 x 200 mA for

encoder)

Amplitude sinusoidal/DC
continuous current

Sinusoidal continuous RMS current
limit (Ic)

2.1

4.2

6.3

Peak current limit

2 x Ic

4.2.1.

Auxiliary Supply

Feature

Details

Auxiliary power supply

Isolated DC source only

Auxiliary supply input voltage

12 V to 95 V

Auxiliary supply input power

≤ 4 VA without external loading

≤ 6 VA with full external loading

Summary of Contents for G-DCWHI Series

Page 1: ...Gold DC Whistle Digital Servo Drive Installation Guide EtherCAT and CAN August 2017 Ver 1 705 www elmomc com ...

Page 2: ...sting users of the Gold DC 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 Information in this document is subject to change without notice Document no MAN G DCWHIIG EC Ver 1 705 Copyright 2017 Elmo Motion Control Ltd All right...

Page 3: ...e ordered separately For further details see the documentation for this cable kit MAN G DCWHI CBLKIT pdf Revision History Version Date Ver 1 700 Jun 2014 Ver 1 701 Jan 2015 Ver 1 702 Jul 2015 Ver 1 703 Oct 2015 Ver 1 704 May 2016 Ver 1 705 Aug 2017 ...

Page 4: ...ds 13 Chapter 5 Installation 14 5 1 Unpacking the Drive Components 14 5 2 Connector Types 15 5 3 Mounting the Gold DC Whistle 18 5 4 The Gold DC Whistle Connection Diagram 19 Chapter 6 Wiring 21 6 1 Basic Recommendations 22 6 1 1 General 22 6 1 2 Feedback Cable Port A and Port B Connector 23 6 1 3 Feedback Cable Port C Connector 24 6 1 4 IO Cable Connector 24 6 1 5 STO Port C Cable Connector 25 6 ...

Page 5: ... Resolver 45 6 8 Port C Digital I Os and Analog Inputs J2 46 6 8 1 Port C Emulated Encoder Output 48 6 8 2 Analog Input 49 6 8 3 Digital Input and Output TTL Mode 50 6 8 4 Digital Input and Output PLC Source Mode 52 6 8 5 Digital Input and Output Sink Mode 54 6 9 USB 2 0 J9 56 6 10 EtherCAT Communication Version 57 6 10 1 EtherCAT IN Ethernet Pin Assignments J7 57 6 10 2 EtherCAT OUT Pin Assignmen...

Page 6: ...ly qualified personnel may install adjust maintain and repair the servo drive A qualified person has the knowledge and authorization to perform tasks such as transporting assembling installing commissioning and operating motors The Gold DC Whistle contains electrostatic sensitive components that can be damaged if handled incorrectly To prevent any electrostatic damage avoid contact with highly ins...

Page 7: ...sing reinforced or double insulation in accordance with approved safety standards Before switching on the Gold DC Whistle verify that all safety precautions have been observed and that the installation procedures in this manual have been followed Make sure that the Safe Torque Off is operational 2 3 CE Marking Conformance The Gold DC Whistle is intended for incorporation in a machine or end produc...

Page 8: ... up to 95V with only one power supply with no need for an auxiliary power supply for the logic The Gold DC Whistle can operate as a stand alone device or as part of a multi axis system in a distributed configuration on a real time network The Gold DC Whistle drive is easily set up and tuned using Elmo Application Studio EAS software tools As part of the Gold product line it is fully programmable w...

Page 9: ...ge VDC 95 Maximum continuous power output W 80 200 400 800 1200 1600 Efficiency at rated power at nominal conditions 99 Maximum output voltage 95 of DC bus voltage at f 22 kHz Auxiliary power supply VDC 12 95 VDC up to 6 VA inc 5 V 2 x 200 mA for encoder Amplitude sinusoidal DC continuous current A 1 0 2 5 5 10 15 20 Sinusoidal continuous RMS current limit Ic A 0 7 1 8 3 5 7 10 6 14 1 Peak current...

Page 10: ...s power output W 480 960 1450 Efficiency at rated power at nominal conditions 99 Maximum output voltage 95 of DC bus voltage at f 22 kHz Auxiliary power supply VDC 12 to 95 VDC up to 6 VA inc 5 V 2 x 200 mA for encoder Amplitude sinusoidal DC continuous current A 3 6 9 Sinusoidal continuous RMS current limit Ic A 2 1 4 2 6 3 Peak current limit A 2 x Ic 4 2 1 Auxiliary Supply Feature Details Auxili...

Page 11: ...re Details Presence and No STO TTL or PLC Source or PLC Sink is not fully certified and not recommended for new designs Digital Input Option TTL or 6 PLC Source or 6 PLC Sink 6 Digital Output Option TTL or 4 PLC Source or 4 PLC Sink 4 Analog Input Differential 10V 1 Feedback Standard Port A B C Communication Option USB EtherCAT option CAN option ...

Page 12: ...re Details Operating ambient temperature according to IEC60068 2 2 0 C to 40 C 32 F to 104 F Storage temperature 20 C to 85 C 4 F to 185 F Maximum non condensing humidity according to IEC60068 2 78 95 Maximum Operating Altitude 2 000 m 6562 feet It should be noted that servo drives capable of higher operating altitudes are available on request Mechanical Shock according to IEC60068 2 27 15g 11ms H...

Page 13: ...Adjustable speed electrical power drive systems Safety requirements Functional EN ISO 13849 1 2008 PL e Cat 3 Safety of machinery Safety related parts of control systems Approved IEC EN 61800 5 1 Adjustable speed electrical power drive systems Safety requirements Electrical thermal and energy Recognized UL61800 5 1 Adjustable speed electrical power drive systems Safety requirements Electrical ther...

Page 14: ...yrofoam protection To unpack the Gold DC Whistle 1 Carefully remove the servo drive from the box and the Styrofoam 2 Check the drive to ensure that there is no visible damage to the instrument If any damage has occurred report it immediately to the carrier that delivered your drive 3 To ensure that the Gold DC Whistle you have unpacked is the appropriate type for your requirements locate the part ...

Page 15: ... com 15 Table of Contents 5 2 Connector Types The Gold DC Whistle has ten connectors No Pins Type Function Bottom Connectors 4 Phoenix 5 mm Pitch HC Motor phases 3 Phoenix 5 mm Pitch HC Main Power 2 Phoenix 3 81 mm Pitch HC Auxiliary supply input Front Connectors Front Connectors EtherCAT ...

Page 16: ...Types www elmomc com 16 Table of Contents No Pins Type Function Front Connectors CAN 3 2 54 mm Pitch Molex STO 24 2 54 mm Pitch Molex Feedback port C and I O 8 2 54 mm Pitch Molex Feedback port B 12 2 54 mm Pitch Molex Feedback port A Top Connectors Top Connectors EtherCAT ...

Page 17: ...ts No Pins Type Function Top Connectors CAN 5 USB Device Mini B USB EtherCAT Version 8 RJ 45 EtherCAT in 8 RJ 45 EtherCAT out CAN Version 8 RJ 45 CAN 8 RJ 45 CAN Table 2 Connector Types The pinouts in Chapter 6 Wiring describe the function of each pin in the Gold DC Whistle connectors that are listed in Table 2 ...

Page 18: ...d DC Whistle The Gold DC Whistle 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 Gold DC Whistle see the diagram below Figure 1 Mounting the Gold DC Whistle ...

Page 19: ...nstallation Guide MAN G DCWHIIG EC Ver 1 705 The Gold DC Whistle Connection Diagram www elmomc com 19 Table of Contents 5 4 The Gold DC Whistle Connection Diagram Figure 2 The Gold DC Whistle Connection Diagram EtherCAT ...

Page 20: ...Gold DC Whistle Installation Guide MAN G DCWHIIG EC Ver 1 705 The Gold DC Whistle Connection Diagram www elmomc com 20 Table of Contents Figure 3 The Gold DC Whistle Connection Diagram CAN ...

Page 21: ...Wiring Symbol Description Earth connection PE Protective Earth Connection Common at the Controller Shielded cable with drain wire The drain wire is a non insulated wire that is in direct contact with the braid shielding Shielded cable with drain wire significantly simplifies the wiring and earthing Shielded cable braid only without drain wire Twisted pair wires Encoder Earthing The cable s shield ...

Page 22: ...o prevent them from affecting the drive Failing to meet this requirement might result in drive controller host failure 4 After completing the wiring carefully inspect all wires to ensure tightness good solder of joints and general safety Figure 4 Feedback and Molex Control Cable Assemblies Note Please pay attention to the location of PIN 1 in the above connector diagram It should be noted that in ...

Page 23: ...st One COMRET Common Return must be connected to the PE Implement the following steps to connect the COMRET to the PE a At the drive connect the feedback drain wire to one of the COMRET terminals in the Molex feedback connector Figure 5 b At the motor connect the feedback cable drain wire to the GND motor chassis terminal of the feedback connector Figure 6 The drawing displays two earth connection...

Page 24: ...nnector 1 At the controller side connections follow the controller manufacturer s recommendations concerning the shield 2 The connection of the Drain wire to the Port C is not mandatory Figure 7 Feedback Port C Cable Assemblies 6 1 4 IO Cable Connector It is recommended to use shielded cable but is not mandatory Figure 8 Feedback IO Cable Assemblies ...

Page 25: ...llation Guide MAN G DCWHIIG EC Ver 1 705 Basic Recommendations www elmomc com 25 Table of Contents 6 1 5 STO Port C Cable Connector It is recommended to use shielded cable but is not mandatory Figure 9 STO Cable Assemblies ...

Page 26: ...e in the MAN G Panel Mounted Drives Hardware manual for full details Pin J14 Signal Function Cable Brushless Motor Brushed DC Motor 1 PE Protective Earth Motor Motor 2 M1 Motor phase Motor N C 3 M2 Motor phase Motor Motor 4 M3 Motor phase Motor Motor 4 Pin Phoenix 5 mm Pitch HC 4 Pin Phoenix Plug in Connector Table 3 Connectors for Motor Figure 10 Brushless Motor Power Connection Diagram ...

Page 27: ...Gold DC Whistle Installation Guide MAN G DCWHIIG EC Ver 1 705 Motor Power Connector Pinouts J14 www elmomc com 27 Table of Contents Figure 11 Brushed Motor Power Connection Diagram ...

Page 28: ...Single DC Power Supply Power to the Gold DC Whistle is provided by a 12 95 VDC single isolated DC power source not included with the Gold DC Whistle A smart control supply algorithm enables the Gold DC Whistle to operate with only one power supply with no need for an auxiliary power supply for the logic Optional Backup Auxiliary Supply If backup functionality is required in case of power loss e g ...

Page 29: ...Main Power Connector To connect the DC power supply 1 The source of the 12 to 195 VDC power supply must be isolated 2 For best immunity it is highly recommended to use twisted and shielded cables for the DC power supply A 3 wire shielded cable should be used The gauge is determined by the actual current consumption of the motor 3 Connect the cable shield to the closest ground connection near the p...

Page 30: ...m the Main Supply and not from the Auxiliary Supply The backup functionality can be used for storing control parameters in case of power outs providing maximum flexibility and backup capability when needed Connect the VL and PR terminal to the Auxiliary Connector To connect the auxiliary supply 1 The source of the Auxiliary Supply must be isolated 2 For safety reasons connect the return common of ...

Page 31: ...iliary Power www elmomc com 31 Table of Contents 6 3 4 Connectivity 6 3 4 1 Power Rating 200 V For Power Rating 200 V two power isolated DC power sources are required main power 12 195V and auxiliary Power 12 95V for the logic Figure 12 200 VDC Power Source Connection Diagram ...

Page 32: ...Rating 100 V 6 3 4 2 a Single Power Supply For power rating 100 V a single Power Supply is required which contains a smart control supply algorithm enabling the Gold DC Whistle to operate with only one power supply with no need for an auxiliary power supply for the logic Figure 13 Main Power Supply Connection Diagram no Auxiliary Supply ...

Page 33: ...d DC Whistle Installation Guide MAN G DCWHIIG EC Ver 1 705 Main and Auxiliary Power www elmomc com 33 Table of Contents 6 3 4 2 b Optional Backup Supply Figure 14 Auxiliary Power Supply Connections Diagram ...

Page 34: ... Drive Status Indicator in the MAN G Panel Mounted Drives Hardware manual Figure 15 Drive Status Indicator EtherCAT Figure 16 Drive Status Indicator CAN The red green dual LED is used for immediate indication of the following states Initiation state In this state the LED indicates whether the drive is in the boot state blinking red or in the operational state steady red Working state In this state...

Page 35: ...11 See Chapter 9 in the in the MAN G Panel Mounted Drives Hardware manual for full details Pin J11 Signal Function 1 STO1 STO1 input default 24 V 2 STO2 STO2 input default 24 V 3 STO_RET STO signal return 3 Pin 2 54 mm Pitch Molex 3 Pin Molex Plug This cable is included in the cable kit described in Section 3 1 1 Table 6 STO Input Pin Assignments ...

Page 36: ...able of Contents 6 5 1 Source Mode PLC Voltage Level Refer to the diagrams below for the PLC Source option connection Figure 17 STO Molex Type Input Connection PLC Source Option 6 5 2 TTL Mode TTL Voltage Level Refer to the diagrams below for TTL option connection Figure 18 STO Input Connection TTL Option ...

Page 37: ...orque Off J11 www elmomc com 37 Table of Contents 6 5 3 Sink Mode PLC Voltage Level Refer to the diagrams below for the PLC Sink option connections which is not fully certified for STO This option is not recommended for new designs Figure 19 STO Input Connection Sink Option ...

Page 38: ... ABS_CLK Absolute encoder clock 4 PortA_ENC_A Channel A ABS_CLK Absolute encoder clock 5 PortA_ENC_B Channel B ABS_DATA Absolute encoder data 6 PortA_ENC_B Channel B ABS_DATA Absolute encoder data 7 PortA_ENC_INDEX Index Reserved Reserved 8 PortA_ENC_INDEX Index Reserved Reserved 9 HA Hall sensor A HA Hall sensor A 10 HB Hall sensor B HB Hall sensor B 11 HC Hall sensor C HC Hall sensor C 12 COMRET...

Page 39: ...HIIG EC Ver 1 705 Port A J1 www elmomc com 39 Table of Contents 6 6 1 Incremental Encoder Figure 20 Port A Molex Type Incremental Encoder Input Recommended Connection Diagram 6 6 2 Halls Sensor Figure 21 Molex Type Hall Sensors Connection Diagram ...

Page 40: ...r The following figures describe the connections at Port A for the Absolute Serial type encoders Figure 22 Absolute Serial Encoder Recommended Connection Diagram for EnDAT Biss SSI Figure 23 Absolute Serial Encoder Recommended Connection Diagram for Sensors Supporting Data Line Only NRZ types e g Panasonic Mitutoyo Sanyo Danki Tamagawa ...

Page 41: ... G DCWHIIG EC Ver 1 705 Port A J1 www elmomc com 41 Table of Contents 6 6 3 1 Hiperface The following figure describes the connection diagram Figure 24 Absolute Serial Encoder Recommended Molex Type Connection Diagram for Stegmann Hiperface ...

Page 42: ...mmon return COMRET Common return 3 PortB_ENC_A SIN Channel A Sine SIN Sine 4 PortB_ENC_A SIN Channel A Sine SIN Sine 5 PortB_ENC_B COS Channel B Cosine COS Cosine 6 PortB_ENC_B COS Channel B Cosine COS Cosine 7 PortB_ENC_INDEX Analog_Index Channel_Index Analog_Index RESOLVER_OUT Vref f 1 TS 50 mA Max 8 PortB_ENC_INDEX Analog_Index Channel_Index Analog_Index RESOLVER_OUT Vref complement f 1 TS 50 m...

Page 43: ...IIG EC Ver 1 705 Port B J3 www elmomc com 43 Table of Contents 6 7 1 Incremental Encoder The following figure describes the connections at Port B for the Incremental encoder Figure 25 Port B Incremental Encoder Input Recommended Connection Diagram ...

Page 44: ...r 1 705 Port B J3 www elmomc com 44 Table of Contents 6 7 2 Interpolated Analog Encoder The following figure describes the connections at Port B for the Interpolated Analog encoder Figure 26 Port B Interpolated Analog Encoder Molex Type Connection Diagram ...

Page 45: ...Gold DC Whistle Installation Guide MAN G DCWHIIG EC Ver 1 705 Port B J3 www elmomc com 45 Table of Contents 6 7 3 Resolver Figure 27 Port B Resolver Molex Type Connection Diagram ...

Page 46: ...nnel A complement output 3 PortC_ENCO_B Buffered Channel B output 4 PortC_ENCO_B Buffered Channel B complement output 5 PortC_ENCO_Index Buffered INDEX output 6 PortC_ENCO_Index Buffered INDEX complement output 7 COMRET Common return 8 COMRET Common return 9 ANALOG1 Analog input complement 10 ANALOG1 Analog input 11 ANARET Analog return 12 INRET1_6 Programmable input 1 6 return 13 IN1 Programmable...

Page 47: ... 705 Port C Digital I Os and Analog Inputs J2 www elmomc com 47 Table of Contents Pin Positions Cable Connector 24 Pin 2 54 mm Pitch Molex 24 Pin Molex Plug This cable is included in the cable kit described in Section 3 1 1 Table 9 Port C Feedback Out and I O ...

Page 48: ...ble of Contents 6 8 1 Port C Emulated Encoder Output The following figure describes the connections at Port C for the Emulated Encoder Differential Figure 28 Emulated Encoder Differential Output Recommended Connection Diagram Note that the user is required to connect a 120 Ω termination at the end of each differential line ...

Page 49: ...e MAN G DCWHIIG EC Ver 1 705 Port C Digital I Os and Analog Inputs J2 www elmomc com 49 Table of Contents 6 8 2 Analog Input The following circuit describes the internal interface of the Analog input Figure 29 Differential Analog Input ...

Page 50: ...C Digital I Os and Analog Inputs J2 www elmomc com 50 Table of Contents 6 8 3 Digital Input and Output TTL Mode The following figure describes the connections at the I O Port for the Digital Input and Output TTL Mode Figure 30 Digital Input TTL Mode Connection Diagram ...

Page 51: ...Gold DC Whistle Installation Guide MAN G DCWHIIG EC Ver 1 705 Port C Digital I Os and Analog Inputs J2 www elmomc com 51 Table of Contents Figure 31 Digital Output Connection Diagram TTL Option ...

Page 52: ...l I Os and Analog Inputs J2 www elmomc com 52 Table of Contents 6 8 4 Digital Input and Output PLC Source Mode The following figure describes the connections at the I O Port for the Digital Input and Output PLC Mode Figure 32 Digital Input Connection Diagram Source PLC Option ...

Page 53: ...Gold DC Whistle Installation Guide MAN G DCWHIIG EC Ver 1 705 Port C Digital I Os and Analog Inputs J2 www elmomc com 53 Table of Contents Figure 33 Digital Output Connection Diagram Source PLC Option ...

Page 54: ...nd Analog Inputs J2 www elmomc com 54 Table of Contents 6 8 5 Digital Input and Output Sink Mode The following figure describes the connections at the I O Port for the Digital Input and Output Sink Mode Figure 34 Digital Input Sink Mode PLC voltage level Molex Type Connection Diagram ...

Page 55: ... Whistle Installation Guide MAN G DCWHIIG EC Ver 1 705 Port C Digital I Os and Analog Inputs J2 www elmomc com 55 Table of Contents Figure 35 Digital Output as Sink Configuration Molex Type Connection Diagram ...

Page 56: ... 12 1 in the in the MAN G Panel Mounted Drives Hardware manual for full details Pin J9 Signal Function 1 USB VBUS USB VBUS 5 V 2 USBD USB _N line 3 USBD USB _P line 5 USB COMRET USB communication return Pin Positions Cable Connector USB Device Mini B USB Device Mini B Plug Table 10 USB 2 0 Pin Assignments Figure 36 USB Network Diagram ...

Page 57: ...bus type industrial network protocol Fieldbus Type Product Number EtherCAT G DCWHI XX YYYEXX 6 10 1 EtherCAT IN Ethernet Pin Assignments J7 Refer to section 12 2 in the MAN G Panel Mounted Drives Hardware manual for more details Pin J7 Signal Function 1 EtherCAT_IN_TX Ethernet_TX EtherCAT in Ethernet transmit 2 EtherCAT_IN_TX Ethernet_TX EtherCAT in Ethernet transmit 3 EtherCAT_IN_RX Ethernet_RX E...

Page 58: ... Hardware manual for the electrical diagram Pin J8 Signal Function 1 EtherCAT_OUT_TX EtherCAT out transmit 2 EtherCAT_OUT_TX EtherCAT out transmit 3 EtherCAT_OUT_RX EtherCAT out receive 4 5 N A 6 EtherCAT_OUT_RX EtherCAT out receive 7 8 N A Connectors 8 Pin RJ 45 Standard Ethernet CAT5 Cable 6 10 3 EtherCAT Wiring Figure 37 describes the wiring diagram for the EtherCAT connections Figure 37 EtherC...

Page 59: ...s LED The EtherCAT status indicator is a single red green dual bi colored LED that combines the green RUN indicator and the red ERROR indicator of the EtherCAT state machine For further details see the EtherCAT Application Manual Note There is no Gold DC Whistle ECAT Status indicator equivalent in the CAN version refer to the figure below Figure 39 Gold DC Whistle Status Indicator CAN ...

Page 60: ...orts the following CAN fieldbus type industrial network protocol Fieldbus Type Product Number CAN G DCWHI XX YYYSXX See Section 12 4 in the MAN G Panel Mounted Drives Hardware manual for the electrical diagram Pin J7 J8 Signal Function 1 CAN_H CAN_H bus line dominant high 2 CAN_L CAN_L bus line dominant low 3 COMRET CAN_RET CAN Return 4 5 N A 6 CAN_SHLD Shield connected to the RJ plug cover 7 CAN_...

Page 61: ...CAN Communication Version www elmomc com 61 Table of Contents 6 11 1 CAN Wiring Figure 40 Gold DC Whistle Connection Diagram CAN Caution When installing the CAN communications ensure that each servo drive is allocated a unique ID Otherwise the CAN network may hang ...

Page 62: ...r ensure that the DC supply is within the specified range and that the proper plus minus connections are in order 6 13 Initializing the System After the Gold DC Whistle has been connected and mounted the system must be set up and initialized This is accomplished using the EASII Elmo s Windows based software application Install the application and then perform setup and initialization according to ...

Page 63: ...Gold DC Whistle Installation Guide MAN G DCWHIIG EC Ver 1 705 www elmomc com 63 Table of Contents Chapter 7 Dimensions This chapter provides detailed technical information regarding the Gold DC Whistle ...

Page 64: ... www elmomc com 64 Table of Contents ...

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