Elmo WorldwideHead OfficeElmo Motion Control Ltd.60 Amal St.,P.O.Box 3078,Petach Tikva 49516IsraelTel+972(3)929-2300·Fax:+972(3)929-2322·info-il@elmomc..North AmericaElmo Motion Control Inc.42 Technology Way,Nashua,NH 03060USATel:+1(603)821-9979·Fax:+1(603)821-9943·info-us@elmomc.EuropeElmo Motion Control GmbHHermann-Schwer-Strasse 3,78048 VS-VillingenGermanyTe:+49(0)7721-9447120·Fax:+49(0)7721-9447130·info-de@elmomc.ChinaElmo Motion Control Technology(Shanghai)Co.Ltd.Room 1414,Huawen Plaza,No.999 Zhongshan West Road,Shanghai (200051)ChinaTel:+86-21-32516651·Fax:+86-21-32516652·info-asia@elmomc.Asia PacificElmo Motion Control APAC Ltd.B-601 Pangyo Innovalley,621 Sampyeong-dong,Bundang-gu,Seongnam-si,Gyeonggi-do,South Korea(463-400)Tel:+82-31-698-2010·Fax:+82-31-801-8078。info-asia@elmomc.Gold Whistle Installation Guide5MAN-G-WHIIG (Ver.1.208)Table of Contentschapter 1:Safety Information.........81.1.Warnings.…1.2.1.3.Directives and Standards..........101.4.CE Marking Conformance..........10Chapter 2:Product Description…2.1.Functional Description..12.2.Product Features.2.2.1.High Power Density.2.22 Supply nput..2.2.3.Servo Control..............122.2.4.Advanced Filters and Gain Scheduling132.2.6.Fully Programmable..132.2.7.2.2.8.Feedback Sensor Specifications.......2.2.9.2.2.10.Safety162.2.11.0 utputs…2.2.13.Built-In Protection ..........172.2.14.Status Indication....2.2.15.Automatic Procedures......2.3.System Architecture..................182.4.How to Use this Guide..............19Chapter 3:Technical Information ..............203.1.Physical Specifications............203.2.Technical Data............203.2.1.Auxiliary Supply ............Chapter 4:Installation.4.1.Site Requirements...................4.2.Unpacking the Drive Components....4.3.1.Connector Types.…4.3.2.4.3.2.1.Motor Power.................4.3.2.2.Main Power.......25Gold Whistle Installation GuideTable of ContentsMAN-G-WHIIG (Ver.1.208)64.3.2.3.Auxiliary Power Connector.....254.3.2.4..264.4.Mounting the Gold Whistle....314.5.Integrating the Gold Whistle on a PCB..324.5.1.Grounds and Returns.4.6.The Gold Whistle Connection Diagram.344.7.Main Power,Auxiliary Power and Motor Power......354.7.2.Main and Auxiliary Power.................364.7.2.1.Main Power....4.7.2.2.Auxiliary Power Supply (Optional)..4.7.2.3.Power Rating 200V...384.7.2.4.Power Rating 100V..................394.8.STO (Safe Torque Off)Inputs.................414.9.Feedback.444.9.1.4.9.1.1.Incremental Encoder....464.9.1.2.Absolute serial Encoder.474.9.13.Hall Sensors..................494.9.2.1.Incremental Encoder........504.9.2.2.Interpolated Analog Encoder51524.9.3.Port C-Emulated Encoder Output (J2).......524.10.User I/0.….544.10.1.Digital Inputs (1)..544.10.2.Digital Outputs (1)....574.10.3.Analog Input...584.11.4.11.1.RS-232 Communication (J2).......594.11.2.CAN Communication (2)...614.11.3.USB 2.0 Communication (J2)................634.11.4.EtherCAT Communication (J2).....4.11.5.Ether Communication (J2)................664.11.6.EtherCAT/Ether Line Interface ....684.13.Initializing the System...........684.14.Heat Dissipation....684.14.1.Thermal Data.............684.14.2.Heat Dissipation Data ............694.14.3.How to Use the Charts................7071Gold Whistle Installation GuideTable of ContentsMAN-G-WHIIG (Ver.1.208)5.2.Environmental Conditions.725.3.735.4.Feedbacks.........5.4.1.Feedback Supply Voltage...745.42.Feedback OptionS........................................745.4.2.1.Incremental Encoder Input..45.4.23.Interpolated Analog (Sine/Cosine)Encoder....755.4.24.5.4.2.5.Absolute serial Encoder.....765.4.3.Port c Feedback Output..5.1.Digital Input Interfaces-TTL Mode......785.5.2.Digital Output Interface-TTLMode.........795.5.2.1.0UT1and0UT2.5.5.2.2.0UT3and0UT4..805.5.3.Analog Input..805.6.Safe Torque off (STO)..................815.6.1.STo Input Interfaces-TTLMode.....815.7.Communications....................825.8.Pulse-Width Modulation(PWM)................835.9.Compliance with Standards..................84Gold Whistle Installation GuideMAN-G-WHIIG (Ver.1.208)Chapter 1:Safety InformationIn order to achieve the optimum,safe operation of the Gold Whistle servo drive,it isimperative that you implement the safety procedures included in this installation guide.Thisinformation is provided to protect you and to keep your work area safe when operating theGold Whistle and acpanying equipment.Please read this chapter carefully before you begin the installation process.Before you start,ensure that all system ponents are connected to earth ground.Electricalsafety is provided through a low-resistance earth connection.Only qualified personnel may install,adjust,maintain and repair the servo drive.A qualifiedperson has the knowledge and authorization to perform tasks such as transporting,assembling,installing,missioning and operating motors.The Gold Whistle servo drive contains electrostatic-sensitive ponents that can be damagedif handled incorrectly.To prevent any electrostatic damage,avoid contact with highly insulatingmaterials,such as plastic film and synthetic fabrics.Place the product on a conductive surfaceand ground yourself in order to discharge any possible static electricity build-up.To avoid any potential hazards that may cause severe personal injury or damage to the productduring operation,keep all covers and cabi doors shut.The following safety symbols are used in this manual:Warning:This information is needed to avoid a safety hazard,which might causebodily injury.Caution:This information is necessary for preventing damage to the product or toother equipment.www.elmomc.Gold Whistle Installation GuideSafety Information9MAN-G-WHIIG (Ver.1.208)1.1.WarningsTo avoid electric arcing and hazards to personnel and electrical contacts,neverconnect/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.Disconnectthe Gold Whistle from all voltage sources before it is opened for servicing..The Gold Whistle servo drive contains grounding conduits for electric current protection.Any disruption to these conduits may cause the instrument to bee hot (live)anddangerous.After shutting off the power and removing the power source from your equipment,wait atleast 1 minute before touching or disconnecting parts of the equipment that are normallyloaded with electrical charges (such as capacitors or contacts).Measuring the electricalcontact points with a meter,before touching the equipment,is remended.1.2.CautionsThe Gold Whistle servo drive contains hot surfaces and electrically-charged ponentsduring operation.The maximum DC power supply connected to the instrument must ply with theparameters outlined in this guide.When connecting the Gold Whistle to an approved isolated 12-95 VDC auxiliary powersupply,connect it through a line that is separated from hazardous live voltages usingreinforced or double insulation in accordance with approved safety standards.Before switching on the Gold Whistle,verify that all safety precautions have been observedand that the installation procedures in this manual have been followed.Do not clean any of the Gold Whistle drive's soldering with solvent cleaning fluids of pHgreater than 7(8 to 14).The solvent corrodes the plastic cover causing cracks and eventualdamage to the drive's PCBs.Elmo remends using the cleaning fluid Vigon-EFM which is pH Neutral (7).For further technical information on this remended cleaning fluid,select the link:://www.zestron./fileadmin/zestron.-usa/daten/electronics/Product_TI1s/TI1-VIGON_EFM-US.pdfwww.elmomc.Gold Whistle Installation GuideSafety Information10MAN-G-WHIIG (Ver.1.208)1.3.Directives and StandardsThe Gold Whistle conforms to the following industry safety standards:Safety StandardItemApproved IEC/EN 61800-5-1,SafetyAdjustable speed electrical power drive systemsRecognized UL 508CPower Conversion EquipmentIn pliance with UL 840Insulation Coordination Including Clearances andCreepage Distances for Electrical EquipmentIn pliance with UL 60950-1Safety of Information Technology Equipment(formerly UL 1950)Including Electrical Business EquipmentIn pliance with EN 60204-1Low Voltage Directive 73/23/EECThe Gold Whistle servo drive has been developed,produced,tested and documented inaccordance with the relevant standards.Elmo Motion Control is not responsible for anydeviation from the configuration and installation described in this documentation.Furthermore,Elmo is not responsible for the performance of new measurements or ensuringthat regulatory requirements are met.1.4.CE Marking ConformanceThe Gold Whistle servo drive is intended for incorporation in a machine or end product.Theactual end product must ply with all safety aspects of the relevant requirements of theEuropean Safety of Machinery Directive 98/37/EC as amended,and with those of the mostrecent versions of standards EN 60204-1 and EN 292-2 at the least.According to Annex lll of Article 13 of Council Directive 93/68/EEC,amending Council Directive73/23/EEC concerning electrical equipment designed for use within certain voltage limits,theGold Whistle meets the provisions outlined in Council Directive 73/23/EEC.The partyresponsible for ensuring that the equipment meets the limits required by EMC regulations isthe manufacturer of the end product.1.5.Warranty InformationThe products covered in this manual are warranted to be free of defects in material andworkmanship and conform to the specifications stated either within this document or in theproduct catalog description.All Elmo drives are warranted for a period of 12 months from thetime of installation,or 18 months from time of shipment,whichever es first.No otherwarranties,expressed or implied-and including a warranty of merchantability and fitness fora particular purpose -extend beyond this warranty.www.elmomc.Gold Whistle Installation Guide11MAN-G-WHIIG (Ver.1.208)Chapter 2:Product Description2.1.Functional DescriptionThe Gold Whistle is an advanced high power density servo drive.It provides top servoperformance,advanced working and built in safety,all in a small PCB mountable package.The Gold Whistle has a fully featured motion controller and local intelligence.The Gold Whistle operates from a DC power source.The drive can operate as a stand-alonedevice or as part of a multi-axis system in a distributed configuration on a real-time work.The Gold Whistle drive is easily set up and tuned using the Elmo Application Studio(EAS)software tools.As part of the Gold product line,it is fully programmable with the Elmo motioncontrol language.For more information about software tools refer to the Elmo ApplicationStudio Software Manual.The Gold Whistle is available in a variety of models.There are multiple power rating options,two different munications options,a number of feedback options and different l/Oconfiguration possibilities.2.2.Product FeaturesNoThe features described in this chapter relate to the range of Gold Whistle models.Depending on the model you have purchased,not all features are available.To see the features for your model,look at the product label on the Gold Whistle and use theproduct catalog number schematic that appears at the beginning of this manual and onpage 23 to determine which specific features are available to you.2.2.1.High Power DensityThe Gold Whistle delivers up to 1.6 kW of continuous power or 3.2 kW of peak power in a38.0cc(2.32in3)pa ckage(55X46X15mmor2.2"x1.8"X0.6").2.2.2.Supply Input.Gold Whistle Power rating is 12 to 195 VDC.Two power ratings for Gold Whistle;100V and 200V:For power rating 200VTwo power isolated DC power sources are required,main power 12-195V andAuxiliary Power 12-95V for the logic.For power rating of 100VSingle DC Power Supply-Power to the Gold Whistle is provided by a 12-95 VDC singleisolated DC power source (not included with the Gold Whistle).A"smart"control-www.elmomc.Gold Whistle Installation GuideProduct Description12MAN-G-WHIIG (Ver.1.208)supply algorithm enables the Gold Whistle to operate with only one power supply withno need for an auxiliary power supply for the logic.Optional Backup (Auxiliary)SupplyIf backup functionality is required in case of power loss,e.g.,to keep the originalposition,a 12-95 VDC external isolated supply should be connected(via the GoldWhistle's VL+terminal).This is more flexible than the requirement for 24 VDC supply.If backup is not needed,a single power supply is used for both the power and logiccircuits.There are two voltage ratings of the Gold Whistle,therefore the correct power supplymust be used,according to the maximum operating voltage of the Gold Whistle.Referto Chapter 3:Technical Information.2.2.3.Servo ControlAdvanced and extremely fast vector control algorithm(current loop bandwidth:4 kHz).Current/Torque sampling rate:up to 25 kHz(40 us)Velocity sampling rate:up to 12.5 kHz (80 us)·Position sampling rate:upto12.5kHz(80μs)Electrical mutation frequency:up to 4 kHz.Current closed loop bandwidth exceeds 4 kHz.Position/Velocity/Acceleration mand range-full 32 bitPosition over velocity,with full dual loop support.S-curve Profile SmoothingCogging,BEMF and xL pensationDual Loop Operation supported by Auto TuningFast,easy and efficient advanced Auto TuningMotion profiler numeric range:Position up to +2 x 10 counts·Velocity up to2x10°counts/.secAcceleration up to 2 x 10 counts/sec?www.elmomc.