Elmo 95VDC User Manual

Duo

Integrated Solution

Installation Guide

June 2007 (Ver. 1.0)

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 Duo 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.

 Elmo Motion Control and the Elmo Motion Control logo are trademarks of Elmo

Motion Control Ltd.

 Information in this document is subject to change without notice.

Document No. MAN-DUOIG

Copyright ©2007

Elmo Motion Control Ltd.

All rights reserved.

Duo Catalog Number:

DUO- A

Axis 1 Ve rs io n

Blank = Standard

A=Advanced

Continu o u s C urrent(Amps)

Axis 2 Ve rs io n

Blank = S tandard

Continu o u s C urrent(Amps)

Axis 1

A = Advanced

Axis 2

XXAXX/YYYZZ

:

:

Cable Kit Catalog No. CBL-BRDKIT-001 (kit optional)

Revision History:

Ver. 1.0 June 2007 First Release (MAN- DUOIG.PDF)

Axis 2 Feedbacks:

E- Incremental Encoder and/or Halls
R- Resolver
I- Interpolated A n a lo g E n c o de r
T- Tachometer and Potentiometer

Axis 1 Feedbacks:

E- Incremental Encoder and/or Halls
R- Resolver
I- Interpolated Analog Encoder
T- Tachometer and Potentiometer

Maximum DC
Operating Voltage

Elmo Motion Control Ltd.

64 Gisin St., P.O. Box 463

Petach Tikva 49103

Tel: [phone]

Fax: [phone]

Elmo Motion Control Inc.

1 Park Drive, Suite 12

Westford, MA 01886

USA

Tel: [phone]

Fax: [phone]

Elmo Motion Control GmbH

Steinkirchring 1

D-78056, Villingen-Schwenningen

Germany

Tel: [phone]

Fax: [phone]

www.elmomc.com

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

Contents

i

Chapter 1: Safety Information..........................................................................................

1-1

1.1 Warnings ............................................................................................................. 1-2

1.2 Cautions............................................................................................................... 1-2

1.3 Directives and Standards................................................................................... 1-3

1.4 CE Mark Conformance....................................................................................... 1-3

1.5 Warranty Information........................................................................................ 1-3

Chapter 2: Introduction..................................................................................................... 2-1

2.1 Product Description ........................................................................................... 2-1

2.2 Product Features................................................................................................. 2-2

2.2.1 Current Control ...................................................................................................... 2-2

2.2.2 Velocity Control...................................................................................................... 2-2

2.2.3 Position Control...................................................................................................... 2-2

2.2.4 Advanced Position Control (in Advanced model only)......................................... 2-2

2.2.5 Communication Options ....................................................................................... 2-2

2.2.6 Feedback Options ................................................................................................... 2-2

2.2.7 Fault Protection....................................................................................................... 2-3

2.3 How to Use this Guide....................................................................................... 2-3

Chapter 3: Installation....................................................................................................... 3-1

3.1 Site Requirements............................................................................................... 3-1

3.2 Unpacking the Drive Components................................................................... 3-1

3.3 Mounting the Duo .............................................................................................. 3-2

3.4 Connecting the Cables ....................................................................................... 3-3

3.4.1 Wiring the Duo ....................................................................................................... 3-3

3.5 Duo Connectors type.......................................................................................... 3-5

3.6 Hardware Requirements.................................................................................... 3-6

3.7 Duo Block Diagram ............................................................................................ 3-7

3.8 The Main Power and Motor Power Connectors.............................................. 3-8

3.8.1 Connecting Motor Power ...................................................................................... 3-8

3.8.2 Connecting Main Power........................................................................................ 3-9

3.8.3 Low power Auxiliary Supply (optional)........................................................... 3-10

3.9 Main Feedback.................................................................................................. 3-12

3.10 Auxiliary Feedback (bi-directional)................................................................ 3-17

3.10.1 Main and Auxiliary Feedback Combinations................................................... 3-18

3.10.2 Auxiliary Feedback – Emulated, Differential Buffered Encoder Output Option

(YA[4]=4) ...............................................................................................................

3.10.3 Auxiliary Feedback - Differential Encoder Input Option (YA[4]=2)............. 3-22

3.10.4 Auxiliary Feedback – Differential Pulse-and-Direction Input Option (YA[4]=0)3-25

3-20

3.11 I/O….................................................................................................................. 3-27

3.11.1 Digital Input .......................................................................................................... 3-28

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3.11.2 Digital Output....................................................................................................... 3-29

3.11.3 Analog Input ......................................................................................................... 3-29

3.12 Communications............................................................................................... 3-30

3.12.1 RS232 Communication......................................................................................... 3-30

3.12.2 CANopen Communication ................................................................................. 3-31

3.13 Powering Up ..................................................................................................... 3-33

3.14 Initializing the System...................................................................................... 3-33

Appendix A: Technical Specifications .............................................................................. A-1

A.1 Features............................................................................................................... A-1

A.2 Built-In Protection ............................................................................................. A-3

A.3 Duo Dimensions ................................................................................................ A-4

A.4 Power Ratings .................................................................................................... A-5

A.5 Control Specifications ....................................................................................... A-6

A.5.1 Current Loop...........................................................................................................A-6

A.5.2 Velocity Loop ..........................................................................................................A-7

A.5.3 Position Loop ..........................................................................................................A-7

ii

A.6 Feedbacks ........................................................................................................... A-8

A.6.1 Incremental Encoder ..............................................................................................A-8

A.6.2 Feedback Supply Voltage......................................................................................A-8

A.6.3 Digital Halls.............................................................................................................A-9

A.6.4 Interpolated Analog Encoder (Sine/Cosine) ......................................................A-9

A.6.5 Resolver..................................................................................................................A-10

A.6.6 Tachometer* ..........................................................................................................A-10

A.6.7 Potentiometer........................................................................................................A-11

A.6.8 Auxiliary Feedback Port (output mode YA[4]= 4)...........................................A-11

A.6.9 Auxiliary Feedback Port (input mode YA[4]= 2, 0).........................................A-12

A.7 I/Os..............................................................................................................…..A-13

A.7.1 Digital Input Interface – 6 Digital Inputs ..........................................................A-13

A.7.2 Digital Output Interface – 2 Digital Outputs...................................................A-14

A.7.3 Analog Inputs – 1 Analog Input..........................................................................A-14

A.8 Mechanical Specifications............................................................................... A-15

A.9 Environmental Conditions ............................................................................. A-15

A.10 Compliance Standards ............................................................................. A-15

A.10.1 Design ....................................................................................................................A-15

A.10.2 Safety ......................................................................................................................A-16

A.10.3 EMC........................................................................................................................A-16

Appendix B: Cables (Optional).........................................................................................B-1

B.1 Cable Photos........................................................................................................ B-1

B.2 Cable Kit.............................................................................................................. B-2

B.3 Main Feedback Cable (CBL-HDRFB-001) ........................................................ B-3

B.4 Auxiliary Feedback (CBL-HDRAUX-001)........................................................ B-4

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B.5 I/O (CBL-HDRIO-001)....................................................................................... B-5

B.6 Communication Cables...................................................................................... B-6

B.6.1 RS-232 Option (CBL-RJ452321)............................................................................. B-6

B.6.2 CAN Open (CBL-RJ45CAN1) ............................................................................... B-7

B.7 Guidelines for Making Your Own Cables........................................................ B-8

B.7.1 Recommended Wire Cross Sections..................................................................... B-8

iii

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

Chapter 1: Safety Information

In order to achieve the optimum, safe operation of the Duo, 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 Duo and
accompanying equipment.

Please read this chapter carefully before you begin the installation process.

Before you start, ensure that all system components are connected to earth ground.
Electrical safety is provided through a low-resistance earth connection.

Only 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 Duo contains electrostatic-sensitive components that can be damaged if handled
incorrectly. To prevent any electrostatic damage, avoid contact with highly insulating
materials, such as plastic film and synthetic fabrics. Place the product on a conductive
surface and ground yourself in order to discharge any possible static electricity build-up.

1-1

To avoid any potential hazards that may cause severe personal injury or damage to the
product during operation, keep all covers and cabinet doors shut.

The following safety symbols are used in this manual:

Warning:
This information is needed to avoid a safety hazard, which might cause
bodily injury.

Caution:
This information is necessary for preventing damage to the product or
to other equipment.

Note:

This is auxiliary information that ensures the correct operation of the
equipment.

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MAN-DUOIG (Ver. 1.0)

1.1 Warnings

To avoid electric arcing and hazards to personnel or electrical damage,
never connect/disconnect any plug or cable from 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 Duo from all voltage sources before it is opened
for servicing.

The Duo contains grounding conduits for electric current protection. Any
disruption to these conduits may cause the instrument to become hot
(live) and dangerous.

After shutting off the power and removing the power source from your
equipment, wait at least 1 minute before touching or disconnecting parts
of the equipment that are normally loaded with electrical charges (such as
capacitors or contacts). Measuring the electrical contact points with a
meter, before touching the equipment, is recommended.

1-2

1.2 Cautions

The Duo contains hot surfaces and electrically-charged components
during operation.

The maximum AC/DC power supply connected to the instrument must
comply with the parameters outlined in this guide. Furthermore, the power
supply must be isolated from hazardous live voltages using reinforced or
double insulation in accordance to approved safety standards.

When connecting the Duo to an approved 12 ~ 95VDC (8.5 ~ 67VAC)
auxiliary power supply, connect it through a line that is isolated from
hazardous live voltages using reinforced or double insulation in
accordance with approved safety standards.

Before switching on the Duo, verify that all safety precautions have been
observed and that the installation procedures in this manual have been
followed.

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MAN-DUOIG (Ver. 1.0)

1.3 Directives and Standards

The Duo conforms to the following industry safety standards:

Safety Standard Item

In compliance with UL508c Power Conversion Equipment

1-3

In compliance with UL840

Insulation Coordination, Including Clearance and
Creepage Distances of Electrical Equipment

In compliance with UL60950-1
(formerly UL1950)

Safety of Information Technology Equipment,
Including Electrical Business Equipment

In compliance with EN60204-1 Low Voltage Directive, 73/23/EEC

The Duo has been developed, produced, tested and documented in accordance with the
relevant standards. Elmo Motion Control is not responsible for any deviation from the
configuration and installation described in this documentation. Furthermore, Elmo is not
responsible for the performance of new measurements or ensuring that regulatory
requirements are met.

1.4 CE Mark Conformance

The Duo is intended for incorporation in a machine or end product. The actual end
product must comply with all safety aspects of the relevant requirements of the European
Safety of Machinery Directive 98/37/EC as amended, and with those of the most recent
versions of standards EN60204-1 and EN292-2 at the least.

According to Annex III of Article 13 of Council Directive 93/68/EEC, amending Council
Directive 73/23/EEC concerning electrical equipment designed for use within certain
voltage limits, the Duo meets the provisions outlined in Council Directive 73/23/EEC.
The party responsible for ensuring that the equipment meets the limits required by EMC
regulations is the manufacturer of the end product.

1.5 Warranty Information

The products covered in this manual are warranted to be free of defects in material and
workmanship and conform to the specifications stated either within this document or in
the product catalog description. All Elmo drives are warranted for a period of 12 months
from the time of installation, or 18 months from time of shipment, whichever comes first.
No other warranties, expressed or implied — and including a warranty of
merchantability and fitness for a particular purpose — extend beyond this warranty.

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MAN-DUOIG (Ver. 1.0)

Chapter 2: Introduction

This installation guide describes the Duo and the steps for its wiring, installation and
power-up. Following these guidelines ensures maximum functionality of the product and
the system to which it is connected.

2.1 Product Description

The Duo series of servo drives enhances Elmo’s range of digital servo drives, recognized
for having the highest power density and intelligence. The Duo is a highly compact
integrated solution containing two drives in a single package. The solution operates
under a single power supply and is designed for applications with up to two axes.

The Duo integrates Elmo’s advanced “Elmo First Control” technology, which contributes
to the product’s excellent control performance, wide range of functionalities and high
efficiency and reliability. The solution includes two fully separated digital motion
controllers that feature:

2-1

• CANopen-based networking operating simultaneously via RS-232 and CANopen

DS 301, DSP 305, DSP 402 communications and featuring a third-generation
programming environment

• Current, velocity and position control loops including PT and PVT

• Commutation types

• Position feedbacks

The benefits are high dynamics and increased precision for dual axis automated
machines such as robots, feeders, up- and down-loaders, conveyor belts and production
lines.

Power to the various Duo models is provided by a 0 - 95VDC source. A “smart” control­supply algorithm enables the Duo to operate with only one power supply and there is no
need for an auxiliary power supply for the logic.

If back-up functionality is required for storing control parameters in case of power-loss,
an external 12 ~ 95VDC supply should be connected (via the +VL terminal on the Duo)
providing maximum flexibility and backup functionality when needed.

Note: This back-up power supply can operate from any voltage source within the

12 ~ 95VDC range. This is much more flexible than a standard 24VDC power supply
requirement.

The Duo series fully complies with all relevant safety and EMC regulations.

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2.2 Product Features

2.2.1 Current Control

 Fully digital
 Sinusoidal commutation with vector control or trapezoidal commutation

with encoder and/or digital Hall sensors

 12-bit current loop resolution
 Automatic gain scheduling, to compensate for variations in the DC bus

power supply

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

2-2

 Automatic, manual and advanced manual tuning and determination of

optimal gain and phase margins

2.2.3 Position Control

 Programmable PIP control filter


Programmable notch and low-pass filters



Position follower mode for monitoring the motion of the slave axis relative
to a master axis, via an auxiliary encoder input



Pulse-and-direction inputs

 Sample rate four times current loop sample time

Fast event capturing inputs



2.2.4 Advanced Position Control (in 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

 PT and PVT motion modes
 Dual (position/velocity) loop
 Fast output compare (OC)

2.2.5 Communication Options

Depending on the application, Duo users can select from two communication
options:

 RS232 serial communication
 CANopen for fast communication in a multi-axis distributed environment

2.2.6 Feedback Options

• Incremental Encoder – up to 20 Mega-Counts (5 Mega-Pulse) per second

• Digital Halls – up to 2 KHz

• Incremental Encoder with Digital Halls for commutation – up to 20 Mega-

Counts per second for encoder

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MAN-DUOIG (Ver. 1.0)

• Interpolated Analog Sine/Cosine Encoder – up to 250 KHz (analog signal)

Internal Interpolation - up to x4096
Automatic Correction of amplitude mismatch, phase mismatch, signals offset
Auxiliary emulated, unbuffered, single-ended, encoder output

• Resolver

Programmable 10~15 bit resolution
Up to 512 Revolution Per Second (RPS)
Auxiliary emulated, unbuffered, single-ended, encoder output

• Tachometer, Potentiometer

• Elmo drives provide supply voltage for all the feedback options

2.2.7 Fault Protection

The Duo includes built-in protection against possible fault conditions, including:

• Software error handling

• Status reporting for a large number of possible fault conditions

• Protection against conditions such as excessive temperature, under/over

voltage, loss of commutation signal, short circuits between the motor power
outputs and between each output and power input return

2-3

• Recovery from loss of commutation signals and from communication errors

2.3 How to Use this Guide

In order to install and operate your Elmo Duo, you will use this manual in conjunction
with a set of Elmo documentation. Installation is your first step; after carefully reading
the safety instructions in the first chapter, the following chapters provide you with
installation instructions as follows:

Chapter 3, Installation, provides step-by-step instructions for unpacking, mounting,

connecting and powering up the Duo.

The Appendices list all the drive ratings and specifications as well as information on the
relevant cables.

Upon completing the instructions in this guide, your Duo should be successfully
mounted and installed. From this stage, you need to consult higher-level Elmo
documentation in order to set up and fine-tune the system for optimal operation. The
following figure describes the accompanying documentation that you will require.

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MAN-DUOIG (Ver. 1.0)

2-4

Figure 2-1: Elmo Digital Servo Drive Documentation Hierarchy

As depicted in the previous figure, this installation guide is an integral part of the Duo
documentation set, comprising:

 The Duo Installation Guide contains information about how to use the Duo

and Cable Kit

 The Composer Software Manual, which includes explanations of all the

software tools that are part of Elmo’s Composer software environment

 The SimplIQ Command Reference Manual, which describes, in detail, each

software command used to manipulate the Whistle motion controllers

 The SimplIQ Software Manual, which describes the comprehensive software

used with the Whistles

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MAN-DUOUG (Ver. 1.0)

Chapter 3: Installation

3.1 Site Requirements

You can guarantee the safe operation of the Duo by ensuring that it is installed in an
appropriate environment.

Feature Value

Ambient operating temperature 0° to 40°C (32° to 104°F)

Maximum operating altitude 10,000m (30,000ft)

Maximum relative humidity 90% non-condensing

Operating area atmosphere No flammable gases or vapors permitted in area

Models for extended environmental conditions are available.

3-1

The Whistle on the Duo dissipates its heat by convection. The maximum
operating ambient temperature of 0° to 40°C (32° to 104°F) must not be
exceeded. Refer to the Heat Dissipation section of the Whistle Installation Guide
for more information.

3.2 Unpacking the Drive Components

Before you begin working with the Duo, verify that you have all of its components, as
follows:

 The Duo.
 The Composer software and software manual.

The Duo is shipped in a cardboard box with styrofoam protection.

To unpack the Duo:

1. Carefully remove the Duo from the box and the Styrofoam.

2. Check the Duo 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 Duo.

3. To ensure that the Duo you have unpacked is the appropriate type for your requirements,

locate the part number sticker on the side of the Duo. It looks like this:

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MAN-DUOUG (Ver. 1.0)

The part number at the top gives the type designation as follows:

3-2

DUO- A

Axis 1 Ve rs io n

Blank = Standard

A = Advanced

Axis 1

Continuous Current(Amps)

Axis 2 Ver s ion

Blank = Standard

A = Advanc ed

Axis 2

Continuous Current(Amps)

XXAXX/YYYZZ

:

:

Axis 2 Feedbacks:

E- Incremental Encoder and/or Halls
R- Resolver
I- Interpolated Analog Encoder
T- Tachometer and Potentiometer

Axis 1 Feedbacks:

E- Incremental Encoder and/or Halls
R- Resolver
I- Interpolated Analog Encoder
T- Tachometer and Potentiometer

Maximum DC
Operating Voltage

Verify that the Duo type is the one that you ordered, and ensure that the voltage meets your
specific requirements.

3.3 Mounting the Duo

The Duo 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 Duo
(see the diagram below).

Figure

3-1: Mounting the Duo

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3.4 Connecting the Cables

3.4.1 Wiring the Duo

Once the Duo 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 Duo.

Follow these instructions to ensure safe and proper wiring

 Use twisted pair shielded cables for control, Feedback and communication connections.

For best results, the cable should have an aluminum foil shield covered by copper braid,
and should contain a drain wire.

The drain wire is a non-insulated wire that is in contact with parts of the cable,
usually the shield. It is used to terminate the shield and as a grounding connection.

 The impedance of the wire must be as low as possible. The size of the wire must be thicker

than actually required by the carrying current. A 26 or 28 AWG wire for control and
Feedback cables is satisfactory although 26 AWG is recommended.

 Use shielded wires for motor connections as well. If the wires are long, ensure that the

capacitance between the wires is not too high: C < 30 nF is satisfactory for most applications.

 Keep all wires and cables as short as possible.
 Keep the motor wires as far away as possible from the Feedback, control and

communication cables.

 Ensure that in normal operating conditions, the shielded wires and drain carry no current.

The only time these conductors carry current is under abnormal conditions, when
electrical equipment has become a potential shock or fire hazard while conducting
external EMI interferences directly to ground, in order to prevent them from affecting the
drive. Failing to meet this requirement can result in drive/controller/host failure.

 After completing the wiring, carefully inspect all wires to ensure tightness, good solder

joints and general safety.

The following connectors are used for wiring the Duo:

3-3

Type Function Connector Location

Main Power VL, VP+, PR, PR, PE

Motor Power PE, M1, M2, M3

Motor Main

Power

Power

Table 3-1: Connectors on the “Bottom” of the Duo

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y

MAN-DUOUG (Ver. 1.0)

Type Function Connector Location

3-4

Main

Feedback

Feedback

I/O I/O

Auxiliary
Feedback

Auxiliary
Feedback

Main

Feedback

Table 3-2: Connectors on the “Front” of the Duo

Type Function Connector Location

CANopen CANopen IN

CANopen CANopen OUT

RS232

Auxiliar
Feedback

Axis 2

I/O

Main Auxiliar

Feedback Feedback

I/O

Axis 1

RS232-1

RS232-2

CANopen

IN

CANopen

OUT

Table 3-3: Connectors on the “Top” of the Duo

RS232-1 RS232-2

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3.5 Duo Connectors type

3-5

Type On Board Connector

Main Power Phoenix 5-pin Header P/N:MSTBA 2.5HC/5-G

Motor
Power

Main

Feedback

I/O 2

Auxiliary
Feedback

CANopen

Qty Conn.

1

2

2

Phoenix 4-pin Header P/N:MSTBA 2.5/4G-5.08

12-pin Molex Header P/N:90130-3212

14-pin Molex Header P/N:90130-3214

2

16-pin Molex Header P/N:90130-3216

2 8-pin RJ-45 Socket

Comm.

RS232

2 8-pin RJ-45 Socket

Comm.

Connector Location

CAN

RS232

Axis 2

RS232
Axis 1

Main

Feedback

Axis 2

Auxiliary
Feedback

Axis 2

Main

Power

I/O

Axis 2

Motor

Power Axis 1

Motor

Power Axis 2

Axis 1

Table 3-4: Connector Types

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3.6 Hardware Requirements

The components that you will need to install your Duo are:

Component

Qty

Conn.

Mating Connector

Function

Described

in section

3-6

Cable

Drawing

Main Power 1

Motor
Power

Main

Feedback

2

2 B.3

I/O 2

Auxiliary
Feedback

RS232

Comm.

2

2 8-pin RJ-45 Plug B.6.1

Phoenix 5-pin Plug

P/N:MSTBT 2.5HC/5-ST

Phoenix 4-pin Plug

P/N:MSTBT 2.5/4-ST-5.08

12-pin Molex Plug

P/N:90142-0012

Pin P/N: 90119-2121

14-pin Molex Plug

P/N:90142-0014

Pin P/N: 90119-2121

16-pin Molex Plug

P/N:90142-0016

Pin P/N: 90119-2121

VL, VP+, PR, PR, PE

PE, M1, M2, M3

Feedback

I/O

B.5

Auxiliary Feedback B.4

RS232-1

RS232-2

PE

VL

Plug

PE

M3

Plug

CANopen

Comm.

CANopen IN

2 8-pin RJ-45 Plug B.6.2

CANopen OUT

Table 3-5: Connector Cross Reference

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3.7 Duo Block Diagram

3-7

Figure 3-2: Duo Block Diagram

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3.8 The Main Power and Motor Power Connectors

Pin Function Cable Pin Positions

PE Protective earth Power

PR Power return Power

PR Aux. Supply Input Return Auxiliary

VP+ Pos. Power input Power

3-8

VL Aux. Supply Input Auxiliary

AC

Motor

Cable

DC

Motor

Cable

M3 Motor phase Motor Motor

M2 Motor phase Motor Motor

M1 Motor phase Motor N/C

PE Protective earth Motor Motor

Table 3-6: Connectors for Main Power and Motors

3.8.1 Connecting Motor Power

Connect the motor power cable to the M1, M2, M3 and PE terminals of the relevant axis.
The phase connection order is arbitrary because the Composer will establish the proper
commutation automatically during setup. If several motor/drive combinations are designed
to operate in an identical manner, it is recommended to download the program into all the
drives and connecting them in the same way.

Notes for connecting the motor cables:

 For the greatest immunity, it is highly recommended to use a shielded (not twisted)

cable for the motor connection. A 4-wire shielded cable should be used. The gauge is
determined by the actual current consumption of the motor.

 Connect the shield of the cable to the closest ground connection at the motor end.
 Be sure that the motor chassis is properly grounded.

Figure 3-3: AC Motor Power Connection Diagram for each AXIS.

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3.8.2 Connecting Main Power

Connect the DC power supply cable to the VP+ and PR terminals of the Main power connector.

Notes for connecting the DC power supply:

 The source of the 0 ~ 95 VDC Power Supply must be isolated.
 For the greatest immunity, it is highly recommended to use twisted and shielded

cables for the DC power supply cable. A 3-wire shielded cable should be used. The
gauge is determined by the actual current consumption of the motor.

 Connect the cable shield to the closest ground connection near the power supply.
 Connect the PE to the closest ground connection near the power supply.
 Connect the PR to the closest ground connection near the power supply.
 Before applying power, first verify the polarity of the connection.

3-9

Figure 3-4: Main Power DC Supply Connection Diagram

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3.8.3 Low power Auxiliary Supply (optional)

Notes for 12 ~ 95 VDC Auxiliary Supply connections:

 The source of the 12 ~ 95 VDC Auxiliary Supply must be isolated from the Main.

the

 For safety reasons, connect the return (common) of

the closest ground near the Auxiliary Supply source.

 Connect the cable shield to the closest ground near the Auxiliary Supply source.
 Before applying power, first verify the polarity of the connection.

Caution: Power to each Whistle and motor must come from the Main Supply

and NOT from the Auxiliary Supply.

Auxiliary Supply source to

3-10

Figure 3-5: Auxiliary Supply Connection Diagram

The back-up functionality can be used for storing control parameters in case of power-loss,
providing maximum flexibility and backup functionality when needed.

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3-11

Figure 3-6: Shared Supply Connection Diagram

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3.9 Main Feedback

The Main Feedback port is used to transfer Feedback data from the motor to the drive.

3-12

The Duo accepts the following as a
Main Feedback mechanism:

 Incremental encoder only
 Incremental encoder with digital hall

sensors

 Digital hall sensors only
 Incremental analog (sine/cosine)

encoder (option)

 Resolver (option)
 Tachometer and potentiometer

(option)

 Analog Halls

The Main Feedback port on the Duo has a 12-pin Molex Header plug.

Interpolated Analog

Incremental Encoder

Encoder

Resolver

Tachometer and

Potentiometer

WHI XX/YYY_ WHI XX/YYYI WHI XX/YYYR WHI XX/YYYT

Pin Signal Function Signal Function Signal Function Signal Function

1 +5V Encoder/Hall

+5V supply

2 SUPRET Supply return SUPRET Supply return SUPRET Supply return SUPRET Supply return

3 CHA Channel A A+ Sine A S1 Sine A Tac 1+ Tacho Input 1

4 CHA- Channel A

complement

5 CHB Channel B B+ Cosine B S2 Cosine B Tac 2+ Tacho Input 2

6 CHB- Channel B

complement

7 INDEX Index R+ Reference R1 Vref f=1/TS,

8 INDEX- Index

complement

9 HA Hall sensor A

input

10 HB Hall sensor B

input

11 HC Hall sensor C

input

12 SUPRET Supply return SUPRET Supply return SUPRET Supply return SUPRET Supply return

+5V Encoder/Hall

+5V supply

A- Sine A

complement

B- Cosine B

complement

R- Reference

complement

HA Hall sensor A

input

HB Hall sensor B

input

HC Hall sensor C

input

+5V Encoder/Hall

S3 Sine A

S4 Cosine B

R2 Vref complement

NC - HA Hall sensor A

NC - HB Hall sensor B

NC - HC Hall sensor C

+5V supply

complement

complement

50mA Max.

f= 1/TS, 50mA
Maximum

+5V Encoder/Hall

+5V supply

Pos. (20V max)

Tac 1- Tacho Input 1

Neg. (20V max)

Pos. (50V max)

Tac 2- Tacho Input 2

Neg. (50V max)

POT Potentiometer

Input

NC -

input

input

input

Table 3-7: Main Feedback Cable Pin Assignment for Each Axis

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3-13

Figure 3-7: Main Feedback- Incremental Encoder With Digital Halls Sensors Connection Diagram

Figure 3-8: Main Feedback- Incremental Encoder Only Connection Diagram

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3-14

Figure 3-9: Main Feedback – Interpolated Analog Encoder Connection Diagram

Figure 3-10: Main Feedback– Resolver Connection Diagram

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3-15

Figure

Figure

3-11: Main Feedback – Tachometer Feedback with Digital Hall Sensor

Connection Diagram for Brushless Motors

3-12: Main Feedback – Tachometer Feedback Connection Diagram for Brush Motors

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3-16

Figure

3-13: Main Feedback – Potentiometer Feedback with Digital Hall Sensor

Connection Diagram for Brushless Motors

Figure

3-14: Main Feedback –

Potentiometer Feedback Connection Diagram for Brush Motors and Voice Coils

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3.10 Auxiliary Feedback (bi-directional)

When using one of the Auxiliary Feedback options, the relevant functionality of the Auxiliary
Feedback's ports are software selected for that option. Refer to the SimplIQ Command Reference
Manual for detailed information about Auxiliary Feedback setup.

The Auxiliary Feedback connector has two ports – B1 and B2.

• Port B1 has three pairs of differential buffered inputs

• Port B2 has three pairs of differential buffered outputs

There are two modes of operation for this interface:

• Mode 1 (Composer Command: YA[4]=4) see 3.10.2

When the Auxiliary port of the Whistle is set by the software to act as an emulated
encoder output (this is practical only when using Resolver or Analog-Encoder as the
Main Feedback):

 B1 input becomes inactive
 B2 presents emulated differential buffered encoder output signals of the Main

Feedback

3-17

• Mode 2 (Composer Command: YA[4]=2 or YA[4]=0) see 3.10.3 & 3.10.4

When the Auxiliary port of the Whistle is set by software to act as an input

 B1 becomes an active differential buffered input
 B2 presents differential buffered encoder output signals of B1

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3.10.1 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 has two ports (B1 and B2).
When used in combination with Main Feedback, the Auxiliary Feedback can be set, by
software, as follows:

3-18

Main
Feedback

Incremental

Encoder

Input

Interpolated

Analog

(Sin/Cos)

Encoder

Input

Resolver

Input





Auxiliary Feedback: Output

YA[4] = 4

(Auxiliary Feedback: output)

N.A

B2 - output
Analog Encoder
position data
emulated in
Differential,
buffere d ,
incremental
Encoder format

B1 - not available

Main Feedback:
Analog Encoder

B2 - output
Resolver
position data
emulated in
differential,
buffered,
incremental
Encod e r fo rm a t

B1 - no t a v a ilable

Main Feedback:

Resolver

Potentiometer

Tachometer

Input

Typical
Applications

N.A

 Analog Encoder applications where position data is required, in the Encoder’s

quadrature format, for other purposes such as position controllers and/or other
drives.

 Resolver applications where position data is required in the Encoder’s quadrature

format, for other purposes such as position controllers and/or other drives.

Duo User Guide

MAN-DUOUG (Ver. 1.0)

Auxiliary Feedback: Input

Main
Feedback

YA[4] = 2

(Auxiliary Feedback: input)

(Auxiliary Feedback: input)

YA[4] = 0

Incremental

Encoder

Input

Interpolated

Analog

(Sin/Cos)

Encoder

Input

Resolver

Input

Main

Feedback:

Incremental

Encoder

or

Analog

Encoder

or

Resolver

or

Tachometer

or

Potentiometer

Input

Auxilia ry
Feedback:

B1

Buffered
Differential
Incremental
Encoder
Input

B2

Differential
Buffered
Encoder
Output of B1

Main

Feedback:

Incremental

Encoder

or

Analog

Encoder

or

Resolver

or

Tachometer

or

Potentiometer

Input

Auxiliary
Feedback:

B2
Buffered
Differential

Pulse &
Direction
Commands
Output of B1

Potentiometer

Tachometer

Input

3-19

B1

Buffered
Differential
Pulse &
Direction
Commands
Input

Typical
Applications

Any application where two Feedbacks are
used by the drive.

The Auxiliary Feedback port serves as an
input for the Auxiliary incremental encoder.

For applications such as Follower, ECAM, or
Dual Loop.

Any application where two Feedbacks are
used by the drive.

The Auxiliary Feedback port serves as an
input for Pulse & Direction Commands.

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3.10.2 Auxiliary Feedback – Emulated, Differential Buffered Encoder Output Option (YA[4]=4)

The Auxiliary Feedback's B2 port can provide emulated encoder signals to other
controllers or drives. This option can be used when:

 A Resolver or Analog Encoder is used as a Main Feedback device.
 The Whistle is used as a current amplifier to provide

position data to the position controller.

 The Whistle is used in velocity mode, to provide

position data to the position controller.

 The Whistle is used as a master in Follower or ECAM mode.

Below are the signals on the Auxiliary Feedback ports when the Whistle Auxiliary Feedback
port is set up for emulated output of the Main Feedback device (Resolver or Analog
Incremental Encoder only).

The Auxiliary Feedback on the Duo has a 16-pin Molex Header plug.

3-20

Port Pin Signal Function

PWR 1 +5V Encoder supply voltage
PWR 2 COMRET Common return

B1 3 NA When YA[4]=4 the B1 port is not available
B1 4 NA When YA[4]=4 the B1 port is not available
B1 5 NA When YA[4]=4 the B1 port is not available
B1 6 NA When YA[4]=4 the B1 port is not available
B1 7 NA When YA[4]=4 the B1 port is not available
B1 8 NA When YA[4]=4 the B1 port is not available
B2 9 CHAO Buffered Channel A output
B2 10 CHAO- Buffered Channel A complement output
B2 11 CHBO Buffered channel B output
B2 12 CHBO- Buffered channel B complement output
B2 13 INDEXO Buffered Index output

B2 14 INDEXO- Buffered Index complement output
PWR 15 +5V Encoder supply voltage
PWR 16 COMRET Common return

Pin Position

Table 3-8: Emulated Encoder Output on the Auxiliary Feedback Port B2 - Pin Assignments

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3-21

Figure 3-15: Emulated Encoder Outputs of the Resolver or Analog Encoder -

Connection Diagram

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3-22

3.10.3 Auxiliary Feedback - Differential Encoder Input Option

(YA[4]=2)

The Whistle 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 of B1 for the next slave axis in Follower or ECAM mode.

Below are the signals on the Auxiliary Feedback ports when the Whistle Auxiliary Feedback
port is set up to run as a differential Auxiliary input:

Port Pin Signal Function

PWR 1 +5V Encoder supply voltage
PWR 2 COMRET Common return

B1 3

B1 4

CHA Auxiliary channel A input

CHA- Auxiliary channel A complement input

B1 5

B1 6

B1 7

B1 8

CHB Auxiliary channel B input

CHB- Auxiliary channel B complement input

INDEX Auxiliary Index Input

INDEX- Auxiliary Index complement Input

B2 9 CHAO Buffered Channel A output
B2 10 CHAO- Buffered Channel A complement output
B2 11 CHBO Buffered channel B output
B2 12 CHBO- Buffered channel B complement output
B2 13 INDEXO Buffered Index output

B2 14 INDEXO- Buffered Index complement output
PWR 15 +5V Encoder supply voltage
PWR 16 COMRET Common return

Pin Position

Table 3-9: Differential Auxiliary Encoder Input Option along with Differential Encoder

Outputs on Auxiliary Feedback - Pin Assignments

Duo User Guide

MAN-DUOUG (Ver. 1.0)

Figure 3-6: Differential Auxiliary Input Option - Block Diagram

3-23

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3-24

Figure 3-16: Differential Auxiliary Input Option on Auxiliary Feedback - Connection Diagram

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3.10.4 Auxiliary Feedback – Differential Pulse-and-Direction

Input Option (YA[4]=0)

This mode is used for input of differential pulse-and-direction position commands on Port B1.
In this mode Port B2 provides differential buffered pulse-and-direction outputs of B1 for
another axis.

Below are the signals on the Auxiliary Feedback ports when set up to run as a differential
pulse-and-direction input:

Port Pin Signal Function

PWR 1 +5V Encoder supply voltage
PWR 2 COMRET Common return

B1 3

B1 4

CHA Auxiliary Pulse input

CHA- Auxiliary Pulse complement input

3-25

B1 5

B1 6

CHB Auxiliary Direction input

CHB- Auxiliary Direction complement input

B1 7 NA Do not connect this pin
B1 8 NA Do not connect this pin
B2 9 CHAO Buffered Pulse output
B2 10 CHAO- Buffered Pulse complement output
B2 11 CHBO Buffered Direction output
B2 12 CHBO- Buffered Direction complement output
B2 13 NA Do not connect this pin

B2 14 NA Do not connect this pin
PWR 15 +5V Encoder supply voltage
PWR 16 COMRET Common return

Pin Position

Table 3-10: Pulse-and-Direction Pin Assignment on Auxiliary Feedback

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3-26

Figure 3-17: Pulse-and-Direction Input Option on Auxiliary Feedback - Connection Diagram

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3.11 I/O

Each Whistle on the Duo has 6 digital inputs, 2 digital outputs and a single analog input.

3-27

The I/O port has a

14-pin Molex Header plug with the following pin-outs.

Pin Signal Function

1 OUT1 Programmable Digital output 1

2 OUTRET1 Programmable Digital output 1 return

3 OUT2 Programmable Digital output 2

4 OUTRET2 Programmable Digital output 2 return

5 IN1 Programmable Digital input 1

6 IN2 Programmable Digital input 2

7 IN3 Programmable Digital input 3

8 IN4 Programmable Digital input 4

9 IN5 Programmable Digital input 5

10 IN6 Programmable Digital input 6

11 INRET Programmable Digital input return

12 COMRET Common return

13 ANALIN1+ Analog input 1+

14 ANALIN1- Analog input 1-

Pin Position

Table 3-11: I/O Port and Cable - Pin Assignment for Each Axis

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3.11.1 Digital Input

The Default Digital Input level Signal is set to 24v (PLC).

Note: 5v is also available (TTL).

3-28

Figure 3-18: Digital Input Connection Diagram

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3.11.2 Digital Output

3-29

Figure 3-19: Digital Output Connection Diagram

3.11.3 Analog Input

Figure 3-20: Analog Input with Single-ended Source

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3.12 Communications

The communication cables use an 8-pin RJ-45 plug that connect to the RS232 and CANopen
ports on the Duo.

The communication interface may differ according to the user’s hardware. The Duo can
communicate using the following options:

1. RS232, full duplex

2. CANopen

RS232 communication requires a standard, commercial 3-core null-modem cable connected
from the Duo to a serial interface on the PC. The interface is selected and set up in the
Composer software.

In order to benefit from CANopen communication, the user must have an understanding of
the basic programming and timing issues of a CANopen network.

For ease of setup and diagnostics of CAN communication, RS232 and CANopen can be used
simultaneously.

3-30

3.12.1 RS232 Communication

Notes for connecting the RS232 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 RS232 communication port is non-isolated.
 The male RJ plug must have a shield cover.
 Ensure that the shield of the cable is connected to the shield of the RJ plug.

The drain wire can be used to facilitate the connection.

Pin Signal Function Pin Position

1 — —

2 — —

3 Tx RS232 transmit

4 — —

5 COMRET Communication return

6 Rx RS232 receive

RS-232

7 — —

8 — —

body Drain Wire

shield

Table 3-12: RS232 Cable - Pin Assignments

Duo User Guide

MAN-DUOUG (Ver. 1.0)

Figure 3-21: RS232 Connection Diagram

3-31

3.12.2 CANopen Communication

Notes for connecting the CANopen communication cable:

 Use 26 or 28 AWG twisted pair shielded cables. For best results, the shield

should have aluminum foil and be 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. You can use the drain wire to
facilitate connection.

 The CANopen communication port is non-isolated.
 The male RJ plug must have a shield cover.
 Ensure that the shield of the cable is connected to the shield of the RJ plug.

The drain wire can be used to facilitate the connection.

 For "daisy-chain" connections, connect a termination 120-ohm resistor at each of the

two ends of the network cable.

Pin Signal Function Pin Position

1 CAN_H CAN_H busline (dominant high)

2 CAN_L CAN_L busline (dominant low)

3 CAN_GND CAN ground

4 — —

CAN

5 — —

6 CAN_SHLD Shield, connected to the RJ plug cover

7 CAN_GND CAN Ground

8 — —

body Drain Wire

shield

Table 3-13: CANopen Cable - Pin Assignments

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3-32

Figure 3-22: CANopen Network Connection Diagram

Caution:

When installing CANopen
communications, ensure
that each servo drive is
allocated a unique ID.
Otherwise, the CANopen
network may hang.

Duo User Guide

MAN-DUOUG (Ver. 1.0)

3.13 Powering Up

After the cables have been connected to their devices, the Duo 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.

3.14 Initializing the System

After the Duo has been connected and mounted, the system must be set up and initialized.
This is accomplished using the Composer, Elmo’s Windows-based software application. Install
the application and then perform setup and initialization according to the directions in the
Composer Software Manual.

3-33

Duo Installation Guide

Appendix A: Technical Specifications

A.1 Features

• Operating power

o DC power supply: 12 - 95 VDC source

• DC BUS

o DC power supply

• Control supply

o A separate DC power supply 12 - 95 VDC serves as both the auxiliary supply

and the backup supply (Option)

• Operating modes

A-1

o Current, velocity and position

• Commutation alternatives

o Sinusoidal vector control
o Trapezoidal
o DC brush

• Feedback alternatives

o Incremental encoder + digital Halls
o Incremental encoder only
o Digital Halls
o Resolver
o Sin / Cos
o Sin / Cos+Digital Halls
o Analog Halls
o Tacho
o Potentiometer

• Communication

o Simultaneous operation of RS-232 and CANopen DS 402 User programming

• User Programming

o Third-generation programming environment (language and Elmo Studio)

• Encoder Inputs

o Two

• Event capturing inputs

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

• Event triggered programming structure

• Analog inputs

o 1 differential inputs with 12-bit resolution

• Enable input, limit switches and emergency stop handling

• Smart multi-purpose inputs

o Programmable as Enable, Forward and Reverse Limit Switches, Home,

Capture

• Uncommitted programmable inputs
o 6 Inputs sharing one single common

• Uncommitted, programmable outputs
o 2 separated outputs

A-2

• Storage memory

o Large, non-volatile storage of controller parameters and user programs

• Setup, startup and tuning software

o Windows-based Composer

• Automatic analysis of kinematics

• Status indication

o Bi-color LED

• Automatic procedures

o Commutation alignment
o Phase sequencing
o Current loop offset adjustment
o Current loop gain tuning
o Current gain scheduling
o Velocity loop offset adjustment
o Velocity gain tuning
o Velocity gain scheduling
o Position gain tuning

• Motion modes

o Point-to-point (PTP)
o Jogging
o Position-Velocity-Time (PVT)
o

Position-Time (PT)

o Pulse-and-direction

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

A.2 Built-In Protection

• Software error handling

o Software-based

• Status reporting

o Available for a large number of fault conditions

• Protection against:

o Short circuit between motor power outputs
o Short circuit between each motor power output and DC bus return
o Failure of internal power supply
o Heatsink over-temperature
o Under/over voltage

A-3

o Loss of commutation signals
o Loss of velocity feedback
o “Bad” commutation
o Communication error

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

A.3 Duo Dimensions

A-4

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

A.4 Power Ratings

Feature Unit 1/60 2.5/60 5/60 10/60 15/60 1/100

Minimum supply voltage VDC 8.5 12

Nominal supply voltage VDC 48 85

Maximum supply voltage VDC 59 95

2.5/100

5/100 10/100 15/100

A-5

Max. output power from
the drive without heatsink

W 50 120 240 480 720 75 180 400 800 1200

Efficiency at rate power % > 99

Output Voltage % > 95% of supply VDC at f=22 KHz

DC and Trapezoidal
Commutation Continuous

A 1 2.5 5 10 15 1 2.5 5 10 15

Current Limit (Ic)

Sinusoidal Commutation
Continuous RMS Current

A 0.7 1.8 3.6 7 10.7 0.7 1.8 3.6 7 10.7

Limit (Ic)

Peak current limit (RMS) A 2 x Ic

PWM Switching
Frequency

KHz 22 +/-5% default on the motor

Switching Method Advanced Unipolar PWM

Notes:

 Current rating:

 The current ratings of the Duo are given in units of DC amperes (ratings that

are used for trapezoidal commutation or DC motors). The RMS (sinusoidal
commutation) value is the DC value divided by 1.41.

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

A.5 Control Specifications

A.5.1 Current Loop

Feature Details

Controller type Vector, digital

A-6

Current sampling time

70 - 100 μsec

Current loop bandwidth 1400 - 2500 Hz

Compensation for bus voltage

Gain scheduling

variations

Motor types

 AC brushless (sinusoidal)
 DC brushless (trapezoidal)
 DC brush
 Linear brushless motor

Current control  Fully digital

 Sinusoidal with vector control
 Programmable PI control filter based on a pair of

PI controls of AC current signals and constant
power at high speed

Current loop step response

300 - 400 μsec

(including settling time)

Current rise time

150 - 200 μsec

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

A.5.2 Velocity Loop

Feature Details

Controller type PI

Speed sampling time 140 - 200 μsec ( x2 current loop sample time)

Velocity loop bandwidth

Velocity control  Fully digital

 Programmable PI and FFW control filters
 On-the-fly gain scheduling
 Automatic, manual and advanced manual tuning

A-7

Velocity and position feedback
options

 Incremental encoder + digital Halls
 Incremental encoder only
 Digital Halls
 Resolver
 Sin / Cos
 Sin / Cos+ Digital Halls
 Analog Halls
 Tacho
 Potentiometer

Note: With all feedback options, 1/T with automatic
mode switching is activated (gap, frequency and
derivative).

Velocity command options  Analog

 Internally calculated by either jogging or step

Note: All software-calculated profiles support
on-the-fly changes.

A.5.3 Position Loop

Feature Details

Controller type 124 PIP

Position sampling time 280 - 400 μsec ( x 4 current loop sample time)

Analog input command

12-bit inputs

resolution

PWM resolution 12-bit

PWM switching frequency on

2/ Ts (factory default 22 kHz on the motor)

the load

Control inputs PLC or +5V level

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

A.6 Feedbacks

A.6.1 Incremental Encoder

Feature Details

A-8

Encoder format

 A, B and Index
 Differential
 Quadrature

Interface: RS-422

Input resistance: Differential: 120 Ω

Maximum incremental encoder
frequency:

Minimum quadrature input
period (P

IN)

Minimum quadrature input
high/low period (P

HL)

Minimum quadrature phase
period (P

PH)

Maximum encoder input voltage
range

Maximum absolute: 5 MHz single,
20 MHz quadrature

112 nsec

56 nsec

28 ns

Common mode: ±7V
Differential mode: ±7V

A.6.2 Feedback Supply Voltage

Feature Details

Encoder/Hall supply voltage 5V +5%

Maximum encoder supply current 200 mA (For the main encoder only)

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

A.6.3 Digital Halls

Feature Details

Halls inputs  HA, HB, HC.

 Single ended inputs
 Built in hysteresis for noise immunity.

A-9

Input voltage Nominal operating range: 0V < V

Maximum absolute: -1V < V
High level input voltage: V
Low level input voltage: V

In_Hall

InHigh

InLow

In_Hall

< 15V

> 2.5V

< 1V

Input current Sink current (when input pulled to the

common): 3ma

Source current: 1.5 ma (designed to also
support open collector Halls)

Maximum frequency f

MAX

: 2 kHz

A.6.4 Interpolated Analog Encoder (Sine/Cosine)

Feature Details

Analog encoder format

Analog input signal level

Input resistance Differential 120 Ω

Maximum analog signal frequency f

Sine and Cosine signals

 Offset voltage: 2.2 V – 2.8 V

Differential, 1 V peak to peak

: 250 kHz

MAX

< 5V

Interpolation multipliers Programmable: x4 to x4096

Maximum “counts” frequency 80 mega-counts/sec "internally"

Automatic errors correction

Signal amplitudes mismatch

Signal phase shift

Signal offsets

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

A.6.5 Resolver

Feature Details

Resolver format  Sine/Cosine

 Differential

Input resistance Differential 2.49 KΩ

Resolution Programmable: 10 ~ 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 Whistle

A-10

Reference current

Up to ±50 mA

A.6.6 Tachometer*

Feature Details

Tachometer format Differential

Maximum operating differential
voltage for TAC1+, TAC1-

Maximum absolute differential input
voltage for TAC1+, TAC1-

Maximum operating differential
voltage for TAC2+, TAC2-

Maximum absolute differential input
voltage for TAC2+, TAC2-

Input resistance for TAC1+, TAC1- 46 KΩ

Input resistance for TAC2+, TAC2- 100 KΩ

Resolution 14 bit

+/- 20V

+/-25V

+/- 50V

+/- 60V

* Only one Tachometer port can be used at a time (either TAC1+/TAC1- or TAC2+/TAC2-).

TAC1+/TAC1- is used in applications with having a Tachometer of less than 20V.
TAC2+/TAC2- is used in applications with having a Tachometer of between 20V and 50V.

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

A.6.7 Potentiometer

Feature Details

Potentiometer Format Single-ended

Operating Voltage Range 0 ~ 5V supplied by the Whistle

Potentiometer Resistance 100Ω ~ 1 KΩ … above this range, linearity is

affected detrimentally

Input Resistance 100KΩ

Resolution 14 Bit

A.6.8 Auxiliary Feedback Port (output mode YA[4]= 4)

Feature Details

A-11

Emulated output

Output current capability

Available as options

Maximum frequency f

Edge separation between A & B

 A, B, Index
 Differential

Maximum output current: I

High level output voltage: V

Minimum output current: I

Low level output voltage:V

 Emulated encoder outputs of analog encoder
 Emulated encoder outputs of resolver

: 5 MHz pulses/output

MAX

(max) = 2 mA

OH

> 3.0 V

OH

= 2 mA

OL

< 0.4 V

OL

Programmable number of clocks to allow
adequate noise filtering at remote receiver of
emulated encoder signals

Index (marker): Length of pulse is one quadrature (one

quarter of an encoder cycle) and synchronized
to A&B

Figure A-1: Auxiliary Feedback - Encoder Phase Diagram

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

A.6.9 Auxiliary Feedback Port (input mode YA[4]= 2, 0)

Feature Details

A-12

Encoder input,
pulse and direction input

Output current capability

 A, B, Index
 Differential

VIn Low: 0V < VIL < 0.8V
V

High: 2V < VIH < 5V

In

Maximum absolute voltage: 0 < V
Input current: ±

1μA

< 5.5V

In

Encoder/Hall supply voltage 5V +5%

Maximum encoder supply current 200 mA

Available as options

 Differential Encoder inputs
 Differential Pulse and Direction inputs

Edge separation between A & B

Programmable number of clocks to allow
adequate noise filtering at remote receiver of
emulated encoder signals

Index (marker): Length of pulse is one quadrature (one quarter of

an encoder cycle) and synchronized to A&B

Figure A-2: Auxiliary Feedback - Encoder Phase Diagram

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

A-13

A.7 I/Os

A.7.1 Digital Input Interface – 6 Digital Inputs

Feature Details Connector Location

Type of input

Input current
for all inputs

Input voltage
level

Minimum
pulse width

Execution time
(all inputs):
the time from
application of
voltage on
input until
execution is
complete

High-speed
inputs – 5 & 6
minimum pulse
width, in high­speed mode

 Optically isolated
 All six inputs share one signal return line

Iin = 6.5 mA @ Vin = 24 V

24 V

Note: 5V level is also available

> 4 x TS, where TS is sampling time

If input is set to one of the built-in functions —
Home, Inhibit, Hard Stop, Soft Stop, Hard and Soft
Stop, Forward Limit, Reverse Limit or Begin —
execution is immediate upon detection: 0<T<4xTS

If input is set to General input, execution depends
on program. Typical execution time: ≅ 0.5 msec.

T < 5 μsec

Notes:

 Home mode is high-speed mode and can be

used for fast capture and precise homing.

 High speed input has a digital filter set to same

value as digital filter (EF) of main encoder.

 Highest speed is achieved when turning on

optocouplers.

Digital Input

Schematic

Duo Installation Guide

−

MAN-DUOIG (Ver. 1.0)

A-14

A.7.2 Digital Output Interface – 2 Digital Outputs

Feature Details Connector Location

Type of output

 Optically isolated
 Open collector and open emitter

Maximum supply output

30 V

(Vcc)

Max. output current

Iout (max) ≤ 10 mA

Iout (max) (Vout = Low)

VOL at maximum output

Vout (on) ≤ 0.3 V

voltage (low level)

RL External resistor RL must be

selected to limit output current to
no more than 10 mA.

VOLVcc

=

R

L

(max)Io

Executable time If output is set to one of the built-

in functions — Home flag, Brake
or AOK — execution is immediate
upon detection:
0 < T < 4 x TS

If output is set to General output
and is executed from a program,
the typical time is approximately

Digital Output Schematic

0.5 msec.

A.7.3 Analog Inputs – 1 Analog Input

Feature Details

Analog input - maximum
differential mode voltage

Analog input - maximum
common mode voltage

Input resistance 3.74 KΩ

+ 20 V

+ 10 V

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

A.8 Mechanical Specifications

Feature Details

A-15

Mounting

The Duo 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

Overall dimensions 150 X 105 X 25.4 (5.9 X 4.13 X 1 in)

Weight

~ 450 grams

A.9 Environmental Conditions

Feature Details

Operating ambient temperature 0° to +40° C (32° to 40° F)

Storage temperature -20° to +85° C (-4° to 185° F)

Humidity 90% maximum non-condensing

Maximum Operating Altitude 10,000m (30,000 feet)

Protection level IP20

A.10 Compliance Standards

Specification Details

ISO9001

A.10.1 Design

Specification Details

MIL-HDBK- 217F

 IPC-D-275
 IPC-SM-782
 IPC-CM-770
 UL508c
 UL840

In compliance with VDE0160 -7 Type testing

Quality Assurance

Reliability prediction of electronic equipment
(rating, de-rating, stress and so on)

Printed wiring for electronic equipment
(clearance, creepage, spacing, conductor
sizing and so on)

Duo Installation Guide

MAN-DUOIG (Ver. 1.0)

A.10.2 Safety

Specification Details

Recognized UL508c Power conversion equipment

In compliance with UL840 Insulation coordination, including clearance

and creepage distances of electrical
equipment

In compliance with UL60950 Safety of information technology equipment,

including electrical business equipment

In compliance with EN60204-1 Low voltage directive, 73/23/EEC

A.10.3 EMC

Specification Details

A-16

In compliance with IEC 1800-3,
Part 3: 1996
(Adjustable speed electrical
power-drive systems - EMC
products standard, including
specific test methods)

Electromagnetic compatibility (EMC)

Duo Installation Guide

Appendix B: Cables (Optional)

B.1 Cable Photos

B-1

Main Feedback: CBL- HDRFB-001

RS-232 Com.: CBL-RJ452321

Auxiliary Feedback: CBL- HDRAUX-001

I/O: CBL- HDRIO-001

CAN Com.: CBL-RJ45CAN1

Duo Installation Guide

MAN-DUO (Ver. 1.0)

B.2 Cable Kit

The cables are all 2m in length. Each set contains the cables listed below. Additional cable kit
and/or individual cables (in multiples of 10 each) are available from Elmo.

Cable Application Cable Part. No. QTY

B-2

Main Feedback

CBL-HDRFB-001 2

Auxiliary Feedback CBL-HDRAUX-001 2

I/O CBL-HDRIO-001 2

RS-232 Communications CBL-RJ452321 1

CAN Communications CBL-RJ45CAN1 1

Duo Installation Guide

MAN-DUO (Ver. 1.0)

B.3 Main Feedback Cable (CBL-HDRFB-001)

The Main Feedback cable (CBL-HDRFB-001) is made of a 24-AWG shielded cable with a
12-pin Molex Header socket. It connects to the Main Feedback port on the Duo. It is open on
its other side so that it can be connected to customer-specific motor connector.

Pin
No.

Color Signal Pairs

B-3

1 Brown +5V

2 White COMRET

3 Cyan CHA

4 Orange CHA-

Purple

5

6

Black

CHB

CHB-

7 Red INDEX

8 Blue INDEX-

9 Green HA

10 Yellow HB

11 Pink HC

12 Drain wire COMRET

pair

pair

pair

pair

pair

pair

12 pin Molex
Header Socket

Front View

Front
View

Figure A-1: Single-sided Main Feedback Cable (Part No. CBL-HDRFB-001)

Duo Installation Guide

MAN-DUO (Ver. 1.0)

B.4 Auxiliary Feedback (CBL-HDRAUX-001)

The Auxiliary Feedback cable (CBL-HDRAUX-001) is made of a 24-AWG shielded cable with
a 16-pin Molex Header socket. It connects to the Auxiliary Feedback port on the Duo.

Pin
No.

Color Signal

Pairs

B-4

1 Brown +5V

2 White COMRET

3 Cyan CHA

4 Orange CHA-

Purple

5

6

Black

CHB

CHB-

7 Red INDEX

8 Blue INDEX-

9 Pink CHAO

10 Grey CHAO-

11 Yellow CHBO

12 Green CHBO-

13 White-Red INDEXO

14 White-Black INDEXO-

pair

pair

pair

pair

pair

pair

pair

16 pin Molex
Header Socket

Front View

15 White-Green +5V

pair

16 White- Yellow COMRET

Front
View

Figure A-2: Single-sided Auxiliary Feedback Cable (Part No. CBL-HDRAUX-001)

Duo Installation Guide

MAN-DUO (Ver. 1.0)

B.5 I/O (CBL-HDRIO-001)

The I/O cable (CBL-HDRIO-001) is made of a 24-AWG shielded cable with a 14-pin Molex
Header socket. It connects to the I/O port on the Duo.

Pin

No.

Color Signal

Pairs

B-5

1 Orange OUT1

2 Cyan OUTRET1

Black

3

4

Purple

OUT2

OUTRET2

5 Brown IN1

6 White IN2

7 Green IN3

8 Yellow IN4

9 Gray IN5

10 Pink IN6

11 Blue INRET

12 Red COMRET

13 White-Black ANALIN1+

14 White-Red ANALIN1-

pair

pair

pair

pair

pair

pair

pair

14 pin Molex
Header Socket

Front View

Front
View

Figure A-3: Single-sided I/O Cable (Part No. CBL-HDRIO-001)

Duo Installation Guide

MAN-DUO (Ver. 1.0)

B.6 Communication Cables

The communication cables use 26-AWG twisted pair shielded cable. They are connected using
an 8-pin RJ-45 plug. Elmo drives can communicate using the following options:

 RS-232 full duplex
 CANopen

B.6.1 RS-232 Option (CBL-RJ452321)

B-6

RJ45

Pin

No.

Color

D-type
Female

Pin No.

Signal

Description

1 — — — —

2 — — — —
3 Brown 2

Tx

RS232 Transmit

4 — — — —

5 White 5 COMRET Communication Return

6 Green 3 Rx RS232 Receive

1

7 — — — —

8 —

— — —

body Drain Wire body shield cable shield

The shields of the RJ-45 and D-type plugs are connected to each other through the cable

braid.

Figure A-4: RS-232 Communications Cable (Part No. CBL-RJ452321)

Duo Installation Guide

MAN-DUO (Ver. 1.0)

B.6.2 CAN Open (CBL-RJ45CAN1)

B-7

RJ45

Pin
No.

1 Green 7

2 Yellow 2

3 White 3

Color

D-type
Female
Pin No.

Signal

CAN-H

CAN_L

CAN_GND

Description

CAN_H bus line

CAN_L bus line

CAN ground

4 — — — —

5 — — — —

7 — — — —

8 — 1— — —

body Drain Wire body shield cable shield

The shields of the RJ-45 and D-type plugs are connected to each other through the cable

braid.

Figure A-5: CAN Cable (Part No. CBL-RJ45CAN1)

Duo Installation Guide

MAN-DUO (Ver. 1.0)

B.7 Guidelines for Making Your Own Cables

Proper wiring, grounding and shielding are essential for ensuring safe, immune and optimal
servo performance of the Duo. If you do not plan to use cables provided by Elmo, follow the
instructions below carefully.

Follow these instructions to ensure safe and proper wiring:

 Use twisted pair shielded cables for control, feedback and communication connections.

For best results, the cable should have an aluminum foil shield covered by a copper braid
and should contain a drain wire.

The drain wire is a non-insulated wire that is in contact with parts of the cable,
usually the shield. It is used to terminate the shield and as a grounding connection.

 The impedance of the wire must be as low as possible. The size of the wire must be thicker

than actually required by the carrying current. A 24, 26 or 28 AWG wire for control and
feedback cables is satisfactory although 24 AWG is recommended.

 Use shielded wires for motor connections as well. If the wires are long, ensure that the

capacitance between the wires is not too high: C < 30 nF is satisfactory for most
applications.

 Keep all wires and cables as short as possible.
 Keep the motor wires as far away as possible from the feedback, control and

communication cables.

 Ensure that in normal operating conditions, the shielded wires and drain carry no current.

The only time these conductors carry current is under abnormal conditions, when
electrical equipment has become a potential shock or fire hazard while conducting
external EMI interferences directly to ground, in order to prevent them from affecting the
drive. Failing to meet this requirement can result in drive/controller/host failure.

 After completing the wiring, carefully inspect all wires to ensure tightness, good solder

joints and general safety.

B-8

B.7.1 Recommended Wire Cross Sections

Function Connection Details

Motor PE, M1, M2, M3 14 AWG

Feedback and Control Main Feedback

Auxiliary Feedback

24 AWG twisted pair shielded
cables

I/O

Communications RS232

CANopen

26 AWG twisted pair shielded
cables