Elmo ExtrIQ line Installation Manual

Falcon

Digital Servo Drive

Installation Guide

July 2012 (Ver. 1.5)

www.elmomc.com

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 Falcon 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.

• Elmo Motion Control and the Elmo Motion Control logo are registered trademarks of

Elmo Motion Control Ltd.

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

Document no. MAN-FALIG (Ver. 1.5)

Copyright  2012

Elmo Motion Control Ltd.

All rights reserved.

Catalog Number

Maximum DC

Operating Voltage

Continuous Current

(Amps)

Feedback:

Blank = Incremental

Encoder
and/or Halls

R = Resolver

FAL-

XX/YYY

R

T =

Tachometer &
Potentiometer

I = Interpolated

Analog
Encoder

Q=

Encoder

Absolute

Cable Kits

Catalog Numbers:

• CBL-CELKIT01 (can be ordered separately)

• CBL-CELKIT02 (can be ordered separately)

For further details, see the documentation for these cable kits (MAN-CBLKIT-CEL.pdf).

Revision History

Version Details

1.0 Initial Release

1.2 August 2008 Added 3.4.7.4: Differential Pulse-and-Direction Input

1.3 September

2008

MTCR 00-100-29: Added Table 7, Figure 16 and Figure 17

1.4 March 2010 MTCR 07-009-56: Added note to 3.4.8.2

1.5 July 2011 Formatted according to the new template

Elmo Worldwide

Head Office

Elmo Motion Control Ltd.

60 Amal St., P.O. Box 3078, Petach Tikva 49516
Israel

Tel: [phone] • Fax: [phone] • [e-mail]

North America

Elmo Motion Control Inc.

42 Technology Way, Nashua, NH 03060
USA

Tel: [phone] • Fax: [phone] • [e-mail]

Europe

Elmo Motion Control GmbH

Hermann-Schwer-Strasse 3, 78048 VS-Villingen
Germany

Tel: [phone] • Fax: [phone] • [e-mail]

China

Elmo Motion Control Technology (Shanghai) Co. Ltd.

Room 1414, Huawen Plaza, No. 999 Zhongshan West Road, Shanghai (200051)
China

Tel: [phone] • Fax: [phone] • [e-mail]

Asia Pacific

Elmo Motion Control

#807, Kofomo Tower, 16-3, Sunae-dong, Bundang-gu, Seongnam-si, Gyeonggi-do,
South Korea

Tel: [phone] • Fax: [phone] • [e-mail]

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Table of Contents

Chapter 1: Safety Information .......................................................................................... 7

1.1. Warnings ......................................................................................................................... 8

1.2. Cautions .......................................................................................................................... 8

1.3. Directives and Standards ................................................................................................ 9

1.4. CE Marking Conformance ............................................................................................. 10

1.5. Warranty Information .................................................................................................. 10

Chapter 2: Introduction ................................................................................................. 11

2.1. ExtrIQ Product Family ................................................................................................... 11

2.2. Drive Description .......................................................................................................... 12

2.3. Product Features .......................................................................................................... 13

2.3.1. Current Control .............................................................................................. 13

2.3.2. Velocity Control ............................................................................................. 13

2.3.3. Position Control ............................................................................................. 13

2.3.4. Communication Options ................................................................................ 13

2.3.5. Feedback Options .......................................................................................... 14

2.3.6. Fault Protection ............................................................................................. 14

2.4. System Architecture ..................................................................................................... 15

2.5. How to Use this Guide .................................................................................................. 15

Chapter 3: Installation ................................................................................................... 17

3.1. Before You Begin .......................................................................................................... 17

3.1.1. Site Requirements ......................................................................................... 17

3.1.2. Hardware Requirements ............................................................................... 17

3.2. Unpacking the Drive Components ................................................................................ 19

3.3. Mounting the Falcon .................................................................................................... 20

3.4. Connecting the Cables .................................................................................................. 21

3.4.1. Wiring the Falcon ........................................................................................... 21

3.4.2. Connecting the Power Cables ........................................................................ 24

3.4.2.1. Connecting the Motor Cable ........................................................ 24

3.4.2.2. Connecting the Main Power Cable ............................................... 25

3.4.3. Connecting the Optional Backup Supply Cable (24v) .................................... 26

3.4.4. Feedback and Control Cable Assemblies ....................................................... 27

3.4.5. Main Feedback Cable (FEEDBACK A) ............................................................. 27

3.4.6. Main and Auxiliary Feedback Combinations ................................................. 35

3.4.7. Auxiliary Feedback (FEEDBACK B) .................................................................. 36

3.4.7.1. Main Encoder Buffered Outputs or Emulated Encoder Outputs

Option on FEEDBACK B (YA[4]=4) ................................................. 36

3.4.7.2. Differential Auxiliary Encoder Input Option on FEEDBACK B

(YA[4]=2) ....................................................................................... 39

3.4.7.3. Single-Ended Auxiliary Input Option on FEEDBACK B (YA[4]=2) ... 41

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3.4.7.4. Pulse-and-Direction Input Option on FEEDBACK B (YA[4]=0) ....... 43

3.4.8. I/O Cables ...................................................................................................... 47

3.4.8.1. General I/O Port (J1) ..................................................................... 47

3.4.8.2. General Input Port (J2) ................................................................. 49

3.4.9. Communication Cables .................................................................................. 51

3.4.9.1. RS-232 Communication ................................................................ 51

3.4.9.2. CANopen Communication ............................................................ 52

3.5. Powering Up ................................................................................................................. 54

3.6. Initializing the System ................................................................................................... 54

Chapter 4: Technical Specifications ................................................................................ 55

4.1. Features ........................................................................................................................ 55

4.1.1. Motion Control Modes .................................................................................. 55

4.1.2. Advanced Positioning Motion Control Modes .............................................. 55

4.1.3. Advanced Filters and Gain Scheduling........................................................... 55

4.1.4. Fully Programmable ....................................................................................... 55

4.1.5. Feedback Options .......................................................................................... 56

4.1.6. Input/Output ................................................................................................. 56

4.1.7. Built-In Protection ......................................................................................... 57

4.2. Falcon Dimensions ........................................................................................................ 58

4.3. Power Ratings ............................................................................................................... 59

4.4. Environmental Conditions ............................................................................................ 60

4.5. Falcon Connections ...................................................................................................... 60

4.5.1. Backup Supply (Optional) .............................................................................. 61

4.6. Control Specifications ................................................................................................... 62

4.6.1. Current Loop .................................................................................................. 62

4.6.2. Velocity Loop ................................................................................................. 63

4.6.3. Position Loop ................................................................................................. 63

4.7. Feedbacks ..................................................................................................................... 64

4.7.1. Feedback Supply Voltage ............................................................................... 64

4.7.2. Incremental Encoder Input ............................................................................ 64

4.7.3. Digital Halls .................................................................................................... 65

4.7.4. Interpolated Analog (Sine/Cosine) Encoder .................................................. 65

4.7.5. Resolver ......................................................................................................... 66

4.7.6. Tachometer.................................................................................................... 66

4.7.7. Potentiometer ............................................................................................... 67

4.7.8. Encoder Outputs ............................................................................................ 67

4.8. I/Os ............................................................................................................................... 68

4.8.1. Digital Input Interfaces .................................................................................. 68

4.8.2. Digital Output Interface ................................................................................. 69

4.8.3. Analog Input .................................................................................................. 70

4.9. Communications ........................................................................................................... 71

4.10. Pulse-Width Modulation (PWM) .................................................................................. 71

4.11. Mechanical Specifications ............................................................................................ 71

4.12. Compliance with Standards .......................................................................................... 72

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Chapter 1: Safety Information

In order to achieve the optimum, safe operation of the Falcon servo drive, it is imperative that
you implement the safety procedures included in this installation guide. This information is
provided to protect you and to keep your work area safe when operating the Falcon 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 Falcon servo drive 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.

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.

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1.1. Warnings

• To avoid electric arcing and hazards to personnel and electrical contacts, never

connect/disconnect the servo drive while the power source is on.

• Power cables can carry a high voltage, even when the motor is not in motion. Disconnect

the Falcon from all voltage sources before it is opened for servicing.

• 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. Cautions

• The Falcon servo drive contains hot surfaces and electrically-charged components during

operation.

• The maximum DC power supply connected to the instrument must comply with the

parameters outlined in this guide.

• The Falcon can operate only through an isolated power source, using an isolated

transformer and a rectifier circuit. Power to this device must be supplied by DC voltage,
within the boundaries specified for the Falcon. High voltages may damage the drive.

The DC power supply voltage range is defined in the table in Section 4.3.

Safety margins must be considered in order to avoid activating the under- or over-voltage
protection against line variations and/or voltage drop under load. The transformer should
be able to deliver the required power to the drive (including peak power) without
significant voltage drops (10% maximum). While driving high-inertia loads, the power
supply circuit must be equipped with a shunt regulator; otherwise, the drive will be
disabled whenever the capacitors are charged above the maximum voltage.

• Before switching on the Falcon, verify that all safety precautions have been observed and

that the installation procedures in this manual have been followed.

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1.3. Directives and Standards

The Falcon conforms to the following industry safety standards:

Safety Standard Item

Approved IEC/EN 61800-5-1, Safety Adjustable speed electrical power drive systems

Recognized UL 508C Power Conversion Equipment

In compliance with UL 840 Insulation Coordination Including Clearances and

Creepage Distances for Electrical Equipment

In compliance with UL 60950-1
(formerly UL 1950)

Safety of Information Technology Equipment
Including Electrical Business Equipment

In compliance with EN 60204-1 Low Voltage Directive 73/23/EEC

The Falcon also conforms to the following military qualitative standards:

Military Qualitative Standard Item

In compliance with MIL-STD-704 Aircraft, Electric Power Characteristics

In compliance with MIL-STD-810 Environmental Engineering Considerations and

Laboratory Tests

In compliance with MIL-STD-1275 Characteristics of 28 Volt DC Electrical Systems in

Military Vehicles

In compliance with MIL-STD-461 Requirements for the Control of Electromagnetic

Interference Characteristics of Subsystems and
Equipment

In compliance with MIL-HDBK-217 Reliability Prediction of Electronic Equipment

In compliance with ISO-9001:2008 Quality Management

The Falcon servo drive 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.

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1.4. CE Marking Conformance

The Falcon servo drive 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 EN 60204-1 and EN 292-2 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
Falcon 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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Chapter 2: Introduction

This installation guide describes the Falcon servo drive and the steps for its wiring, installation
and powering up. Following these guidelines ensures maximum functionality of the drive and
the system to which it is connected.

2.1.

ExtrIQ

Product Family

Elmo Motion Control’s ExtrIQ product family is a set of durable motion control products for
applications operating under extreme environmental conditions. The products are capable of
withstanding the following extreme conditions:

Feature Operation Conditions Range

Ambient
Temperature
Range

Non-operating conditions -50 °C to +100 °C (-58 °F to 212 °F)

Operating conditions -40 °C to +71 °C (-40 °F to 160 °F)

Temperature
Shock

Non-operating conditions -40 °C to +71 °C (-40 °F to 160 °F) within 3 min

Altitude

Non-operating conditions Unlimited

Operating conditions -400 m to 155,000 m (-1,300 ft to 510,000 ft)

Humidity

Non-operating conditions Up to 95% non-condensing humidity at 35 °C

(95 °F)

Operating conditions Up to 95% non-condensing humidity at 25 °C

(77 °F), up to 90% non-condensing humidity at
42 °C (108 °F)

Vibration

Operating conditions 20 Hz to 2000 Hz, 14.6 g

Mechanical
Shock

Non-operating conditions ±40 g; Half sine, 11 msec

Operating conditions ±20 g; Half sine, 11 msec

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ExtrIQ products have a high power density in the range from 50 W to 18,000 W and a current
carrying capacity of up to 140 A (280 A peak).

All ExtrIQ servo drives have been tested using methods and procedures specified in a variety of
extended environmental conditions (EEC) standards, including:

• MIL-STD-704 – Aircraft, Electric Power Characteristics

• MIL-STD-810 – Environmental Engineering Considerations and Laboratory Tests

• MIL-STD-1275 – Characteristics of 28 Volt DC Electrical Systems in Military Vehicles

• MIL-STD-461 – Requirements for the Control of Electromagnetic Interference

Characteristics of Subsystems and Equipment

• MIL-HDBK-217 – Reliability Prediction of Electronic Equipment

• ISO-9001:2008

Based on Elmo Motion Control's innovative ExtrIQ core technology, they support a wide range
of motor feedback options, programming capabilities and communication protocols.

2.2. Drive Descriptio n

The Falcon is a series of highly durable and intelligent servo drives. Designed for OEMs, the
Falcon is part of the Elmo’s ExtrIQ product line designed to endure extended environmental
operating conditions.

The digital drives are based on Elmo's advanced ExtrIQ motion control technology. They
operate from a DC power source in current, velocity, position and advanced position modes, in
conjunction with a permanent-magnet synchronous brushless motor, DC brush motor, linear
motor or voice coil. They are designed for use with any type of sinusoidal and trapezoidal
commutation, with vector control. The Falcon 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 Falcon drive is set up and tuned using Elmo’s Composer software. This Windows-based
application enables users to quickly and simply configure the servo drive for optimal use with
their motor.

Power to the Falcon is provided by a 10 to 195 VDC source. A smart control-supply algorithm
enables the Falcon to operate with the power supply only, with no need for an auxiliary 24 Volt
supply. If backup functionality is required for storing control parameters in case of power-outs,
an external 24 VDC power supply can be connected, providing maximum flexibility and optional
backup functionality when needed.

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2.3. Product Features

2.3.1. 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

2.3.2. Velocity Control

• Fully digital

• Programmable PI and FFW (feed forward) control filters

• Sample rate two times current loop sample time

• “On-the-fly” gain scheduling

• Automatic, manual and advanced manual tuning and determination of optimal gain and

phase margins

2.3.3. 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 time: four times that of current loop

• Fast event capturing inputs

• 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)

2.3.4. Communication Options

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

• RS-232 serial communication

• CANopen for fast communication in a multi-axis distributed environment

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2.3.5. Feedback Options

• Incremental Encoder – up to 20 Megacounts (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

• Absolute Encoder

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

 Internal Interpolation – programmable up to x4096
 Automatic Correction of:

• amplitude mismatch

• phase mismatch

• signals offset

 Encoder outputs, buffered, differential.

• Resolver

 Programmable 10 to 15 bit resolution
 Up to 512 revolutions per second (RPS)
 Encoder outputs, buffered, differential

• Tachometer and Potentiometer

Two inputs for Tachometer Feedback:

 Up to ±50 VDC
 Up to ±20 VDC

Potentiometer Feedback:

 0 V to 5 V voltage range
 Resistance: 100 Ω to 1000 Ω

• Elmo drives provide supply voltage for all the feedback options.

2.3.6. Fault Protection

The Falcon 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

• Recovery from loss of commutation signals and from communication errors

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2.4. System Architecture

Auxiliary

Power

Supply

PWM

Controller

Power Stage

Protection

Current
Feedback

Incremental

Encoder

24 VDC

I/Os

Incremental Encoder

Buffered Output

or

Emulated Output

Resolver

Analog

Encoder

Auxiliary

Encoder

or

or

Potentiometer

Tachometer

or

or

Communication

RS 232 and CANopen

Figure 1: Falcon System Block Diagram

2.5. How to Use this Guide

In order to install and operate your Elmo Falcon servo drive, 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 Falcon.

Chapter 4, Technical Specifications, lists all the drive ratings and specifications.

Upon completing the instructions in this guide, your Falcon servo drive 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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Figure 2: Elmo Documentation Hierarchy

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

• 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 Falcon motion controller.

• The SimplIQ Software Manual, which describes the comprehensive software used with the

Falcon.

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Chapter 3:

Installation

The Falcon must be installed in a suitable environment and properly connected to its voltage
supplies and the motor.

3.1. Before You Begin

3.1.1. Site Requirements

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

Feature Value

Ambient operating temperature -40 °C to +70 °C (-40 °F to 160 °F)

Maximum operating altitude 155,000 m (510,000 ft)

Maximum non-condensing humidity 95%

Operating area atmosphere No flammable gases or vapors permitted in area

Models for extended environmental conditions are available.

Caution: The Falcon dissipates its heat by natural convection. The maximum ambient
operating temperature of -40 °C to +70 °C (-40 °F to 160 °F) must not be exceeded.

3.1.2. Hardware Requirements

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

Component Wire Described

in Section

Drawing

Main Power
Cable

VP+ - red

PR- black

3.4.2.2

Motor Cable M1 M2 M3-

white

3.4.2.1

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Component Wire Described

in Section

Drawing

Backup Supply
Cable (if
needed)

24 V-

red/black

3.4.3

Main
Feedback
Cable

FEEDBACK A 3.4.5

Auxiliary
Feedback
Cable
(if needed)

FEEDBACK B 3.4.7

Digital I/O
Cable
(if needed)

GENERAL

I/O

J1

3.4.8.1

Digital Inputs
and
Analog Inputs
Cable
(if needed)

GENERAL

I/O

J2

3.4.8.2

RS232
Communicatio
n Cable

RS232 3.4.9.1

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Component Wire Described

in Section

Drawing

CANopen
Communicatio
n cable(s) (if
needed)

CAN (in)

CAN (out)

3.4.9.2

PC for drive
setup and
tuning

Motor data
sheet or
manual

3.2. Unpacking the Drive Components

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

• The Falcon servo drive

• The Composer software and software manual

The Falcon is shipped in a cardboard box with Styrofoam protection.

To unpack the Falcon:

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 Falcon you have unpacked is the appropriate type for your

requirements, locate the part number sticker on the side of the Falcon. It looks like this:

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The P/N number at the top gives the type designation as follows:

Maximum DC

Operating Voltage

Continuous Current

(Amps)

Feedback:

Blank = Incremental

Encoder
and/or Halls

R = Resolver

FAL- XX/YYY

R

T =

Tachometer &
Potentiometer

I = Interpolated

Analog
Encoder

Q=

Encoder

Absolute

4. Verify that the Falcon type is the one that you ordered, and ensure that the voltage meets

your specific requirements.

3.3. Mounting the Falcon

The Falcon 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
Falcon (see the diagram below).

Figure 3: Mounting the Falcon

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3.4. Connecting the Cables

The Falcon has ten connectors.

3.4.1. Wiring the Falcon

Once the Falcon 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 Falcon.

Caution: 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 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.

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The following connectors are used for wiring the Falcon.

Type Function Port Connector Location

5-P

in Phoenix (first 2

pins) (provided)

Power VP+, PR

5-P

in Phoenix (last 3

pins) (provided)

Motor M1, M2, M3

3 ground screws Ground PE, PE, PE

2-Pin Phoenix
(provided)

Optional
Backup
Supply

24 VDC

Table 1: Connectors on the “Bottom” of the Falcon

Type Function Port Connector Location

15-Pin D-Sub Feedback A Feedback A

15-Pin D-Sub
(high-density)

General I/O J1

15-Pin D-Sub
(high-density)

General I/O J2

Table 2: Connectors on the “Front” of the Falcon

Type Function Port Connector Location

8-Pin RJ-45 CANopen CAN

8-Pin RJ-45 CANopen CAN

15-Pin D-Sub
(high-density)

Feedback B Feedback B

8-Pin RJ-45 RS-232 RS-232

Table 3: Connectors on the “Top” of the Falcon

Optional

Backup Supply

Ground

Power & Motor

RS-232

CANopen

Feedback B

J2: I/O

J1: I/O

Feedback A

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Figure 4: Falcon Detailed Connection Diagram

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3.4.2. Connecting the Power Cables

The main power connector located at the bottom of the Falcon, as follows:

Pin Function Cable Pin Positions

VP+ Pos. Power input Power

PR Power return Power

PE Protective earth Power

AC Motor

Cable

DC Motor

Cable

PE Protective earth Motor Motor

M1 Motor phase Motor N/C

M2 Motor phase Motor Motor

M3 Motor phase Motor Motor

Note: When connecting several motors, all must be wired in an identical manner.

Table 4: Connector for Main Power and Motor Cables

3.4.2.1. Connecting the Motor Cable

Connect the motor power cable to the M1, M2, and M3 terminals of the main power connector
and the fourth wire to the PE (Protective Earth) on the heat sink (see diagram above). The
phase connection order is arbitrary because the Composer will establish the proper
commutation automatically during setup.

Notes for connecting the motor cables:

• For best 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.

• Connect the shield of the cable to the PE terminal on the Falcon.

• Be sure that the motor chassis is properly grounded.

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Figure 5: AC Motor Power Connection Diagram

3.4.2.2. Connecting the Main Power Cable

Connect the main power supply cable to the VP+ and PR terminals of the main power
connector. Connect the Protective Earth wire to the PE terminal on the Falcon’s heatsink.

Notes for connecting the DC power supply:

• Be sure to isolate the source of the DC power supply.

• For best immunity, it is highly recommended to use twisted 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 both ends of the cable shield to the closest ground connection, one end near the

power supply and the other end to the PE terminal on the Falcon’s heatsink.

• For safety reasons connect the PR of the power supply to the closest ground connection.

Figure 6: Main Power Supply Connection Diagram

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3.4.3. Connecting the Optional Backup Supply Cable (24v)

Power to the Falcon is provided by a 10 to 195 VDC source. A “smart” control-supply algorithm
enables the Falcon to operate with the power supply only, with no need for an auxiliary 24 volt
supply. If backup functionality is required for storing control parameters in case of power-outs,
an external 24 VDC power supply (13 Vmin to 40 Vmax) can be connected, providing maximum
flexibility and optional backup functionality when needed.

To connect the backup supply to the 24v port on the bottom of the Falcon, use the 2-pin power
plug provided with the Falcon. Remember, you are working with DC power; be sure to exercise
caution. The required voltage is 24 VDC.

Notes for 24 VDC backup supply connections:

• Use a 24 AWG twisted pair shielded cable. The shield should have copper braid.

• The source of the 24 VDC must be isolated.

• For safety reasons, connect the return of the 24 VDC source to the closest ground.

• Connect the cable shield to the closest ground near the 24 VDC source.

• Before applying power, first verify the polarity of the connection.

Pin Signal Function Pin Positions

[+] +24VDC +24 VDC backup supply

[-] RET24VDC Return (common) of the

24 VDC backup supply

Table 5: Backup Cable Plug

Figure 7: Backup Supply (24v) Connection Diagram

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“Smart” Control Supply Options:

• Internal DC-to-DC converter that allows operation from DC power (no need for an auxiliary

external 24 VDC supply for normal operation).

• 24 VDC (13 V min to 40 V max) supply for backing up the control parameters if DC power is

shut off.

3.4.4. Feedback and Control Cable Assemblies

The Falcon features easy-to-use D-Sub type connections for all Control and Feedback cables.
Instructions and diagrams describing how to assemble those cables are presented below.

1. Use 24, 26 or 28 AWG twisted-pair shielded cables (24 AWG cable is recommended). For

best results, the shield should have aluminum foil covered by copper braid.

2. Use only a D-Sub connector with a metal housing.

3. Ideally, solder the drain wire to the connector body as shown in Figure 8.

However, the shield may also be attached without soldering, as long as the braid shield is in
tight contact with the metal housing of the D-type connector.

4. On the motor side connections, ground the shield to the motor chassis.

5. On controller side connections, follow the controller manufacturer’s recommendations

concerning the shield.

Figure 8: Feedback and Control Cable Assemblies

Note: All D-Sub type connectors used with the Falcon should be assembled in this way.

3.4.5. Main Feedback Cable (FEEDBACK A)

The main feedback cable is used to transfer feedback data from the motor to the drive.

The Falcon accepts the following as a main feedback mechanism:

• Incremental encoder only

• Incremental encoder with digital Hall sensors

• Digital Hall sensors only

• Interpolated Analog (Sine/Cosine) encoder (option)

• Resolver (option)

• Tachometer & Potentiometer

Connector

body

Drain wire

soldered to
the metal

housing

Make sure that the

braid shield is in tight
contact with the metal

housing

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FEEDBACK A on the “front” of the Falcon has a 15-pin D-Sub socket. Connect the Main
Feedback cable from the motor to FEEDBACK A using a 15-pin, D-Sub plug with a metal
housing. When assembling the Main Feedback cable, follow the instructions in Section 3.4.4
(Feedback and Control Cable Assemblies).

Incremental

Encoder

Interpolated

Analog Encoder

Resolver Tachometer and

Potentiometer

FAL-XX/YYY_ FAL-XX/YYYI FAL-XX/YYYR FAL-XX/YYYT

Pin Signal Function Signal Function Signal Function Signal Function

1 HC Hall sensor C

input

HC Hall sensor C

input

NC - HC Hall sensor C input

2 HA Hall sensor A

input

HA Hall sensor A

input

NC - HA Hall sensor A

input

3 SUPRET Supply return SUPRET Supply return SUPRET Supply return SUPRET Supply return

4 +5V Encoder/Hall

+5V supply

+5V Encoder/Hall

+5V supply

+5V Encoder/Hall

+5V supply

+5V Encoder/Hall +5V

supply

5 CHA- Channel A

complement

A- Sine A

complement

S3 Sine A

complement

Tac 1- Tacho Input 1

Neg. (20 V max)

6 CHA Channel A A+ Sine A S1 Sine A Tac 1+ Tacho Input 1 Pos.

(20 V max)

7 INDEX- Index

complement

R- Reference

complement

R2 Vref

complement
f= 1/TS, 50 mA
Maximum

NC -

8 INDEX Index R+ Reference R1 Vref f=1/TS, 50

mA Max.

POT Potentiometer

Input

9 SUPRET Supply return SUPRET Supply return SUPRET Supply return SUPRET Supply return

10 HB Hall sensor B

input

HB Hall sensor B

input

NC - HB Hall sensor B input

11 SUPRET Supply return SUPRET Supply return SUPRET Supply return SUPRET Supply return

12 +5V Encoder/Hall

+5V supply

+5V Encoder/Hall

+5V supply

+5V Encoder/Hall

+5V supply

+5V Encoder/Hall +5V

supply

13 SUPRET Supply return SUPRET Supply return SUPRET Supply return SUPRET Supply return

14 CHB- Channel B

complement

B- Cosine B

complement

S4 Cosine B

complement

Tac 2- Tacho Input 2

Neg. (50 V max)

15 CHB Channel B B+ Cosine B S2 Cosine B Tac 2+ Tacho Input 2 Pos.

(50 V max)

Table 6: Main Feedback Cable Pin Assignments (Part A)

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Absolute Encoders

FAL-XX/YYYQ

Pin Signal Heidenhain Stegmann

1 HC Hall C Hall C

2 HA Hall A Hall A

3 SUPRET Supply return Supply return

4 +5V EnDat (Heidenhain) Encoder +5 supply Halls supply +5V

5 A- Sine A complement Sine A

6 A+ Sine A Sine A complement

7 DATA- Data complement Data complement

8 DATA+ DATA DATA

9 SUPRET Supply return Supply return

10 HB Hall B Hall B

11 CLK- CLOCK complement -

12 +8V - Stegmann Encoder +8V supply

8 V @90 mA maximum

13 CLK+ CLOCK -

14 B- Cosine B complement Cosine B complement

15 B+ Cosine B Cosine B

Table 7: Main Feedback Cable Pin Assignments (Part B)

Figure 9: Main Feedback – Incremental Encoder Connection Diagram

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Figure 10: Main Feedback – Interpolated Analog (Sine/Cosine) Encoder Connection Diagram

Figure 11: Main Feedback – Resolver Connection Diagram

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Figure 12: Main Feedback – Tachometer Feedback with Digital Hall Sensor

Connection Diagram for Brushless Motors

Figure 13: Main Feedback – Tachometer Feedback Connection Diagram for Brush Motors

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Figure 14: Main Feedback – Potentiometer Feedback with Digital Hall Sensor

Connection Diagram for Brushless Motors

Figure 15: Main Feedback –

Potentiometer Feedback Connection Diagram for Brush Motors and Voice Coils

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Figure 16: Main Feedback – Stegmann Feedback Connection Diagram

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Figure 17: Main Feedback – Heidenhain Feedback Connection Diagram

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3.4.6. Main and Auxiliary Feedback Combinations

The Main Feedback is always used in motion control devices whereas Auxiliary Feedback is
often, but not always used. The Auxiliary Feedback connector on the Falcon, “FEEDBACK B” has
two ports, Port B1 and Port B2. When used in combination with the Main Feedback port,
“FEEDBACK A”, the ports can be set, by software, as follows:

FEEDBACK A FEEDBACK B Ports B1 and B2

Software
Setting

YA[4] = 4 YA[4] = 2 YA[4] = 0

Incremental

Encoder Input

Incremental

Encoder

B1

- output

B2

- output

same as B1

Differential
and
Buffered
Main
Encoder
Signal

A

- input

Differential
or
Single-ended
Auxiliary
Incremental
Encoder

B1

B2

Differential
and
Buffered
Auxiliary
Encoder
Signal

Incremental

Encoder

or

Analog

Encoder

or

Resolver

or

Tachometer

or

Potentiometer

Differential or
Single-ended
Pulse &
Direction
Commands

Differential
Buffered
Pulse &
Direction
Signals

B1

B2

Incremental

Encoder

or

Analog

Encoder

or

Resolver

or

Tachometer

or

Potentiometer

Interpolated

Analog

(Sine/Cosine)

Encoder Input

Analog

Encoder

Analog
Encoder
Position
Data
Emulated in
Incremental
Encoder
Format
(signals are
quadrature,
differential
& buffered)

same as B1

B1

- output

B2

- output

A

- input

Resolver

Input

Resolver

Resolver
Position
Data
Emulated in
Incremental
Encoder
Format
(signals are
quadrature,
differential
& buffered)

same as B1

B1

- output

B2

- output

A

- input

Tachometer

Input

Tachometer

Tachometer
Position
Data
Emulated in
Incremental
Encoder
Format
(signals are
quadrature,
differential
& buffered)

same as B1

B1

- output

B2

- output

A

- input







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FEEDBACK A FEEDBACK B Ports B1 and B2

Software
Setting

YA[4] = 4 YA[4] = 2 YA[4] = 0

Potentiometer

Input

Potentiometer

Potentiometer
Position
Data Emulated
in Incremental
Encoder
Format
(signals are
quadrature,
differential &
buffered)

same as B1

B1

- output

B2

- output

A

- input

Differential
or
Single-ended
Auxiliary
Incremental
Encoder

B1

B2

Differential
and
Buffered
Auxiliary
Encoder
Signal

Incremental

Encoder

or

Analog

Encoder

or

Resolver

or

Tachometer

or

Potentiometer

Differential or
Single-ended
Pulse &
Direction
Commands

Differential
Buffered
Pulse &
Direction
Signals

B1

B2

Incremental

Encoder

or

Analog

Encoder

or

Resolver

or

Tachometer

or

Potentiometer

Typical
Applications

 Any application where the

main encoder is used, not only
for the drive, but also for other

purposes such as position

controllers and/or other drives.

 Analog Encoder applications

where position data is required

in the Encoder’s quadrature
format.

 Resolver applications where

position data is required in the

Encoder’s quadrature format.

Any application where two
feedbacks are used by the drive.

Port B1 serves as an input for the
auxiliary incremental encoder
(differential or single-ended).

Port B2 is used to output
differential buffered Auxiliary
Incremental Encoder signals.

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

Port B1 serves as an input for
Pulse & Direction commands
(differential or single-ended).

Port B2 is used to output
differential buffered Pulse &
Direction signals.

3.4.7. Auxiliary Feedback (FEEDBACK B)

When using one of the auxiliary feedback options, the relevant functionality of FEEDBACK B
ports are software selected for that option. Refer to the SimplIQ Command Reference Manual
for detailed information about FEEDBACK B setup.

3.4.7.1. Main Encoder Buffered Outputs or Emulated Encoder Outputs Option on

FEEDBACK B (YA[4]=4)

Through FEEDBACK B (Ports B1 and B2) the Falcon can provide two simultaneous buffered
main, or emulated, encoder signals to other controllers or drives. This option can be used

when:

• The Falcon is used as a current amplifier to provide position data to the position controller.

• The Falcon is used in velocity mode, to provide position data to the position controller.

• The Falcon is used as a master in Follower or ECAM mode.

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Below are the signals on the Auxiliary Feedback ports when set up to run as a buffered outputs
or emulated outputs of the main encoder (on FEEDBACK A):

Port Pin Signal Function Pin Positions

B1 1

CHA

Auxiliary channel A high output

15-Pin High Density

D-Sub Plug

B1 2 CHA- Auxiliary channel A low output

B1 3 CHB Auxiliary channel B high output

B1 4 CHB- Auxiliary channel B low output

B1 5 INDEX Auxiliary Index high output

B2 6 CHAO Buffered channel A output

B2 7 CHAO- Buffered channel A complement output

PWR 8 +5V Encoder supply voltage

PWR 9 SUPRET Encoder supply voltage return

5

15

10

1

11

6

Port B1
Port B2
Power

15-Pin High Density

D-Sub Socket

B1 10 INDEX- Auxiliary Index low 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 SUPRET Supply return

Table 8: Main Encoder Buffered Outputs or Emulated Encoder Outputs on FEEDBACK B – Pin

Assignments

FEEDBACK B on the “top” of the Falcon has a 15-pin high density D-Sub socket. Connect the
Auxiliary Feedback cable, from the controller or other device, to FEEDBACK B using a 15-pin,
high density D-Sub plug with a metal housing. When assembling the Auxiliary Feedback cable,
follow the instructions in Section 3.4.4 (Feedback and Control Cable Assemblies).

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Figure 18: Main Encoder Buffered Output or Emulated Encoder Output on FEEDBACK B -

Connection Diagram

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3.4.7.2. Differential Auxiliary Encoder Input Option on FEEDBACK B (YA[4]=2)

The Falcon can be used as a slave by receiving the position of the master encoder data (on Port
B1) in Follower or ECAM mode. In this mode Port B2 provides differential buffered auxiliary
outputs for the next slave axis in follower or ECAM mode.

Below are the signals on the Auxiliary Feedback port when set up to run as a differential
auxiliary encoder input:

Port Pin Signal Function Pin Positions

B1 1 CHA Auxiliary channel A high input

15-Pin High Density

D-Sub Plug

B1 2 CHA- Auxiliary channel A low input

B1 3 CHB Auxiliary channel B high input

B1 4 CHB- Auxiliary channel B low input

B1 5 INDEX Auxiliary Index high input

B2 6 CHAO Buffered channel A output

B2 7 CHAO- Buffered channel A complement output

PWR 8 +5V Encoder supply voltage

PWR 9 SUPRET Encoder supply voltage return

5

15

10

1

11

6

Port B1
Port B2
Power

15-Pin High Density

D-Sub Socket

B1 10 INDEX- Auxiliary Index low input

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 SUPRET Supply return

Table 9: Differential Auxiliary Encoder Input Option on FEEDBACK B

Pin Assignments

FEEDBACK B on the “top” of the Falcon has a 15-pin high density D-Sub socket. Connect the
Auxiliary Feedback cable from the feedback device to FEEDBACK B using a 15-pin, high density
D-Sub plug with a metal housing. When assembling the Auxiliary Feedback cable, follow the
instructions in Section 3.4.4 (Feedback and Control Cable Assemblies).

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Figure 19: Differential Auxiliary Encoder Input Option on FEEDBACK B –

Connection Diagram

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3.4.7.3. Single-Ended Auxiliary Input Option on FEEDBACK B (YA[4]=2)

The Falcon can be used as a slave by receiving the position data (on Port B1) of the master
encoder in Follower or ECAM mode. In this mode Port B2 provides differential buffered
auxiliary outputs for the next slave axis in Follower or ECAM mode.

Below are the signals on the Auxiliary Feedback ports when set up to run as a single-ended
auxiliary input:

Port Pin Signal Function Pin Positions

B1 1 CHA Auxiliary channel A high input

15-Pin High Density D-Sub

Plug

2 NC Do not connect this pin

B1 3 CHB Auxiliary channel B high input

4 NC Do not connect this pin

B1 5 INDEX Auxiliary Index high input

B2 6 CHAO Channel A output

B2 7 CHAO- Channel A complement output

PWR 8 +5V Encoder supply voltage

PWR 9 SUPRET Encoder supply voltage return

5

15

10

1

11

6

Port B1
Port B2

Power
N.C.

15-Pin High Density D-Sub

Socket

10 NC Do not connect this pin

B2 11 CHBO Channel B output

B2 12 CHBO- Channel B complement output

B2 13 INDEXO Index output

B2 14 INDEXO- Index complement output

PWR 15 SUPRET Supply return

Table 10: Single-Ended Auxiliary Encoder Option on FEEDBACK B – Pin Assignments

FEEDBACK B on the “top” of the Falcon has a 15-pin high density D-Sub socket. Connect the
Auxiliary Feedback cable from the feedback device to FEEDBACK B using a 15-pin, high density
D-Sub plug with a metal housing. When assembling the Auxiliary Feedback cable, follow the
instructions in Section 3.4.4 (Feedback and Control Cable Assemblies).

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Figure 20: Single-Ended Auxiliary Input Option on FEEDBACK B – Connection Diagram

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3.4.7.4. Pulse-and-Direction Input Option on FEEDBACK B (YA[4]=0)

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

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

Port Pin Signal Function Pin Positions

B1 1 PULS/CHA Pulse/Auxiliary channel A high input

15-Pin D-Sub Plug

2 NC Do not connect this pin

B1 3 DIR/CHB Direction/Auxiliary channel B high input

4 NC Do not connect this pin

5 NC Do not connect this pin

B2 6 CHAO Channel A output

B2 7 CHAO- Channel A complement output

PWR 8 +5V Encoder supply voltage

PWR 9 SUPRET Encoder supply voltage return

5

15

10

1

11

6

Port B1
Port B2

Power
N.C.

15-Pin D-Sub Socket

10 NC Do not connect this pin

B2 11 CHBO Channel B output.

B2 12 CHBO- Channel B complement output

13 NC Do not connect this pin

14 NC Do not connect this pin

PWR 15 SUPRET Supply return

Table 11: Pulse-and-Direction Auxiliary Encoder Pin Assignment on FEEDBACK B

FEEDBACK B on the “top” of the Falcon has a 15-pin high density D-Sub socket. Connect the
Auxiliary Feedback cable from the Pulse and Direction Controller to FEEDBACK B using a 15-pin,
high density D-Sub plug with a metal housing. When assembling the Auxiliary Feedback cable,
follow the instructions in Section 3.4.4 (Feedback and Control Cable Assemblies).

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Figure 21: Pulse-and-Direction Input Option on FEEDBACK B – Connection Diagram

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

Port Pin Signal Function Pin Positions

B1 1 PULS/CHA Pulse/Auxiliary channel A high input

15 Pin D-Sub Plug

B1 2 PULS-/CHA- Pulse-/Auxiliary channel A low input

B1 3 DIR/CHB Direction/Auxiliary channel B high input

B1 4 DIR-/CHB- Direction-/Auxiliary channel B low input

5 NC Do not connect this pin

B2 6 CHAO Channel A output

B2 7 CHAO- Channel A complement output

PWR 8 +5V Encoder supply voltage

PWR 9 SUPRET Encoder supply voltage return

5

15

10

1

11

6

Port B1
Port B2

Power
N.C.

15 Pin D-Sub Socket

10 NC Do not connect this pin

B2 11 CHBO Channel B output.

B2 12 CHBO- Channel B complement output

13 NC Do not connect this pin

14 NC Do not connect this pin

PWR 15 SUPRET Supply return

Table 12: Differential Pulse-and-Direction Auxiliary Encoder Pin Assignment on FEEDBACK B

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Figure 22: Differential Pulse-and-Direction Input Option on FEEDBACK B – Connection

Diagram

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3.4.8. I/O Cables

The Falcon has two I/O ports, J1 and J2. J1 is a general I/O which can be used to connect 6
digital inputs and 5 digital outputs. J2 is an input port for connecting up to 4 separate digital
inputs and 2 (Sine/Cosine) inputs:

I/O J1 Port J2 Port Total

Digital Input 6 4 10

Digital Output 5 - 5

Analog Input - 2 2

3.4.8.1. General I/O Port (J1)

Port J1 has a 15-pin high density D-Sub plug. When assembling this I/O cable, follow the
instructions in Section 3.4.4 (Feedback and Control Cable Assemblies) using a 15-pin high
density metal case D-Sub female connector (socket).

Pin Signal Function Pin Positions

1 IN1 Programmable input 1

2 IN2 Programmable input 2

3 IN3 Programmable input 3

4 OUT2 Programmable output 2

5 OUT3 Programmable output 3

6 IN4 Programmable input 4

7 IN7 Programmable input 7

8 IN8 Programmable input 8

9 INRET General input return

10 OUTRET2-3 Programmable output return 2 & 3

11 OUT4 Programmable output 4

12 OUTRET4-5 Programmable output return 4 & 5

13 OUT5 Programmable output 5

14 OUT1 Programmable output 1

15 OUTRET 1 Programmable output return 1

Table 13: J1 I/O Cable - Pin Assignments

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Figure 23: General J1 I/O Connection Diagram

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3.4.8.2. General Input Port (J2)

Port J2 has a 15-pin high density D-Sub socket. When assembling this I/O cable, follow the
instructions in Section 3.4.4 (Feedback and Control Cable Assemblies) using a 15-pin high
density metal case D-Sub male connector (plug).

Note: Analog Inputs 1 and 2 are functionally identical. However, note that the velocity and

current commands can only be given on Analog Input 1.

Pin Signal Function Pin Positions

1 IN5 Programmable input 5 (high-speed input)

2 IN6 Programmable input 6 (high-speed input)

3 IN9 Programmable input 9

4 IN10 Programmable input 10

5 ANLIN1+ Analog input 1

6 INRET5 Programmable input return 5 (high-speed input)

7 INRET6 Programmable input return 6 (high-speed input)

8 INRET9 Programmable input return 9

9 INRET10 Programmable input return 10

10 ANLIN1- Analog input 1

11 ANLIN2+ Analog input 2

12 ANLIN2- Analog input 2

13 ANLRET Analog return

14 ANLRET Analog return

15 SUPRET Supply return

Table 14: General Input J2 Cable – Pin Assignments

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Figure 24: General Input J2 Connection Diagram

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3.4.9. Communication Cables

The communication cables use an 8-pin RJ-45 plug that connect to the RS-232 and CANopen
ports on the “top” of the Falcon.

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

a. RS-232, full duplex
b. CANopen

RS-232 communication requires a standard, commercial 3-core null-modem cable connected
from the Falcon 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. The interface is electrically
isolated by optocouplers.

For ease of setup and diagnostics of CAN communication, RS-232 and CANopen can be used
simultaneously.

3.4.9.1. RS-232 Communication

Notes for connecting the RS-232 communication cable:

• Use a 26 or 28 AWG twisted pair shielded cable. The shield should have aluminum foil

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 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 Locations

1,2 N/A —

3 Tx RS-232 transmit

4 — —

5 COMRET Communication return

6 Rx RS-232 receive

7, 8 N/A —

Table 15: RS-232 Cable - Pin Assignments

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Figure 25: RS-232 Connection Diagram

3.4.9.2. 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 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 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.

• Connect a termination 120-Ω 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, 5 N/A —

6 CAN_SHLD Shield, connected to the RJ plug cover

7 CAN_GND CAN Ground

8 N/A —

Table 16: CANopen Cable – Pin Assignments

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Figure 26: CANopen Connection Diagram

Caution:

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

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3.5. Powering Up

After the Falcon has been mounted, check that the cables are intact. The Falcon servo drive is
then ready to be powered up.

Caution: Before applying power, ensure that the DC supply is within the range specified for
your specific type of Falcon and that the proper plus-minus connections are in order.

3.6. Initializing the System

After the Falcon 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.

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Chapter 4: Technical Specifications

This chapter provides detailed technical information regarding the Falcon. This includes its
dimensions, power ratings, the environmental conditions under which it can be used, the
standards to which it complies and other specifications.

4.1. Features

The Falcon's features determine how it controls motion, as well as how it processes host
commands, feedback and other input.

4.1.1. Motion Control Modes

• Current/Torque - up to 14 kHz sampling rate

• Velocity - up to 7 kHz sampling rate

• Position - up to 3.5 kHz sampling rate

4.1.2. Advanced Positioning Motion Control Modes

• PTP, PT, PVT, ECAM, Follower, Pulse and Direction, Dual Loop

• Fast event capturing inputs

• Fast output compare (OC)

4.1.3. Advanced Filters and Gain Scheduling

• “On-the-Fly” gain scheduling of current and velocity

• Velocity and position with “1-2-4” PIP controllers

• Automatic commutation alignment

• Automatic motor phase sequencing

4.1.4. Fully Programmable

• Third generation programming structure with motion commands

• Event capturing interrupts

• Event triggered programming

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4.1.5. 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

• Absolute Encoder

• 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
 Encoder outputs, buffered, differential.

• Resolver

 Programmable 10 to 15 bit resolution
 Up to 512 revolutions per second (RPS)
 Encoder outputs, buffered, differential

• Elmo drives provide supply voltage for all the feedback options

• Tachometer, Potentiometer

4.1.6. Input/Output

• Analog Inputs – up to 14-bit resolution

• Programmable digital inputs, optically isolated

 Inhibit/Enable motion
 Software and analog reference stop
 Motion limit switches
 Begin on input
 Abort motion
 General-purpose
 Homing

• 2 Fast event capture inputs, optically isolated IN5-IN6

• Programmable digital outputs

 Brake Control
 Amplifier fault indication
 General-purpose
 Servo enable indication

• Buffered and differential outputs of the main encoder with up to 5 MHz pulses

• Buffered and differential outputs of the auxiliary encoder

• Emulated output of the resolver or interpolated analog encoder

• Fast output compare (OC), optically isolated

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4.1.7. Built-In Protection

• Software error handling

• Abort (hard stops and soft stops)

• Status reporting

• Protection against

 Shorts between motor power outputs
 Shorts between motor power outputs and power input/return
 Failure of internal power supplies
 Overheating
 Over/Under voltage
 Loss of feedback
 Following error
 Current limits

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4.2. Falcon Dimensions

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4.3. Power Ratings

Feature Units 15/60 30/60 15/100 30/100 15/200

Minimum supply voltage VDC 10 20 40

Nominal supply voltage VDC 50 85 170

Maximum supply voltage VDC 59 95 195

Maximum continuous power
output

W 720 1440 1200 2400 2400

Efficiency at
rated power (at nominal
conditions)

% > 97

Maximum output voltage 97% of DC bus voltage at f=22 kHz

Auxiliary supply voltage VDC 24 ± 20%

Auxiliary power supply VA 12

Amplitude sinusoidal/
DC continuous current

A 15 30 15 30 15

Sinusoidal continuous RMS
current limit (Ic)

A 10.6 21.2 10.6 21.2 10.6

Peak current limit A 2 x Ic

Weight g (oz) 640 g (22.6 oz)

Dimensions mm (in) 150 x 25.4 x 105 (5.9" x 1" x 4.1")

Digital in/Digital out/Analog in 10/5/2

Mounting method Panel Mount

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4.4. Environmental Conditions

Feature Operation Conditions Range

Ambient
Temperature
Range

Non-operating conditions -50 °C to +100 °C (-58 °F to 212 °F)

Operating conditions -40 °C to +70 °C (-40 °F to 160 °F)

Temperature
Shock

Non-operating conditions -40 °C to +70 °C (-40 °F to 160 °F) within 3

min

Altitude

Non-operating conditions Unlimited

Operating conditions -400 m to 155,000 m (-1,300 ft to 510,000 ft)

Humidity

Non-operating conditions Up to 95% non-condensing humidity at 35 °C

(95 °F)

Operating conditions Up to 95% non-condensing humidity at 25 °C

(77 °F), up to 90% non-condensing humidity
at 42 °C (108 °F)

Vibration

Operating conditions 20 Hz to 2000 Hz, 14.6 g

Mechanical
Shock

Non-operating conditions ±40 g; Half sine, 11 msec

Operating conditions ±20 g; Half sine, 11 msec

4.5. Falcon Connections

The following connectors are used for wiring the Falcon.

Pins Type Maker & Part

No.

Port

-

14 AWG Wires FLDW CO311-14

Rychem

VP+, PR

M1, M2, M3

3

M4 screws PE, PE, PE

-

20 AWG wires FLDW CO311-20

Rychem

24v

Connector Location

Table 17: Connectors on the Bottom of the Falcon

Optional

Backup

Power

Ground

Power and

Motor

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Pins Type Port Connector Location

15 D-Sub Socket FEEDBACK A

15 High Density D-Sub Plug J1

15 High Density D-Sub Socket J2

Table 18: Connectors on the Front of the Falcon

Pins Type Port Connector Location

8 RJ-45 CAN

8 RJ-45 CAN

15 High Density D-Sub Socket FEEDBACK B

8 RJ-45 RS-232

Table 19: Connectors on the Top of the Falcon

4.5.1. Backup Supply (Optional)

Feature Details

Auxiliary power supply DC source only

Auxiliary supply input voltage 24 V, 13 Vmin to 40 Vmax

Auxiliary supply input power 10 W

Note: The Falcon can operate without a 24 Volt backup power supply

J2: I/O

J1: I/O

Feedback A

CANopen

Feedback B

RS-232

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4.6. Control Specifications

4.6.1. Current Loop

Feature Details

Controller type Vector, digital

Compensation for bus voltage
variations

“On-the-fly” gain scheduling

Motor types

• AC brushless (sinusoidal)

• DC brushless (trapezoidal)

• DC brush

• Linear motors

• Moving coils

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 bandwidth < 2.5 kHz

Current sampling time

Programmable 70 to 100 µsec

Current sampling rate Up to 16 kHz; default 11 kHz

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4.6.2. Velocity Loop

Feature Details

Controller type PI

Velocity control

• Fully digital

• Programmable PI and FFW control filters

• On-the-fly gain scheduling

• Automatic, manual and advanced manual tuning

Velocity and position feedback
options

• Incremental Encoder

• Digital Halls

• Interpolated Analog (Sine/Cosine) Encoder (optional)

• Resolver (optional)

Note: With all feedback options, 1/T with automatic

mode switching is activated (gap, frequency and
derivative).

Velocity loop bandwidth < 350 Hz

Velocity sampling time

140 to 200 µsec (x2 current loop sample time)

Velocity sampling rate Up to 8 kHz; default 5.5 kHz

Velocity command options

• Analog

• Internally calculated by either jogging or step

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

changes.

4.6.3. Position Loop

Feature Details

Controller type “1-2-4” PIP

Position command options

• Software

• Pulse and Direction

Position loop bandwidth < 80 Hz

Position sampling time

280 to 400 µsec (x 4 current loop sample time)

Position sampling rate Up to 4 kHz; default 2.75 kHz

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4.7. Feedbacks

The Falcon can receive and process feedback input from diverse types of devices.

4.7.1. Feedback Supply Voltage

Feature Details

Main encoder supply voltage 5 V +5% @ 200 mA maximum

Auxiliary encoder supply voltage 5 V +5% @ 200 mA maximum

4.7.2. Incremental Encoder Input

Feature Details

Encoder format

• A, B and Index

• Differential

• Quadrature

Interface: RS-422

Input resistance:

Differential: 120 Ω

Maximum incremental encoder frequency: Maximum: 5 MHz pulses

Minimum quadrature input period (PIN) 112 nsec

Minimum quadrature input high/low period (PHL) 56 nsec

Minimum quadrature phase period (PPH) 28 nsec

Maximum encoder input voltage range

Common mode: ±7 V

Differential mode: ±7 V

Figure 27: Encoder Phase Diagram

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4.7.3. Digital Halls

Feature Details

Halls inputs

• H

A

, HB, HC.

• Single ended inputs

• Built in hysteresis for noise immunity.

Input voltage Nominal operating range: 0 V < V

In_Hall

< 5 V

Maximum absolute: -1 V < V

In_Hall

< 15 V

High level input voltage: V

InHigh

> 2.5 V

Low level input voltage: V

InLow

< 1 V

Input current Sink current (when input pulled to the common): 3 mA

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

Maximum frequency f

MAX

: 2 kHz

4.7.4. Interpolated Analog (Sine/Cosine) Encoder

Feature Details

Analog encoder format Sine and Cosine signals

Analog input signal level

• Offset voltage: 2.2 V – 2.8 V

• Differential, 1 V peak to peak

Input resistance

Differential 120 Ω

Maximum analog signal frequency f

MAX

: 250 kHz

Interpolation multipliers Programmable: x4 to x4096

Maximum “counts” frequency 80 megacounts/sec “internally”

Automatic errors correction

Signal amplitudes mismatch
Signal phase shift
Signal offsets

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4.7.5. Resolver

Feature Details

Resolver format

• Sine/Cosine

• Differential

Input resistance

Differential 2.49 kΩ

Resolution Programmable: 10 to 15 bits

Maximum electrical frequency (RPS) 512 revolutions/sec

Resolver transfer ratio 0.5

Reference frequency 1/Ts (Ts = sample time in seconds)

Reference voltage Supplied by the Falcon

Reference current up to ±50 mA

4.7.6. Tachometer*

Feature Details

Tachometer format Differential

Maximum operating differential voltage for
TAC1+, TAC1-

±20 V

Maximum absolute differential input voltage
for TAC1+, TAC1-

±25 V

Maximum operating differential voltage for
TAC2+, TAC2-

±50 V

Maximum absolute differential input voltage
for TAC2+, TAC2-

±60 V

Input resistance for TAC1+, TAC1- 46 kΩ

Input resistance for TAC2+, TAC2- 100 kΩ

Resolution 14 bit

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

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4.7.7. Potentiometer

Feature Details

Potentiometer Format Single-ended

Operating Voltage Range 0 V to 5 V supplied by the Falcon

Potentiometer Resistance 100 Ω to 1 kΩ … above this range, linearity is

affected detrimentally

Input Resistance 100 kΩ

Resolution 14 bit

4.7.8. Encoder Outputs

Feature Details

Encoder output format

• A, B, Index

• Differential outputs

• Quadrature

Interface RS-422

Port B1 output current capability

 Driving differential loads of 200 Ω on

INDEX/INDEX-, CHB/CHB- and CHA/CHA- pairs

Port B2 output current capability



INDEXO/INDEXO-, CHBO/CHBO- and CHAO/CHAO- pairs are

not loaded

Available as options

• Two simultaneous buffered outputs of main-

incremental encoder input

• Two simultaneous emulated encoder outputs of

analog encoder input

• Two simultaneous emulated encoder outputs of

resolver input

• Buffered output of auxiliary input

Maximum frequency f

MAX

: 5 MHz pulses/output

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

encoder cycle) and synchronized to A&B

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4.8. I/Os

The Falcon has:

• 10 Digital Inputs

• 5 Digital Outputs

• 2 Analog Input

4.8.1. Digital Input Interfaces

Feature Details

Type of input

• Optically isolated

• Single ended

• PLC level

Input current

* I

in

= 2.2 mA for Vin = 12 V

Input current for high speed
inputs

* I

in

= 4.4 mA for Vin = 12 V

High-level input voltage 12 V < Vin < 30 V, 24 V typical

Low-level input voltage 0 V < Vin < 6.5 V

Minimum pulse width > 4 x TS, where TS is sampling time

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

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 < 4 x TS

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

High-speed inputs - minimum
pulse width, in high-speed
mode
(IN5 - IN6)

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.

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Feature Details

Connector location

Figure 28: Digital Input Schematic

4.8.2. Digital Output Interface

Feature Details Connector Location

Type of output

• Optically isolated

• Open collector and open emitter

Maximum supply output
(VCC)

30 V

Max. output current
I

out

(max) (V

out

= Low)

I

out

(max) ≤ 15 mA

VOL at maximum output
voltage (low level)

V

out

(on) ≤ 0.3 V + 0.02 * I

out

(mA)

RL The external resistor RL must be

selected to limit the output current
to no more than 15 mA.

J2: General

purpose I/O

J1: General

purpose I/O

J2:

General

Purpose

I/O

J1:

General

Purpose

I/O

General input return

Rin = 2.5K

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Feature Details Connector Location

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 0.5
msec.

Digital Output Schematic

4.8.3. Analog Input

Feature Details

Maximum operating differential voltage ± 10 V

Maximum absolute differential input voltage ± 16 V

Differential input resistance 3 kΩ

Analog input command resolution 14-bit

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4.9. Communications

Specification Details Connector Location

RS-232

Signals:

• RxD , TxD , GND

• Full duplex, serial communication for

setup and control.

• Baud Rate of 9,600 to 115,200

bit/sec.

CANopen

CAN bus Signals:

• CAN_H, CAN_L, CAN_GND

• Maximum Baud Rate of 1 Mbit/sec.

Version:

• DS 301 V4.01

Device Profile (drive and motion control):

• DS 402

4.10. Pulse-Width Modulation (PWM)

Feature Details

PWM resolution 12-bit

PWM switching frequency on the load 2/Ts (factory default 22 kHz on the motor)

4.11. Mechanical Specifications

Feature Details

Mounting method Wall Mount

Overall dimensions 150 x 105 x 25.4 mm (5.9 x 4.13 x 1 in)

Weight 640 g (22.6 oz)

CANopen

port

CANopen

port

RS-232

port

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4.12. Compliance with Standards

Specification Details

Quality Assurance

ISO 9001:2008 Quality Management

Design

Approved IEC/EN 61800-5-1, Safety Printed wiring for electronic equipment

(clearance, creepage, spacing, conductors
sizing, etc.)

MIL-HDBK- 217F Reliability prediction of electronic equipment

(rating, de-rating, stress, etc.)

• UL 60950

• IPC-D-275

• IPC-SM-782

• IPC-CM-770

• UL 508C

• UL 840

Printed wiring for electronic equipment
(clearance, creepage, spacing, conductors
sizing, etc.)

In compliance with VDE0160-7 (IEC 68) Type testing

Safety

Recognized UL 508C Power Conversion Equipment

In compliance with UL 840 Insulation Coordination Including Clearances

and Creepage Distances for Electrical
Equipment

In compliance with UL 60950 Safety of Information Technology Equipment

Including Electrical Business Equipment

Approved IEC/EN 61800-5-1, Safety Adjustable speed electrical power drive

systems

In compliance with EN 60204-1 Low Voltage Directive 73/23/EEC

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EMC

Approved IEC/EN 61800-3, EMC Adjustable speed electrical power drive

systems

In compliance with EN 55011 Class A with
EN 61000-6-2: Immunity for industrial
environment, according to:

IEC 61000-4-2 / criteria B
IEC 61000-4-3 / criteria A
IEC 61000-4-4 / criteria B
IEC 61000-4-5 / criteria B
IEC 61000-4-6 / criteria A
IEC 61000-4-8 / criteria A
IEC 61000-4-11 / criteria B/C

Electromagnetic compatibility (EMC)

Workmanship

In compliance with IPC-A-610, level 3 Acceptability of electronic assemblies

PCB

In compliance with IPC-A-600, level 2 Acceptability of printed circuit boards

Packing

In compliance with EN 100015 Protection of electrostatic sensitive devices

Environmental

In compliance with 2002/96/EC Waste Electrical and Electronic Equipment

regulations (WEEE)

Note: Out-of-service Elmo drives should be

sent to the nearest Elmo sales office.

In compliance with 2002/95/EC
(effective July 2006)

Restrictions on Application of Hazardous
Substances in Electric and Electronic
Equipment (RoHS)