Elmo GOLD-MAESTRO01, GOLD-MAESTRO02 Installation Manual

Gold Maestro

Network Motion Controller

Installation Guide

October 2012 (Ver. 1.300)

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 Gold
Maestro servo drive in its installation.

• The text and graphics included in this manual are for the purpose of illustration and

reference only. The specifications on which they are based are subject to change
without notice.

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

Elmo Motion Control and the Elmo Motion Control logo are
registered trademarks of Elmo Motion Control Ltd.

EtherCAT Conformance Tested. EtherCAT® is a registered

trademark and patented technology, licensed by Beckhoff
Automation GmbH, Germany.

Document no. MAN-GOLD-MAESTRO-IG (Ver. 1.300)

Copyright  2012

Elmo Motion Control Ltd.

All rights reserved.

Catalog Number

GOLD-MAESTRO01

13 to 96 VDC power supply

GOLD-MAESTRO02 20 to 196 VDC power supply

Revision History

Version Date Details

Ver. 1.0 6th May 2010 Initial Release

Ver. 1.1 13th May 2010 Minor updates

Ver. 1.2 July 2010 Updates to Chapter 3 and Chapter 4 (Appendix)

Ver. 1.300 Oct. 2012 Updates to Chapter 3 and minor updates in other

chapters.

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 ...................................................................................... 6

1.1. Cautions ......................................................................................................................6

1.2. Directives and Standards ............................................................................................7

1.3. Warranty Information ................................................................................................7

Chapter 2: Product Description .................................................................................... 8

2.1. Description .................................................................................................................8

2.2. Specifications ..............................................................................................................9

2.2.1. Gold Maestro Hardware ..............................................................................9

2.2.2. Gold Maestro Software ............................................................................ 10

2.3. Communication Options .......................................................................................... 12

2.4. How to Use this Guide ............................................................................................. 12

Chapter 3: Installation ............................................................................................... 13

3.1. Before You Begin ..................................................................................................... 13

3.1.1. Site Requirements .................................................................................... 13

3.1.2. Working Environment ............................................................................... 13

3.2. Unpacking the Components .................................................................................... 13

3.3. Connectors............................................................................................................... 14

3.3.1. Connector Types ....................................................................................... 14

3.3.2. Pinouts ...................................................................................................... 15

3.3.2.1. Power Connector ..................................................................... 15

3.3.2.2. EtherCAT In Connector ............................................................ 16

3.3.2.3. EtherCAT Out Connector ......................................................... 16

3.3.2.4. CANopen Connectors............................................................... 17

3.3.2.5. Ethernet Connector ................................................................. 17

3.3.2.6. USB 2.0 Connector ................................................................... 18

3.4. Mounting the Gold Maestro .................................................................................... 18

3.4.1. Wall Mount ............................................................................................... 18

3.4.2. Surface Mount .......................................................................................... 20

3.4.3. Installation on a DIN Rail .......................................................................... 20

3.5. Connecting the Cables ............................................................................................. 21

3.5.1. Wiring the Gold Maestro .......................................................................... 21

3.5.2. Connecting the DC Power Supply ............................................................. 22

3.5.3. Ethernet .................................................................................................... 23

3.5.4. USB 2.0 Communication ........................................................................... 24

3.5.5. CANopen Communication ........................................................................ 25

3.5.6. EtherCAT Communication ........................................................................ 27

3.6. Powering Up ............................................................................................................ 28

3.7. Initializing the System .............................................................................................. 28

Chapter 4: Technical Specifications ............................................................................ 29

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4.1. Gold Maestro Dimensions ....................................................................................... 29

4.2. General Specifications ............................................................................................. 29

4.3. Environmental Conditions ....................................................................................... 29

4.4. Power Supply ........................................................................................................... 30

4.5. Communications ...................................................................................................... 30

4.6. Compliance with Standards ..................................................................................... 31

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Chapter 1: Safety Information

In order to achieve the optimum, safe operation of the Gold Maestro Multi-Axis Controller, 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
Gold Maestro 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.

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.

1.1. Cautions

• The Gold Maestro must be connected to an approved 24 VDC power supply through a

line that is separated from hazardous line voltages using reinforced or double
insulation in accordance with approved safety standards.

• Before switching on the Gold Maestro, verify that all safety precautions have been

observed and that the installation procedures in this manual have been followed.

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1.2. Directives and Standards

The Gold Maestro 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 Gold Maestro 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.

1.3. 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. The Gold Maestro is 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: Product Description

This installation guide describes the Gold Maestro Network Motion Controller and the steps for
its wiring, installation and power up. Following these guidelines ensures maximum functionality
of the system to which it is connected.

2.1. Description

The Gold Maestro is Elmo’s network motion controller. It works in a network based system in
conjunction with Elmo’s intelligent servo drives to provide a total multi-axis motion control
system solution.

The Gold Maestro is designed to support both the existing SimplIQ drives, based on standard
CANopen network architecture, as well as the new Gold Line, adding EtherCAT networking.

While being a true network controller, the Gold Maestro shares the motion processing
workload with Elmo’s SimplIQ and Gold Line drives, forming a distributed motion control
system. The best servo and system performance is achieved combining the Gold Family drives,
and the new real-time motion control capabilities of the Gold Maestro controller.

The Gold Maestro provides:

• Full, real-time, multi-axis motion synchronization

• Advanced user programming capabilities based on the leading standards

• Time deterministic control over motion, I/Os and processes in the system

The Gold Maestro offers real-time motion control support for full multi-axis system
synchronization, using the well known industry interface PLCopen for Motion Control standard.

Various programming capabilities, such as the IEC-61131-3 standard languages, as well as
native C programming support, dramatically accelerate user level program execution. Standard
solutions were selected for ease of use.

Low level communication with drives and I/O devices over the device network uses the
CANopen industry standard (DS 301, DS 401 for I/O devices, and DS 402 for drives and motion
device profiles). These are used over standard CAN networks, as well as with the new EtherCAT
CoE (CANopen over EtherCAT) protocols.

Host interfaces are implemented using industry standard communications protocols, such as
Ethernet TCP/IP and higher level protocols such as Ethernet/IP and Modbus.

Standardization in protocols, definitions and APIs allows users rapid system level integration
and opens the system to third party devices on the device network.

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2.2. Specifications

2.2.1. Gold Maestro Hardware

• Hardware: Stand-alone

• Power Supply: Single DC supply, with two product options available:

 13 VDC to 96 VDC
 20 VDC to 196 VDC

• Processor: PowerPC, 333 MHz, with double precision floating point support by

hardware.

• Memory

 Flash: 32 MB
 RAM: 64 MB (DDR2, 333 MHz)

• Communication Hardware

 Host:

• Ethernet: 1 port, Standard Ethernet, 10/100 Mbps, automatically detected

• USB: 1 port, USB2.0, 12 Mbps

 Device Networks:

• EtherCAT: 2 x EtherCAT master ports, with redundancy support (optional)

• CAN: CANopen master port

• I/O System: All I/O interfaces are handled via the device network.

• Internal System BIT: The Gold Maestro supports internal hardware BIT (Built-in-tests)

procedures to check the system integrity level on each power up.

• Diagnostic LEDs: EtherCAT and Ethernet activity

• Dimensions: 115 mm x 75 mm x 25.4 mm (4.53" x 2.95" x 1")

• Weight: 250 g ( 8.75 oz)

• Operational Temperature: 0 °C to 40 °C

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2.2.2. Gold Maestro Software

• Operating System: Linux Operating System, with Elmo’s RT extension for real-time

motion control support

• Motion Programming and Debugging

 Native C Programming, running on the target CPU. Compiling and debugging via the

Eclipse IDE using GCC under Cygwin

 IEC 61131-3 with PLCopen Motion Library extension, using Elmo IDE. The following

languages are supported:

• Structured text (ST), textual

• Function block diagram (FBD), graphical

• Ladder diagram (LD), graphical

• Sequential function chart (SFC), has elements to organize programs for sequential

and parallel control processing.

• Number of Axes: Up to 96 axes, allowing mixed single axis, multiple axis and

coordinated axes motions

• Axis Types

 Intelligent Servo Drives (Elmo), supporting both the SimplIQ and Gold lines
 Operation in Numeric Control – NC - (real-time master synchronization) as well as

non-NC modes

 DS 402 CoE for EtherCAT and standard DS 402 drives for CANopen

• Control System Update Rate

 EtherCAT

• Cycle Update Rate: ≥ 500 µs (up to 16 axes can be updated simultaneously at a rate

of 500 µs)

• Cycle Jitter: < 1 µs, based on Master DC (Distributed Clock) support, for the full

network

 CAN

• Cycle Update Rate ≥ 1 ms (CAN physical network limitations only)

• Cycle Jitter: < 100 µs for CAN Sync message initiation (actual jitter dependant on the

CAN network’s physical limitations)

• Motion Modes and Interfaces: The Gold Maestro motion interfaces use the PLCopen

Standard.

 64 bit, real-time, double precision profile calculations, allowing full on-the-fly control

over speed, acceleration, deceleration and jerk

 Complex motion schemes, including look-ahead optimizing of trajectory speed

calculations, for complex vector motions

 Cyclic buffer for 1,000 function blocks (a buffer for 1,000 motion segments). The cyclical

buffer removes any practical limit on the number of function blocks.

• Communication Protocols

 Host

• Ethernet TCP-IP/UDP for operational modes