ElmoMC ExtrIQ Digital Servo Drives-Solo Hornet User Manual

Solo Hornet

Digital Servo Drive

Installation Guide

July 2014 (Ver. 1.003)

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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 Solo Hornet 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 trademarks of Elmo Motion
Control Ltd.

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

Document no. MAN-SOLHRNIG (Ver. 1.003)

Copyright  2014

Elmo Motion Control Ltd.

All rights reserved.

Catalog Number

Revision History

Version Date Details

1.0 Sep 2012 Initial release

1.001 Jan 2013 Updated the auxiliary voltage value

Added a caution and recommendation on the type of cleaning
solution to use for the Elmo unit.

1.002 Apr 2013 Small changes to Diferential RS-232 Communication

1.003 July 2014 General format update

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 APAC Ltd.

B-601 Pangyo Innovalley, 621 Sampyeong-dong, Bundang-gu, Seongnam-si, Gyeonggi-do,
South Korea (463-400)

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

MAN-SOLHR NIG (Ver . 1.003)

Table of Contents

Solo Hornet Installation Guide

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

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

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

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

1.4. CE Marking Conformance ...........................................................................................9

1.5. Warranty Information ................................................................................................9

Chapter 2: Introduction ............................................................................................. 10

2.1. Drive Description ..................................................................................................... 10

2.2. Product Features ..................................................................................................... 11

2.2.1. Current Control ......................................................................................... 11

2.2.2. Velocity Control ........................................................................................ 11

2.2.3. Position Control ........................................................................................ 11

2.2.4. Advanced Position Control ....................................................................... 12

2.2.5. Communication Options ........................................................................... 12

2.2.6. Feedback Options ..................................................................................... 12

2.2.7. Fault Protection ........................................................................................ 12

2.3. System Architecture ................................................................................................ 13

2.4. How to Use this Guide ............................................................................................. 13

4

Chapter 3: Technical Information ............................................................................... 15

3.1. Technical Data ......................................................................................................... 15

3.1.1. Auxiliary Supply ........................................................................................ 15

Chapter 4: Installation ............................................................................................... 16

4.1. Site Requirements ................................................................................................... 16

4.2. Unpacking the Drive ................................................................................................ 16

4.3. Connector Types ...................................................................................................... 18

4.4. Main and Motor Power – J1 and J2 ......................................................................... 19

4.4.1. Connecting Main Power ........................................................................... 20

4.5. Motor Power ........................................................................................................... 21

4.5.1. Connecting Motor Power ......................................................................... 21

4.6. Main Feedback – J1 ................................................................................................. 22

4.7. Auxiliary Feedback – J2 ............................................................................................ 29

4.7.1. Auxiliary Feedback Operation Modes ...................................................... 31

4.7.2. Main and Auxiliary Feedback Combinations ............................................ 32

4.7.3. Auxiliary Feedback: Emulated Encoder Output Option (YA[4]=4) ............ 35

4.7.4. Auxiliary Feedback: Differential Encoder Input Option (YA[4]=2) ............ 37

4.7.5. Auxiliary Feedback: Differential Pulse-and-Direction Input Option (YA[4]=0)

.................................................................................................................. 39

4.8. I/Os .......................................................................................................................... 41

4.8.1. Digital Input (J2) ........................................................................................ 41

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4.8.1.1. Digital Input 5 V (TTL) .............................................................. 42

4.8.1.2. Digital Input 24 V (PLC) ............................................................ 43

4.8.2. Digital Output ........................................................................................... 44

4.8.3. Analog Input ............................................................................................. 45

4.9. Communications ...................................................................................................... 46

4.9.1. RS-232 Communication (J2) ...................................................................... 47

4.9.2. Differential RS-232 Communication (RS-422) – J2 ................................... 48

4.9.3. CAN Communication (J2) .......................................................................... 49

4.10. Powering Up ............................................................................................................ 51

4.11. Initializing the System .............................................................................................. 51

4.12. Heat Dissipation....................................................................................................... 51

4.12.1. Solo Hornet Thermal Data ........................................................................ 51

4.12.2. Heat Dissipation Data ............................................................................... 52

4.12.3. How to Use the Charts .............................................................................. 53

Chapter 5: Technical Specifications ............................................................................ 54

5.1. Features ................................................................................................................... 54

5.1.1. Motion Control Modes ............................................................................. 54

5.1.2. Advanced Positioning Control Modes ...................................................... 54

5.1.3. Advanced Filters and Gain Scheduling...................................................... 54

5.1.4. Fully Programmable .................................................................................. 54

5.1.5. Feedback Options ..................................................................................... 55

5.1.6. Input/Output ............................................................................................ 55

5.1.7. Built-In Protection .................................................................................... 56

5.1.8. Accessories ............................................................................................... 56

5.1.9. Status Indication ....................................................................................... 56

5.1.10. Automatic Procedures .............................................................................. 56

5.2. Solo Hornet Dimensions .......................................................................................... 57

5.3. Environmental Conditions ....................................................................................... 58

5.4. Control Specifications .............................................................................................. 59

5.4.1. Current Loop ............................................................................................. 59

5.4.2. Velocity Loop ............................................................................................ 60

5.4.3. Position Loop ............................................................................................ 60

5.5. Feedbacks ................................................................................................................ 61

5.5.1. Feedback Supply Voltage .......................................................................... 61

5.5.2. Main Feedback Options ............................................................................ 61

5.5.2.1. Incremental Encoder Input ...................................................... 61

5.5.2.2. Digital Halls .............................................................................. 62

5.5.2.3. Interpolated Analog (Sine/Cosine) Encoder ............................ 62

5.5.2.4. Resolver ................................................................................... 63

5.5.2.5.

Tachometer .............................................................................. 63

5.5.2.6. Potentiometer ......................................................................... 64

5.5.3. Auxiliary Feedback Port (output mode YA[4]= 4) ..................................... 64

5.5.4. Auxiliary Feedback Port (input mode YA[4]= 2, 0).................................... 65

5.6. I/Os .......................................................................................................................... 66

5

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5.6.1. Digital Input Interfaces ............................................................................. 66

5.6.2. Digital Output Interface ............................................................................ 67

5.6.3. Analog Input ............................................................................................. 68

5.7. Communications ...................................................................................................... 68

5.8. Pulse-Width Modulation (PWM) ............................................................................. 68

5.9. Compliance with Standards ..................................................................................... 69

6

MAN-SOLHR NIG (Ver . 1.003)

Chapter 1: Safety Information

Solo Hornet Installation Guide

In order to achieve the optimum, safe operation of the Solo Hornet 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 Solo Hornet as
well as the 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 Solo Hornet 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.

7

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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Solo Hornet Installation Guide Safety Information

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 Solo Hornet from all voltage sources before it is opened for servicing.

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

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

1.2. Cautions

• The Solo Hornet servo drive contains hot surfaces and electrically-charged components
during operation.

8

• The maximum DC power supply connected to the instrument must comply with the
parameters outlined in this guide.

• When connecting the Solo Hornet to an approved 11 to 95 VDC auxiliary power supply,
connect it through a line that is separated from hazardous live voltages using
reinforced or double insulation in accordance with approved safety standards.

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

• Do not clean any of the Solo Hornet drive's soldering with solvent cleaning fluids of pH
greater than 7 (8 to 14). The solvent corrodes the plastic cover causing cracks and
eventual damage to the drive's PCBs.

Elmo recommends using the cleaning fluid Vigon-EFM which is pH Neutral (7).

For further technical information on this recommended cleaning fluid, select the link:

http://www.zestron.com/fileadmin/zestron.com­usa/daten/electronics/Product_TI1s/TI1-VIGON_EFM-US.pdf

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Solo Hornet Installation Guide Safety Information

1.3. Directives and Standards

The Solo Hornet drives conform 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

9

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 Solo Hornet 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.

1.4. CE Marking Conformance

The Solo Hornet 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
Solo Hornet drive meets the provisions outlined in Council Directive 73/23/EEC. The party
responsible for ensuring that the equipment meets the limits required by EMC regulations is
the manufacturer of the end product.

1.5. Warranty Information

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

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MAN-SOLHR NIG (Ver. 1.003)

Chapter 2: Introduction

Solo Hornet Installation Guide

The Solo Hornet is an integrated solution designed to simply and efficiently connect Elmo’s
Hornet servo drive directly to the application. The solution consists of the Hornet together with
a convenient connection interface which either eliminates or reduces development time and
resources when designing an application’s PCB board.

This installation guide describes the Solo Hornet servo drive and the steps for its wiring,
installation and power-up. Following these guidelines ensures maximum functionality of the
drive and the systems to which it is connected.

2.1. Drive Description

The Solo Hornet series of digital servo drives is designed to deliver “the highest density of
power and intelligence”. The Solo Hornet is a lightweight and highly compact solution which
can be used whenever reduced size and weight are essential to the application. The Solo
Hornet delivers up to 1600 W of continuous power or 3200 W of peak power in a

72.87 cm3/4.41 in³ (59 x 24.7 x 50 mm or 2.32" x 0.97" x 1.96") package.

10

The Solo Hornet drive is designed for OEMs. It operates 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. It is designed for use
with any type of sinusoidal and trapezoidal commutation, with vector control. The Solo Hornet
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 drive is easily set up and tuned using Elmo’s Composer software tools. This Windows-based
application enables users to quickly and simply configure the servo drive for optimal use with
their motor. The Solo Hornet, as part of the ExtrIQ product line, is fully programmable with
Elmo’s Composer motion control language.

Power to the drive is provided by an 11 to 95 VDC isolated DC power source (not included with
the Solo Hornet). A “smart” control-supply algorithm enables the Solo Hornet to operate with
only one power supply with no need for an auxiliary power supply for the logic.

If backup functionality is required for storing control parameters in case of power-loss, an
external 11 to 95 VDC isolated supply should be connected via the +VL, providing maximum
flexibility and backup functionality when needed.

Note: This backup functionality can operate from any voltage source within the 11 to 95

VDC range. This is much more flexible than to be restricted by only using a standard 24 VDC
power supply.

If backup power is not required, two terminals (VP and VL) are shorted so that the main power
supply will also power the control/logic supply. In this way there is no need for a separate
control/logic supply.

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Solo Hornet Installation Guide Introduction

The Solo Hornet drive is available in two models:

• The standard model is a basic servo drive which operates in current, velocity and
position modes including PT & PVT. It operates simultaneously via RS-232/RS-422 and
CAN DS-301, DS-305, DS-402 communications and features a third-generation
programming environment.

• The advanced model includes all the motion capabilities and communication options
included in the standard model, as well as advanced positioning capabilities – ECAM,
Follower and Dual Loop-and increased program size.

The two models operate with both RS-232/RS-422 and CAN communication.

2.2. Product Features

2.2.1. Current Control

• Fully digital

• Sinusoidal commutation with vector control or trapezoidal commutation with encoder

and/or digital Hall sensors

• 12-bit current loop resolution

11

• Automatic gain scheduling, to compensate for variations in the DC bus power supply

2.2.2. Velocity Control

• Fully digital

• Programmable PI and FFW (feed forward) control filters

• Sample rate two times current loop sample time

• “On-the-fly” gain scheduling

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

and phase margins

2.2.3. Position Control

• Programmable PIP control filter

• Programmable notch and low-pass filters

• Sample time: four times that of the current loop

• Fast event capturing inputs

• PT and PVT motion modes

• Fast output compare (OC)

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Solo Hornet Installation Guide Introduction

2.2.4. Advanced Position Control

This relates to the Advanced model only.

• Position-based and time-based ECAM mode that supports a non-linear follower mode,
in which the motor tracks the master motion using an ECAM table stored in flash
memory

• Dual (position/velocity) loop

2.2.5. Communication Options

Solo Hornet users can use two communication options:

• RS-232 or RS-422 (depending on the catalogue number) serial communication

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

2.2.6. Feedback Options

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

• Digital Halls – up to 2 kHz

12

• Incremental Encoder with Digital Halls for commutation – up to 20 Mega-Counts per
second for 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
 Emulated encoder outputs

• Resolver

 Programmable 10 to 15 bit resolution
 Up to 512 revolutions per second (RPS)
 Emulated encoder outputs

• Tachometer, Potentiometer

• Elmo drives provide supply voltage for all the feedback options

2.2.7. Fault Protection

The Solo Hornet drive 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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Resolver

Motor

PWM

Controller

Power Stage

Protection

Analog

Encoder

Tachometer

or

Auxilliary

Encoder

Potentiometer

or

or

or

Incremental

Encoder

Main

12~95 VDC

Power Supply

Optional

12~95 VDC

Auxiliary Supply

Communication

RS-232/RS-422 and

CANopen

Current

Feedback

I/Os

Solo Hornet Installation Guide Introduction

2.3. System Architecture

13

Figure 1: Solo Hornet System Block Diagram

2.4. How to Use this Guide

In order to install and operate your Elmo Solo Hornet 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 Solo Hornet.

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

Upon completing the instructions in this guide, your Solo Hornet 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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Solo Hornet Installation Guide Introduction

14

Figure 2: Elmo Digital Servo Drive Documentation Hierarchy

As depicted in the previous figure, this installation guide is an integral part of the Solo Hornet
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 Solo Hornet motion controller.

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

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Chapter 3: Technical Information

5/60

2.5/100

5/100

Solo Hornet Installation Guide

3.1. Technical Data

Feature Units

15/48

20/48

Minimum supply voltage VDC 6 7.5 12

Nominal supply voltage VDC 42 50 85

Maximum supply voltage VDC 48 59 95

10/60

15/60

20/60

15

15/100

20/100

Maximum continuous
power output

Efficiency at rated power
(at nominal conditions)

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

Auxiliary power supply VDC 11 – 95 VDC (up to 2.5 VA inc. 5 V/200 mA for encoder)

Amplitude sinusoidal/DC
continuous current

Sinusoidal continuous
RMS current limit (I

Peak current limit A 2 x Ic

Weight g (oz) 68.4 g (2.4 oz)

Dimensions mm (in) 59 x 24.7 x 50 (2.32" x 0.97" x 1.86")

Digital in/Digital
out/Analog in

)

c

W 600 800 240 480 720 960 200 400 1200 1600

% > 99

A 15 20 5 10 15 20 2.5 5 15 20

A 10.6 14.1 3.5 7 10.6 14.1 1.8 3.5 10.6 14.1

6/2/1

3.1.1. Auxiliary Supply

Feature Details

Auxiliary power supply Isolated DC source only

Auxiliary supply input voltage 11 VDC to 95 VDC

Auxiliary supply input power <2.5 VA (this includes the 5 V/200 mA load for

the main encoder only)

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Chapter 4: Installation

Solo Hornet Installation Guide Installation

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

4.1. Site Requirements

You can guarantee the safe operation of the Solo Hornet drive 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 12,000 m (39370 feet)

Maximum non-condensing humidity 95%

Operating area atmosphere No flammable gases or vapors permitted in area

16

Caution: The Solo Hornet drive dissipates heat by convection. The maximum
operating ambient temperature of 0 °C to 40 °C (32 °F to 104° F) must not be
exceeded.

4.2. Unpacking the Drive

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

• The Solo Hornet servo drive

• The Composer software and software manual

The Solo Hornet is shipped in a cardboard box with Styrofoam protection.

To unpack the Solo Hornet:

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.

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Solo Hornet Installation Guide Installation

3. To ensure that the Solo Hornet drive you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Solo Hornet.

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

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4. Verify that the Solo Hornet model is the one that you ordered, and ensure that the voltage
meets your specific requirements.

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J1

J2

Solo Hornet Installation Guide Installation

4.3. Connector Types

The Solo Hornet has two connectors (in the connectors version).

Pins Type Port Function

6

Nicomatics CM220 6HP/12 Pins J1 Motor Power and Main Feedback

2 x 6

2 x 15 Nicomatics CM220 2 x 15 Pins J2 I/O, Communication and Aux Feedback

Connector Locations

18

Table 1: Connector Types

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Solo Hornet Installation Guide Installation

4.4. Main and Motor Power – J1 and J2

Pin (J1) Signal Function

P1 VP+ Pos. power input

P2 PR Power return

P3 PE Protective earth

AC Motor DC Motor

P4 M1 Motor phase Motor N/C

P5 M2 Motor phase Motor Motor

P6 M3 Motor phase Motor Motor

Pin (J2) Signal Function

1 VL+ Auxiliary supply input

2 PR Auxiliary supply input return

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Pin Positions

Note: When connecting several drives to several motors, all should be wired in the same

motor phases and feedback sequences. This will enable the same ExtrIQ program to run on
all drives.

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Solo Hornet Installation Guide Installation

4.4.1. Connecting Main Power

Power to the Solo Hornet is provided by an 11 to 95 VDC source. A smart control-supply
algorithm enables the Solo Hornet 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
additional backup supply can be connected by implementing "diode coupling" to the VL+.

Note: The source of the 11 to 95 VDC Main Power Supply must be isolated.

20

Figure 3: Main Power Supply Connection Diagram

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Solo Hornet Installation Guide Installation

4.5. Motor Power

4.5.1. Connecting Motor Power

Connect the M1, M2, M3 and PE pins on the Solo Hornet. The phase connection is arbitrary as
the Composer will establish the proper commutation automatically during setup. However, if
you plan to copy the setup to other drives, then the phase order on all copy drives must be the
same.

21

Figure 4: AC Motor Power Connection Diagram

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