Page 1
Solo Hornet
Digital Servo Drive
Installation Guide
July 2014 (Ver. 1.003)
www.elmomc.com
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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
Page 3
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: +972 (3) 929-2300 • Fax: +972 (3) 929-2322 • info-il@elmomc.com
North America
Elmo Motion Control Inc.
42 Technology Way, Nashua, NH 03060
USA
Tel: +1 (603) 821-9979 • Fax: +1 (603) 821-9943 • info-us@elmomc.com
Europe
Elmo Motion Control GmbH
Hermann-Schwer-Strasse 3, 78048 VS-Villingen
Germany
Tel: +49 (0) 7721-944 7120 • Fax: +49 (0) 7721-944 7130 • info-de@elmomc.com
China
Elmo Motion Control Technology (Shanghai) Co. Ltd.
Room 1414, Huawen Plaza, No. 999 Zhongshan West Road, Shanghai (200051)
China
Tel: +86-21-32516651 • Fax: +86-21-32516652 • info-asia@elmomc.com
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: +82-31-698-2010 • Fax: +82-31-801-8078 • info-asia@elmomc.com
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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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Solo Hornet Installation Guide Table of Contents
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
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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
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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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MAN-SOLHR NIG (Ver . 1.003)
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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MAN-SOLHR NIG (Ver . 1.003)
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.
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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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MAN-SOLHR NIG (Ver . 1.003)
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
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• 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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MAN-SOLHR NIG (Ver . 1.003)
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:
17
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
19
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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Solo Hornet Installation Guide Installation
4.6. Main Feedback – J1
The Main Feedback port is used to transfer feedback data from the motor to the drive. In order
to copy the setup to other drives, the phase order on all copy drives must be the same.
The Solo Hornet can accept any one of the following devices as a main feedback mechanism:
• Incremental encoder only
• Incremental encoder with digital Hall sensors
• Digital Hall sensors only
• Incremental Analog (Sine/Cosine) encoder (option)
• Resolver (option)
• Tachometer (option)
• Potentiometer (option)
22
Incremental Encoder Interpolated Analog
Encoder
Resolver Tachometer and
Potentiometer
SOL-HORXX/YYYEZZ SOL-HORXX/YYYIZZ SOL-HORXX/YYYRZZ SOL-HORXX/YYYTZZ
Pin
Signal Function Signal Function Signal Function Signal Function
(J1)
1 +5V Encoder/Hall +5V
supply
2 SUPRET Supply return SUPRET Supply return SUPRET Supply return SUPRET Supply return
3 HC Hall sensor C input HC Hall sensor C input NC - HC Hall sensor C input
4 HB Hall sensor B input HB Hall sensor B input NC - HB Hall sensor B input
5 HA Hall sensor A input HA Hall sensor A input NC - HA Hall sensor A input
6 PE Protective Earth PE Protective Earth PE Protective Earth PE Protective Earth
7 CHA- Channel A
complement
8 CHA Channel A A+ Sine A S1 Sine A Tac 1+ Tacho Input 1 Pos.
9 CHB- Channel B
complement
10 CHB Channel B B+ Cosine B S2 Cosine B Tac 2+ Tacho Input 2 Pos.
+5V Encoder/Hall +5V
supply
A- Sine A complement S3 Sine A complement Tac 1- Tacho Input 1 Neg.
B- Cosine B
complement
+5V Encoder/Hall +5V
supply
S4 Cosine B
complement
+5V Encoder/Hall +5V
supply
(20 V max)
(20 V max)
Tac 2- Tacho Input 2 Neg.
(50 V max)
(50 V max)
11 INDEX- Index complement R- Reference
complement
12 INDEX Index R+ Reference R1 Vref f=1/TS, 50 mA
R2 Vref complement
f= 1/TS, 50 mA
Maximum
Max.
NC -
POT Potentiometer
Input (5 V Max)
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23
Incremental Encoder Interpolated Analog
Pin Positions
Encoder
Resolver Tachometer and
Potentiometer
Table 2: Main Feedback Pin Assignments
Figure 5: Main Feedback- Incremental Encoder with Digital Hall Sensor Connection Diagram
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24
Figure 6: Main Feedback – Interpolated Analog (Sine/Cosine) Encoder Connection Diagram
Figure 7: Main Feedback – Interpolated Analog (Sine/Cosine) Encoder with Digital Hall Sensor
Connection Diagram
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25
Figure 8: Main Feedback – Resolver Connection Diagram
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26
Figure 9: Main Feedback – Resolver with Digital Hall Sensor Connection Diagram
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27
Figure 10: Main Feedback – Tachometer Feedback with Digital Hall Sensor
Connection Diagram for Brushless Motors
Figure 11: Main Feedback – Tachometer Feedback Connection Diagram for Brush Motors
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28
Figure 12: Main Feedback,
Potentiometer Feedback with Digital Hall Sensor Connection Diagram for Brushless Motors
Figure 13: Main Feedback,
Potentiometer Feedback Connection Diagram for Brush Motors and Voice Coils
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4.7. Auxiliary Feedback – J2
Pin (J2) Signal Function
1 VL+ Auxiliary Power Supply
2 PR Auxiliary Power Supply RET
3 PE Protective Earth
29
4 CHAO-
5 CHAO
6 IN6
7 IN_RET
8 INDEXO
9 INDEXO-
10 OUT1
11 OUT_RET1
12 OUT2
13 OUT_RET2
Buffered Channel A complement output
Buffered Channel A output
Hi-Speed Programmable input 6 (event capture, Main Home,
general purpose, RLS, FLS, INH)
Programmable input return
Buffered Index output
Buffered Index complement output
Programmable digital output 1
Programmable digital output return 1
Programmable digital output 2
Programmable digital output return 2
14 IN1
15 IN2
16 IN3
17 IN4
18 IN5
Programmable input 1 (general purpose, RLS, FLS, INH)
Programmable input 2 (general purpose, RLS, FLS, INH)
Programmable input 3 (general purpose, RLS, FLS, INH)
Programmable input 4 (general purpose, RLS, FLS, INH)
Hi-Speed Programmable input 5 (event capture, Main Home,
general purpose, RLS, FLS, INH)
19 CHBO
20 CHBO-
Buffered Channel B output
Buffered Channel B complement output
21 ANLRET Analog Return
22 ANLIN1+
Analog input 1+
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Pin (J2) Signal Function
30
23 ANLIN1-
Analog input 1-
24 COMRET Common Return
25 RS422_RX+ RS-422 Receive+
26 RS422_RX- RS-422 Receive-
27 RS232_TX/
RS422_TX+
28 RS232_RX/
RS422_TX-
29 CAN_L
30 CAN_H
RS-232 Transmit or
RS422 Transmit +
RS-232 Receive or
RS422 Transmit -
CAN_L busline (dominant low)
CAN_H busline (dominant low)
Pin Positions
When using one of the Auxiliary Feedback options, the relevant functionality of the Auxiliary
Feedback's ports are software- and hardware-selected for that option. Refer to the SimplIQ
Command Reference Manual for detailed information about Auxiliary Feedback setup.
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4.7.1. Auxiliary Feedback Operation Modes
There are two modes of operation for the Solo Hornet:
• Mode 1: Auxiliary output (Composer command: YA[4]=4) – see Section 4.7.2
For SOL-HORXXX/YYYY51 to SOL-HORXXX/YYYY52
And SOL-HORXXX/YYYY55 to SOL-HORXXX/YYYY56
Differential emulated encoder outputs are used to provide emulated encoder signals to
another controller or drive. The emulated encoder output option is only available when
using a resolver or analog encoder as the main feedback device.
This option can be used when the Solo Hornet is used:
As a current amplifier to provide position data to the position controller.
In velocity mode to provide position data to the position controller.
As a master in follower or ECAM mode.
• Mode 2: Auxiliary input (Composer command: YA[4]=2 or YA[4]=0) - see Sections 4.7.3
and 4.7.4
For SOL-HORXXX/YYYY53 to SOL-HORXXX/YYYY54
And SOL-HORXXX/YYYY57 to SOL-HORXXX/YYYY58
31
Differential auxiliary inputs, for the input of position data of the master encoder in
follower or ECAM mode. This mode can also be used for differential pulse-and-direction
position commands.
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Main Feedback:
Incremental Encoder
Interpolated Analog
(Sin/Cos) Encoder
OR Resolver
OR Potentiometer
OR Tachometer
Auxiliary Feedback:
Emulated Differential
Buffered Encoder
Output
Solo Hornet Installation Guide Installation
4.7.2. 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 Solo Hornet has three bi-
directional pins (CHA, CHB and INDEX). When used in combination with Main Feedback, the
Auxiliary Feedback can be set, by software, as follows:
32
Main
Feedback
Software
Setting
Incremental
Encoder Input
Interpolated
Analog
(Sine/Cosine)
Encoder Input
Resolver Input
Potentiometer/
Tachometer
Input
Auxiliary Feedback: Output
YA[4] = 4
(Auxiliary Feedback: output)
Typical
Applications
Analog Encoder applications where position data is required, in the
Encoder’s quadrature format, for other purposes such as position
controllers and/or other drives.
Resolver applications where position data is required in the Encoder’s
quadrature format, for other purposes such as position controllers
and/or other drives.
Potentiometer and Tachometer applications where position data is
required, in the Encoder’s quadrature format, for other purposes such
as position controllers and/or other drives.
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Main Feedback:
Incremental Encoder
Input
OR Interpolated Analog
(Sin/Cos) Encoder Input
OR Resolver
OR Potentiometer
OR Tachometer
Auxiliary Feedback:
Differential Auxiliary
Encoder Input
Solo Hornet Installation Guide Installation
33
Main
Feedback
Software
Setting
Incremental
Encoder Input
Interpolated
Analog
(Sine/Cosine)
Encoder Input
Resolver Input
Potentiometer
Tachometer
Input
Auxiliary Feedback: Input
YA[4] = 2
(Auxiliary Feedback: input)
Typical
Applications
Any application where two Feedbacks are used by the drive.
The Auxiliary Feedback port serves as an input for the Auxiliary
incremental encoder.
For applications such as Follower, ECAM, or Dual Loop.
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Main Feedback:
Incremental Encoder
Input
OR Interpolated Analog
(Sin/Cos) Encoder Input
OR Resolver
OR Potentiometer
OR Tachometer
Auxiliary Feedback:
Differential Pulse &
Direction Input
Solo Hornet Installation Guide Installation
34
Main
Feedback
Software
Setting
Incremental
Encoder Input
Interpolated
Analog
(Sine/Cosine)
Encoder Input
Resolver Input
Potentiometer
Tachometer
Input
Auxiliary Feedback: Input
YA[4] = 0
(Auxiliary Feedback: input)
Typical
Applications
Any application where two Feedbacks are used by the drive.
The Auxiliary Feedback port serves as an input for Pulse & Direction
Commands.
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4.7.3. Auxiliary Feedback: Emulated Encoder Output Option
(YA[4]=4)
Pin (J2) Signal Function
3 PE Protective Earth
24 COMRET Common Return
35
5
4
19
20
8
9
CHA
CHA-
CHB
CHB-
INDEX
INDEX-
Pin Positions
Buffered Channel A output
Buffered Channel A complement output
Buffered Channel B output
Buffered Channel B complement output
Buffered Index output
Buffered Index complement output
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36
Figure 14: Emulated Encoder Differential Output Diagram
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4.7.4. Auxiliary Feedback: Differential Encoder Input Option
(YA[4]=2)
Pin (J2) Signal Function
3 PE Protective Earth
24 COMRET Common Return
37
5
4
19
20
8
9
CHA
CHA-
CHB
CHB-
INDEX
INDEX-
Pin Positions
Auxiliary channel A Input
Auxiliary channel A complement input
Auxiliary channel B input
Auxiliary channel B complement input
Auxiliary Index input
Auxiliary Index complement Input
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Figure 15: Differential Auxiliary (Controller) Encoder Input Option Diagram
Figure 16: Differential Auxiliary (Incremental) Encoder Input Option Diagram
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4.7.5. Auxiliary Feedback: Differential Pulse-and-Direction Input
Option (YA[4]=0)
Pin (J2) Signal Function
3 PE Protective Earth
24 COMRET Common Return
39
5
4
19
20
8
9
CHA
CHA-
CHB
CHB-
INDEX
INDEX-
Pin Positions
Auxiliary Pulse input
Auxiliary Pulse complement input
Auxiliary Direction input
Auxiliary Direction complement input
NA
NA
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40
Figure 17: Pulse-and-Direction Diagram
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4.8. I/Os
The Solo Hornet has four digital inputs, two digital outputs and one analog input.
4.8.1. Digital Input (J2)
The digital input level signal can be 5 V (TTL).
Pin (J2) Signal Function
14 IN1 Programmable input 1 (general purpose, RLS, FLS, INH)
15 IN2 Programmable input 2 (general purpose, RLS, FLS, INH)
16 IN3 Programmable input 3 (general purpose, RLS, FLS, INH)
17 IN4 Programmable input 4 (general purpose, RLS, FLS, INH)
18 IN5 Hi-Speed Programmable input 5 (event capture, Main Home,
general purpose, RLS, FLS, INH)
6 IN6 Hi-Speed Programmable input 6 (event capture, Auxiliary Home,
general purpose, RLS, FLS, INH)
41
7 INRET Programmable input return
Pin Positions
Table 3: Digital Input Pin Assignments
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4.8.1.1. Digital Input 5 V (TTL)
42
Figure 18: Digital Input 5 V Connection Diagram
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4.8.1.2. Digital Input 24 V (PLC)
43
Figure 19: Digital Input 24 Connection Diagram
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4.8.2. Digital Output
Pin (J2) Signal Function
10 OUT1 Programmable digital output 1
11 OUTRET1 Programmable digital output return 1
12 OUT2 Programmable digital output 2
13 OUTRET2 Programmable digital output return 2
Pin Positions
44
Table 4: Digital Output Pin Assignment
Figure 20: Digital Output Connection Diagram
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4.8.3. Analog Input
Pin (J2) Signal Function
22 ANLIN1+ Analog input 1+
23 ANLIN1- Analog input 1-
21 ANLRET Analog return
Pin Positions
45
Table 5: Analog Input Pin Assignments
Figure 21: Analog Input with Single-Ended Source
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4.9. Communications
The communication interface may differ according to the user’s hardware. The Solo Hornet can
communicate using the following options:
a. RS-232, full duplex
b. RS-422, Differential RS-232
c. CAN
RS-232 communication requires a standard, commercial 3-core null-modem cable connected
from the Solo Hornet to a serial interface on the PC. The interface is selected and set up in the
Composer software.
Differential RS-232 (RS-422)communication requires four wires connected from the Solo
Hornet to a controller . The RS-232 interface is selected and set up in the Composer software.
In order to benefit from CAN communication, the user must have an understanding of the basic
programming and timing issues of a CAN network.
For ease of setup and diagnostics of CAN communication, RS-232 and CAN can be used
simultaneously.
46
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4.9.1. RS-232 Communication (J2)
Notes for connecting the RS-232 communication cable:
• Connect the shield to the ground of the host (PC). Usually, this connection is soldered
internally inside the connector at the PC end. You can use the drain wire to facilitate
connection.
• The RS-232 communication port is non-isolated.
Pin (J2) Signal Function
28 RS232_Rx RS-232 receive
27 RS232_Tx RS-232 transmit
24 COMRET Common Return
Pin Positions
47
Table 6: RS-232 Pin Assignments
Figure 22: RS-232 Connection Diagram
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4.9.2. Differential RS-232 Communication (RS-422) – J2
Note for connecting the RS-232 communication cable:
• This is Differential RS-232 Communication based on RS-422. Connect the shield to the
ground of the Controller. Usually, this connection is soldered internally inside the
connector at the PC end. You can use the drain wire to facilitate connection.
Pin (J2) Signal Function
27 Differential RS422_Tx + Differential RS-232/RS-422 Transmit +
28 Differential RS422_Tx - Differential RS-233/RS-422 Transmit -
25 Differential RS422_Rx + Differential RS-232/RS-422 Receive +
26 Differential RS422_Rx - Differential RS-232/RS-422 Receive -
24 COMRET Common Return
48
Figure 23: Differential RS-232 Communication
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4.9.3. CAN Communication (J2)
Notes for connecting the CAN communication cable:
• Connect the shield to the ground of the host (PC). Usually, this connection is soldered
internally inside the connector at the PC end. You can use the drain wire to facilitate
connection.
• Make sure to have a 120-Ω resistor termination at each of the two ends of the network
cable.
• The Solo Hornet’s CAN ports are non-isolated.
Pin (J2) Signal Function
24 COM-RET Common Return
29 CAN_L CAN_L busline (dominant low)
30 CAN_H CAN_H busline (dominant high)
49
Table 7: CAN - Pin Assignments
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50
Figure 24: CAN Network Diagram
Caution: When installing CAN communication, ensure that each servo drive is
allocated a unique ID. Otherwise, the CAN network may hang.
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4.10. Powering Up
After the Solo Hornet is connected to its device, it is ready to be powered up.
Caution: Before applying power, ensure that the DC supply is within the
specified range and that the proper plus-minus connections are in order.
4.11. Initializing the System
After the Solo Hornet 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.
4.12. Heat Dissipation
The best way to dissipate heat from the Solo Hornet is to mount it so that its heat sink faces up.
For best results leave approximately 10 mm of space between the Solo Hornet's heat sink and
any other assembly.
51
4.12.1. Solo Hornet Thermal Data
• Heat dissipation capability (θ): Approximately 10 °C/W.
• Thermal time constant: Approximately 240 seconds (thermal time constant means that
the Solo Hornet will reach 2/3 of its final temperature after 4 minutes).
• Shut-off temperature: 86 °C to 88 °C (measured on the heat sink)
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Whistle
-
60
Series Power Dissipation
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
0
0
.
75
1
.
5
2
.
25
3
3
.
75
4
.
5
5
.
25
6
6
.
75
7
.
5
8
.
25
9
9
.
75
Peak Current (A)
Power Dissipation (Watts
50V
40V
30V
20V
Standard 40 °C Ambient Temp.
External
Heatsink
Solo Hornet
Whistle 100 Series Power Dissipation
0.0
1.0
2.0
3.0
4.0
5.0
6.0
0
0.511.522.533.544.5
5
Peak Current (A)
Power Dissipation (W)
85VDC
70VDC
50VDC
Standard 40 °C Ambient Temp.
External
Heatsink
Solo Hornet
Solo Hornet Installation Guide Installation
4.12.2. Heat Dissipation Data
Heat dissipation is shown in graphically below:
52
Heatsink
Required
not
Required
Heatsink
Required
not
Required
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4.12.3. How to Use the Charts
The charts above are based upon theoretical worst-case conditions. Actual test results show
30% to 50% better power dissipation.
To determine if your application needs a heat sink:
1. Allow maximum heat sink temperature to be 80 °C or less.
2. Determine the ambient operating temperature of the Solo Hornet.
3. Calculate the allowable temperature increase as follows:
For an ambient temperature of 40 °C , ΔT= 80°C – 40 °C = 40 °C
4. Use the chart to find the actual dissipation power of the drive. Follow the voltage curve to
the desired output current and then find the dissipated power.
5. If the dissipated power is below 4 W the Solo Hornet will need no additional cooling.
Note: The chart above shows that no heat sink is needed when the heat sink temperature is
80 °C, ambient temperature is 40 °C and heat dissipated is 4 Watts.
53
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Chapter 5: Technical Specifications
Solo Hornet Installation Guide
This chapter provides detailed technical information regarding the Solo Hornet. This includes its
dimensions, power ratings, the environmental conditions under which it can be used, the
standards to which it complies and other specifications.
5.1. Features
The Solo Hornet's features determine how it controls motion, as well as how it processes host
commands, feedback and other input.
5.1.1. 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
54
5.1.2. Advanced Positioning Control Modes
• PTP, PT, PVT, ECAM, Follower, Dual Loop, Current Follower
• Fast event capturing inputs
• Fast output compare (OC)
• Motion Commands: Analog current and velocity, pulse-width modulation (PWM)
current and velocity
5.1.3. 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
5.1.4. Fully Programmable
• Third generation programming structure with motion commands – “Composer”
• Event capturing interrupts
• Event triggered programming
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5.1.5. 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
• Interpolated Analog (Sine/Cosine) Encoder – up to 250 kHz (analog signal)
Internal Interpolation - up to x4096
Automatic Correction of amplitude mismatch, phase mismatch, signal offset
Emulated encoder outputs
• Analog Hall Sensor
• Resolver
Programmable 10 to 15 bit resolution
Up to 512 revolutions per second (RPS)
Emulated encoder outputs
• Tachometer & Potentiometer
55
• Provide power (5 V, 200 mA max) for one Encoder, Resolver or Hall.
5.1.6. Input/Output
• One Analog Input – up to 14-bit resolution
• Six programmable Digital Inputs, optically isolated (two of which are fast event capture
inputs).
Inhibit/Enable motion
Software and analog reference stop
Motion limit switches
Begin on input
Abort motion
Homing
General-purpose
• Two programmable Digital Outputs, optically isolated (open collector) one with fast
output compare (OC)
Brake Control
Amplifier fault indication
General-purpose
Servo enable indication
• PWM current command output for torque and velocity
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5.1.7. 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 output and power input/return
Failure of internal power supplies
Over temperature
Continuous temperature measurement; temperature can be read on the fly; warning
can be initiated x degrees before temp disable is activated.
Over/Under voltage
Loss of feedback
Following error
Current limits
56
5.1.8. Accessories
• Heat sinks
5.1.9. Status Indication
• Output for a bi-color LED
5.1.10. Automatic Procedures
• Commutation alignment
• Phase sequencing
• Current loop offset adjustment
• Current loop gain tuning
• Current gain scheduling
• Velocity loop offset adjustment
• Velocity gain tuning
• Velocity gain scheduling
• Position gain tuning
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5.2. Solo Hornet Dimensions
57
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5.3. Environmental Conditions
Feature Operation Conditions Range
58
Ambient
Non-operating conditions -50 °C to +100 °C (-58 °F to 212 °F)
Temperature
Range
Temperature
Shock
Operating conditions -40 °C to +70 °C (-40 °F to 160 °F)
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 12,000 m (-1312 to 39370 feet)
Maximum
Humidity
Non-operating conditions Up to 95% relative humidity non-condensing
at 35 °C (95 °F)
Operating conditions Up to 95% relative humidity non-condensing
at 25 °C (77 °F), up to 90% relative humidity
non-condensing at 42 °C (108 °F)
Vibration Operating conditions 20 Hz to 2,000 Hz, 14.6g
Mechanical
Non-operating conditions ±40g; Half sine, 11 msec
Shock
Operating conditions ±20g; Half sine, 11 msec
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5.4. Control Specifications
5.4.1. Current Loop
Feature Details
Controller type Vector, digital
59
Compensation for bus voltage
“On-the-fly” automatic gain scheduling
variations
Motor types
• AC brushless (sinusoidal)
• DC brushless (trapezoidal)
• DC brush
• Linear motors
• "Voice" coils
Current control
• Fully digital
• Sinusoidal with vector control
• Programmable PI control filter based on
Current loop bandwidth < 2.5 kHz
Current loop sampling time
Current sampling rate
Programmable 70 to 120 µsec
Up to 6 kHz; default 11 kHz
a pair of PI controls of AC current signals
and constant power at high speed
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5.4.2. Velocity Loop
Feature Details
Controller type PI
60
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)
• Tachometer and Potentiometer (optional)
Note: With all feedback options, 1/T with automatic
mode switching is activated (gap, frequency and
derivative).
Velocity loop bandwidth <350 Hz
Velocity loop sampling time
140 to 240 µsec (2x current loop sample time)
Velocity loop 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.
5.4.3. Position Loop
Feature Details
Controller type “1-2-4” PIP
Position command options
Position loop bandwidth <80 Hz
Position loop sampling time
Position loop sampling rate Up to 4 kHz; default 2.75 kHz
• Software
• Pulse and Direction
• Analog Potentiometer
280 to 480 µsec (4x current loop sample time)
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MAN-SOLHR NIG (Ver . 1.003)
Solo Hornet Installation Guide Technical Specifications
5.5. Feedbacks
5.5.1. Feedback Supply Voltage
The Solo Hornet has two feedback ports (Main and Auxiliary). The drive supplies voltage to the
main feedback device only.
Feature Details
Main encoder supply voltage 5 V +5% @ 200 mA maximum
5.5.2. Main Feedback Options
The Solo Hornet can receive and process feedback input from diverse types of devices.
5.5.2.1. Incremental Encoder Input
Feature Details
61
Encoder format
• A, B and Index
• Differential
• Quadrature
Interface RS-422
Input resistance
Differential: 120 Ω (TBD)
Maximum incremental encoder frequency Maximum absolute: 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 25: Main Feedback - Encoder Phase Diagram
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Signal offsets
( 5.5.3)
Solo Hornet Installation Guide Technical Specifications
5.5.2.2. Digital Halls
Feature Details
62
Halls inputs
• H
, HB, HC.
A
• Single ended inputs
• Built in hysteresis of 1 V for noise
immunity
Input voltage Nominal operating range: 0 V < V
Maximum absolute: -1 V < V
High level input voltage: V
Low level input voltage: V
In_Hall
InHigh
InLow
> 2.5 V
< 1 V
< 5 V
In_Hall
< 15 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
5.5.2.3. Interpolated Analog (Sine/Cosine) Encoder
Feature Details
Analog encoder format Sine and Cosine signals
Analog input signal level
• Offset voltage: 2.2 V to 2.8 V
• Differential, 1 V peak to peak
Input resistance
Maximum analog signal frequency f
Differential 120 Ω
: 250 kHz
MAX
Interpolation multipliers Programmable: x4 to x4096
Maximum “counts” frequency 80 mega-counts/sec “internally”
Automatic errors correction
Signal amplitudes mismatch
Signal phase shift
Encoder outputs
See Auxiliary Encoder Outputs specifications
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MAN-SOLHR NIG (Ver . 1.003)
( 5.5.3)
Solo Hornet Installation Guide Technical Specifications
5.5.2.4. Resolver
Feature Details
63
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 Solo Hornet
Reference current
Encoder outputs
Up to
±50 mA
See Auxiliary Encoder Output specifications
5.5.2.5. Tachometer*
Feature Details
Tachometer format Differential
Maximum operating differential voltage for TAC1+, TAC1-
Maximum absolute differential input voltage for TAC1+, TAC1-
Maximum operating differential voltage for TAC2+, TAC2-
Maximum absolute differential input voltage for TAC2+, TAC2-
±20 V
±25 V
±50 V
±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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MAN-SOLHR NIG (Ver . 1.003)
Solo Hornet Installation Guide Technical Specifications
5.5.2.6. Potentiometer
Feature Details
Potentiometer Format Single-ended
Operating Voltage Range 0 to 5 V supplied by the Solo Hornet
Potentiometer Resistance 100 Ω to 1 kΩ above this range, linearity is affected
detrimentally
Input Resistance 100 kΩ
Resolution 14 bit
5.5.3. Auxiliary Feedback Port (output mode YA[4]= 4)
Feature Details
64
Encoder output and main buffered
output
• A, B, Index
• Differential outputs
• Quadrature
Interface RS-422
Output current capability
Driving differential loads of 200 Ω on
INDEX/INDEX-, CHB/CHB- and CHA/CHA- pairs
Available as options
• Simultaneous buffered outputs of main-
incremental encoder input
• Simultaneous emulated encoder outputs of
analog encoder input
• Simultaneous emulated encoder outputs of
resolver input
Maximum frequency f
: 5 MHz pulses/output
MAX
Index (marker) Length of pulse is one quadrature (one quarter of
an encoder cycle) and synchronized to A&B
Figure 26: Auxiliary Feedback - Encoder Phase Diagram
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MAN-SOLHR NIG (Ver . 1.003)
Solo Hornet Installation Guide Technical Specifications
5.5.4. Auxiliary Feedback Port (input mode YA[4]= 2, 0)
Feature Details
65
Encoder input,
pulse and direction input
• A, B, Index
• Differential
Input voltage Vin Low: 0 V < VIL < 0.8 V
V
High: 2 V < VIH < 5 V
in
Maximum absolute voltage: 0 < V
< 5.5 V
in
Input current: ±1 µA
Available as options
• Differential Buffered Encoder inputs
• Differential Buffered Pulse and Direction
inputs
Edge separation between A & B Programmable number of clocks to allow adequate
noise filtering at remote receiver of emulated
encoder signals
Index (marker): Length of pulse is one quadrature (one quarter of
an encoder cycle) and synchronized to A&B
Figure 27: Auxiliary Feedback - Encoder Phase Diagram
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MAN-SOLHR NIG (Ver . 1.003)
Solo Hornet Installation Guide Technical Specifications
5.6. I/Os
The Solo Hornet has:
• 4 Digital Inputs
• 2 Digital Outputs
• 1 Analog Input
5.6.1. Digital Input Interfaces
Feature Details
66
Type of input
• Optically isolated
• All four inputs share one signal return
line
Input current for 5 V DI level Rin=1.43K, Iin = 2.8 mA @ Vin = 5 V
Input current for 24 V DI level Rin=10.52k, Iin = 2.2 mA @ Vin = 24 V
High-level input voltage 5 V < Vin < 24 V
Low-level input voltage 0 V < Vin < 1 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<4xTS
If input is set to General input, execution
depends on program.
Typical execution time: ≅ 0.5 msec.
High-speed inputs – 5 & 6 minimum pulse
width, in high-speed mode
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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MAN-SOLHR NIG (Ver . 1.003)
Rin = 1.43K
General Input Return
Solo Hornet Installation Guide Technical Specifications
Feature Details
Figure 28: Digital Input Schematic
5.6.2. Digital Output Interface
Feature Details
67
Type of output
• Optically isolated
• Open collector and open emitter
Maximum supply output (VCC) 30 V
Max. output current
I
(max) (V
out
= Low)
out
VOL at maximum output voltage (low
(max) ≤ 10 mA
I
out
V
(on) ≤ 0.3 V
out
level)
RL The external resistor RL must be selected to limit
the output current to no more than 10 mA.
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.
Figure 29: Digital Output Schematic
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MAN-SOLHR NIG (Ver . 1.003)
Solo Hornet Installation Guide Technical Specifications
5.6.3. Analog Input
Feature Details
Maximum operating differential voltage ± 10 V
Maximum absolute differential input voltage ± 16 V
Differential input resistance 3.74 kΩ
Analog input command resolution 14-bit
5.7. Communications
Specification Details
RS-232 Signals:
• RxD , TxD , GND
• Full duplex, serial communication for setup and
control.
68
• Baud Rate of 9,600 to 57,600 bit/sec.
Differential RS-232
(RS-422)
Signals:
• RxD , TxD , GND
• Full duplex, serial communication for setup and
control.
• Baud Rate of 9,600 to 57,600 bit/sec.
CAN CAN bus Signals:
• CAN_H, CAN_L, CAN_GND
• Maximum Baud Rate of 1 Mbit/sec.
Version:
• DS 301 V4.01
Layer Setting Service and Protocol Support:
• DS 305
Device Profile (drive and motion control):
• DS 402
5.8. 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)
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MAN-SOLHR NIG (Ver . 1.003)
Solo Hornet Installation Guide Technical Specifications
5.9. 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.)
69
• UL 60950
• IPC-D-275
• IPC-SM-782
Printed wiring for electronic equipment
(clearance, creepage, spacing, conductors
sizing, etc.)
• IPC-CM-770
• UL 508C
• UL 840
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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MAN-SOLHR NIG (Ver . 1.003)
Solo Hornet Installation Guide Technical Specifications
Specification Details
EMC
Approved IEC/EN 61800-3, EMC Adjustable speed electrical power drive
systems
70
In compliance with EN 55011 Class A with
Electromagnetic compatibility (EMC)
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
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)
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