Page 1
Gold DC Whistle
Digital Servo Drive
Installation Guide
EtherCAT and CAN
June 2014 (Ver. 1.700) www.elmomc.com
Page 2
Notice
This guide is delivered subject to the following conditions and restrictions:
• This guide contains proprietary information belonging to Elmo Motion Control Ltd. Such
information is supplied solely for the purpose of assisting users of the Gold DC Whistle servo
drive in its installation.
• The text and graphics included in this manual are for the purpose of illustration and reference
only. The specifications on which they are based are subject to change without notice.
• Information in this document is subject to change without notice.
Document no. MAN-G-DCWHIIG-EC (Ver. 1.700)
Copyright 2014
Elmo Motion Control Ltd.
All rights reserved.
Catalog Number
It should be noted that Gold DC Whistle servo drives with Cat. No. G-DCWHIRXX/YYYERAP may also
be ordered, and are the same servo drives as the revised Cat. No. below.
Page 3
Cable Kit
Catalog number: CBL-GDCWHIKIT02 (can be ordered separately).
For further details, see the documentation for this cable kit (MAN-G-DCWHI-CBLKIT.pdf).
Revision History
Version Date Details
Ver. 1.700 June 2014 Initial release in new format
Page 4
Table of Contents
MAN-G-DCWHIIG-EC (Ver. 1.700)
Chapter 1: This Installation Guide ................................................................................. 6
Chapter 2: Safety Information ...................................................................................... 6
2.1. Warnings .................................................................................................................... 7
2.2. Cautions ...................................................................................................................... 7
2.3. CE Marking Conformance ........................................................................................... 7
2.4. Warranty Information ................................................................................................ 7
Chapter 3: Product Description ..................................................................................... 8
3.1.1. Accessories .................................................................................................. 8
Chapter 4: Technical Information .................................................................................. 9
4.1. Physical Specifications ................................................................................................ 9
4.2. Technical Data ............................................................................................................ 9
4.2.1. Auxiliary Supply ......................................................................................... 10
4.2.2. Product Features ....................................................................................... 11
4
Chapter 5: Installation ................................................................................................ 12
5.1. Unpacking the Drive Components ........................................................................... 12
5.2. Connector Types ....................................................................................................... 13
5.3. Mounting the Gold DC Whistle ................................................................................ 16
5.4. The Gold DC Whistle Connection Diagram ............................................................... 17
Chapter 6: Wiring ....................................................................................................... 19
6.1. Basic Recommendations .......................................................................................... 20
6.1.1. General ...................................................................................................... 20
6.1.2. Feedback Cable Port A and Port B Connector ........................................... 21
6.1.3. Feedback Cable Port C Connector ............................................................. 22
6.1.4. IO Cable Connector .................................................................................... 22
6.1.5. STO (Port C) Cable Connector .................................................................... 23
6.2. Motor Power Connector Pinouts (J14) ..................................................................... 24
6.3. Main and Auxiliary Power ........................................................................................ 26
6.3.1. Description ................................................................................................ 26
6.3.2. Main Power (J13) ....................................................................................... 27
6.3.3. Auxiliary Power Supply (J12) ..................................................................... 28
6.3.3.1. Power Rating 200 V .................................................................. 29
6.3.3.2. Power Rating 100 V .................................................................. 30
6.4. Drive Status Indicator ............................................................................................... 31
6.5. STO (Safe Torque Off) (J11) ...................................................................................... 32
6.5.1. Source Mode – PLC Voltage Level ............................................................. 33
6.5.2. TTL Mode – TTL Voltage Level ................................................................... 33
6.5.3. Sink Mode – PLC Voltage Level .................................................................. 34
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Table of Contents
MAN-G-DCWHIIG-EC (Ver. 1.700)
6.6. Port A (J1) ................................................................................................................. 35
6.6.1. Incremental Encoder ................................................................................. 36
6.6.2. Halls Sensor ............................................................................................... 36
6.6.3. Absolute Serial Encoder ............................................................................. 37
6.6.3.1. Hiperface .................................................................................. 38
6.7. Port B (J3) ................................................................................................................. 39
6.7.1. Incremental Encoder ................................................................................. 40
6.7.2. Interpolated Analog Encoder .................................................................... 41
6.7.3. Resolver ..................................................................................................... 42
6.8. Port C, Digital I/Os, and Analog Inputs (J2) .............................................................. 43
6.8.1. Port C – Emulated Encoder Output ........................................................... 45
6.8.2. Analog Input .............................................................................................. 46
6.8.3. Digital Input and Output TTL Mode ........................................................... 47
6.8.4. Digital Input and Output PLC Source Mode .............................................. 49
6.8.5. Digital Input and Output Sink Mode .......................................................... 51
6.9. USB 2.0 (J9) ............................................................................................................... 53
6.10. EtherCAT Communication Version ........................................................................... 54
6.10.1. EtherCAT IN/Ethernet Pin Assignments (J7) .............................................. 54
6.10.2. EtherCAT OUT Pin Assignments (J8) .......................................................... 55
6.10.3. EtherCAT Wiring ........................................................................................ 55
6.10.4. EtherCAT Status Indicator ......................................................................... 56
6.11. CAN Communication Version ................................................................................... 57
6.11.1. CAN Wiring ................................................................................................ 58
6.12. Powering Up ............................................................................................................. 59
6.13. Initializing the System .............................................................................................. 59
5
Chapter 7: Dimensions ............................................................................................... 60
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Gold DC Whistle Installation Guide
Table of Contents
Chapter 1: This Installation Guide
Chapter 2: Safety Information
Warning:
Caution:
Important:
MAN-G-DCWHI IG-EC (Ver. 1.700)
6
This installation Guide details the technical data, pinouts, wiring and power connectivity of the Gold
DC Whistle. For a comprehensive detailed description of the functions refer to the
MAN-G-Panel Mounted Drives Hardware manual which describes Panel Mounted products.
In order to achieve the optimum, safe operation of the Gold DC Whistle, it is imperative that you
implement the safety procedures included in this installation guide. This information is provided to
protect you and to keep your work area safe when operating the Gold DC Whistle and
accompanying equipment.
Please read this chapter carefully before you begin the installation process.
Before you start, ensure that all system components are connected to earth ground. Electrical
safety is provided through a low-resistance earth connection.
Only qualified personnel may install, adjust, maintain and repair the servo drive. A qualified person
has the knowledge and authorization to perform tasks such as transporting, assembling, installing,
commissioning and operating motors.
The Gold DC Whistle contains electrostatic-sensitive components that can be damaged if handled
incorrectly. To prevent any electrostatic damage, avoid contact with highly insulating materials,
such as plastic film and synthetic fabrics. Place the product on a conductive surface and ground
yourself in order to discharge any possible static electricity build-up.
To avoid any potential hazards that may cause severe personal injury or damage to the product
during operation, keep all covers and cabinet doors shut.
The following safety symbols are used in this and all Elmo Motion Control manuals:
This information is needed to avoid a safety hazard, which might cause bodily injury
or death as a result of incorrect operation.
This information is necessary to prevent bodily injury, damage to the product or to
other equipment.
Identifies information that is critical for successful application and understanding of
the product.
||Warnings|www.elmomc.com
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MAN-G-DCWHI IG-EC (Ver. 1.700)
7
2.1. 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 Gold DC Whistle from all voltage sources before servicing.
• The high voltage products within the Gold Line range contain 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.
2.2. Cautions
• The maximum DC power supply connected to the instrument must comply with the
parameters outlined in this guide.
• When connecting the Gold DC Whistle to an approved isolated 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 Gold DC Whistle, verify that all safety precautions have been
observed and that the installation procedures in this manual have been followed.
• Make sure that the Safe Torque Off is operational
2.3. CE Marking Conformance
The Gold DC Whistle 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 2006/42/EC as amended, and with those of the most recent versions of
standards EN 60204-1 and
Concerning electrical equipment designed for use within certain voltage limits, the Gold DC Whistle
meets the provisions outlined in 2006/95/EC. The party responsible for ensuring that the
equipment meets the limits required by EMC regulations is the manufacturer of the end product.
EN ISO 12100 at the least, and in accordance with 2006/95/EC.
2.4. 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.
||Warnings|www.elmomc.com
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Chapter 3: Product Description
MAN-G-DCWHI IG-EC (Ver. 1.700)
8
The Gold DC Whistle is an advanced high power density servo drive which delivers up to 1.6 kW of
continuous power or 3.2 kW of peak power in a 222.5 cc (13.58 in³) package (115 x 75 x 25.8 mm
or 4.5" x 3.0" x 1").
This advanced, high power density servo drive provides top performance, advanced networking and
built-in safety, as well as a fully featured motion controller and local intelligence. The Gold DC
Whistle is powered by a single 12 V – 195 V isolated DC power source (not included) and a “smart”
control-supply algorithm enables the drive to operate up to 95V with only one power supply with
no need for an auxiliary power supply for the logic.
The Gold DC Whistle 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 Gold DC Whistle drive is easily set up and tuned using Elmo Application Studio (EAS) software
tools. As part of the Gold product line, it is fully programmable with the Elmo motion control
language. For more about software tools, refer to the Elmo Application Studio Software Manual.
The Gold DC Whistle is available in a variety of options. There are multiple power rating options,
two different communications options, a variety of feedback selections and I/O configuration
possibilities.
3.1.1. Accessories
Cable Kit, catalog number: CBL-GDCWHIKIT02 (can be ordered separately)
For further details, see the documentation for this cable kit (MAN-G-DCWHI-CBLKIT.pdf).
||Warranty Information|www.elmomc.com
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Chapter 4: Technical Information
MAN-G-DCWHI IG-EC (Ver. 1.700)
9
4.1. Physical Specifications
Feature Units All Types
Weight g (oz) 267 g (9.42 oz)
Dimensions mm (in) 115 x 75 x 25.8 mm (4.5" x 3.0" x 1")
Mounting method Wall Mount / Book Shelf
4.2. Technical Data
Feature Units 1/100 2.5/100 5/100 10/100 15/100 20/100
Minimum supply voltage VDC 12
Nominal supply voltage VDC 85
Maximum supply voltage VDC 95
Maximum continuous power output W 80 200 400 800 1200 1600
Efficiency at rated power (at
nominal conditions)
Maximum output voltage > 95% of DC bus voltage at f = 22 kHz
Auxiliary power supply VDC 12 – 95 VDC
Amplitude sinusoidal/DC continuous
current
Sinusoidal continuous RMS current
limit (Ic)
Peak current limit A 2 x Ic
% > 99
(up to 6 VA inc. 5 V/2 x 200 mA for encoder)
A 1.0 2.5 5 10 15 20
A 0.7 1.8 3.5 7 10.6 14.1
Table 1: Power Ratings
Note on current ratings: The current ratings of the Gold DC Whistle are given in units of DC
amperes (ratings that are used for trapezoidal commutation or DC motors). The RMS (sinusoidal
commutation) value is the DC value divided by 1.41.small
||Physical Specifications|www.elmomc.com
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MAN-G-DCWHI IG-EC (Ver. 1.700)
Elmo now offers a 200 VDC maximum output rating selection of Gold DC Whistle, according to the
following technical data:
Feature Units 3/200 6/200 9/200
Minimum supply voltage VDC 12
Nominal supply voltage VDC 170
Maximum supply voltage VDC 195
Maximum continuous power output W 480 960 1450
10
Efficiency at rated power (at
% > 99
nominal conditions)
Maximum output voltage > 95% of DC bus voltage at f = 22 kHz
Auxiliary power supply VDC 12 to 95 VDC
(up to 6 VA inc. 5 V/2 x 200 mA for
encoder)
Amplitude sinusoidal/DC
A 3 6 9
continuous current
Sinusoidal continuous RMS current
A 2.1 4.2 6.3
limit (Ic)
Peak current limit A 2 x Ic
4.2.1. Auxiliary Supply
Feature Details
Auxiliary power supply Isolated DC source only
Auxiliary supply input voltage 12 V to 95 V
Auxiliary supply input power ≤ 4 VA without external loading
≤ 6 VA with full external loading
||Technical Data|www.elmomc.com
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4.2.2. Product Features
Main Feature Details Presence and No.
11
STO
Digital Input
Option
Digital Output
Option
Analog Input
Feedback
Communication
Option
TTL, or √
PLC Source, or √
PLC Sink (is not fully certified, and
√
not recommended for new designs)
TTL, or 6
PLC Source, or 6
PLC Sink 6
TTL, or 4
PLC Source, or 4
PLC Sink 4
Differential ±10V 1
Standard Port A, B, & C √
USB √
EtherCAT option √
CAN option √
||Technical Data|www.elmomc.com
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Chapter 5: Installation
MAN-G-DCWHI IG-EC (Ver. 1.700)
The Gold DC Whistle must be installed in a suitable environment and properly connected to its
voltage supplies and the motor.
5.1. Unpacking the Drive Components
Before you begin working with the Gold DC Whistle, verify that you have all of its components, as
follows:
• The Gold DC Whistle servo drive
• The Elmo Application Studio software and software manual
The Gold DC Whistle is shipped in a cardboard box with Styrofoam protection.
To unpack the Gold DC Whistle:
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
12
has occurred, report it immediately to the carrier that delivered your drive.
3. To ensure that the Gold DC Whistle you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Gold DC Whistle. It looks
like this:
4. Verify that the Gold DC Whistle type is the one that you ordered, and ensure that the
voltage meets your specific requirements.
The part number at the top provides the type designation. Refer to the appropriate part
number in the section Catalog Number at the beginning of the installation guide.
||Unpacking the Drive Components|www.elmomc.com
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5.2. Connector Types
The Gold DC Whistle has ten connectors.
No. Pins Type Function
Bottom Connectors
13
4 Phoenix 5 mm Pitch ‘HC’ Motor phases
3 Phoenix 5 mm Pitch ‘HC’ Main Power
2 Phoenix 3.81 mm Pitch ‘HC’ Auxiliary supply input
Front Connectors
Front Connectors - EtherCAT
||Connector Types|www.elmomc.com
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MAN-G-DCWHI IG-EC (Ver. 1.700)
No. Pins Type Function
Front Connectors - CAN
3 2.54 mm Pitch Molex STO
14
24 2.54 mm Pitch Molex Feedback port C and I/O
8 2.54 mm Pitch Molex Feedback port B
12 2.54 mm Pitch Molex Feedback port A
Top Connectors
Top Connectors - EtherCAT
||Connector Types|www.elmomc.com
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MAN-G-DCWHI IG-EC (Ver. 1.700)
No. Pins Type Function
Top Connectors - CAN
5 USB Device Mini-B USB
15
EtherCAT Version
8 RJ-45 EtherCAT in
8 RJ-45 EtherCAT out
CAN Version
8 RJ-45
8 RJ-45
CAN
CAN
Table 2: Connector Types
The pinouts in Chapter 6: Wiring describe the function of each pin in the Gold DC Whistle
connectors that are listed in Table 2.
||Connector Types|www.elmomc.com
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5.3. Mounting the Gold DC Whistle
The Gold DC Whistle has been designed for two standard mounting options:
• Wall Mount along the back (can also be mounted horizontally on a metal surface)
• Book Shelf along the side
M4 round head screws, one through each opening in the heat sink, are used to mount the Gold DC
Whistle (see the diagram below).
16
Figure 1: Mounting the Gold DC Whistle
||Mounting the Gold DC Whistle|www.elmomc.com
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MAN-G-DCWHI IG-EC (Ver. 1.700)
5.4. The Gold DC Whistle Connection Diagram
17
Figure 2: The Gold DC Whistle Connection Diagram – EtherCAT
||The Gold DC Whistle Connection Diagram|www.elmomc.com
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Figure 3: The Gold DC Whistle Connection Diagram - CAN
||The Gold DC Whistle Connection Diagram|www.elmomc.com
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Chapter 6: Wiring
MAN-G-DCWHI IG-EC (Ver. 1.700)
Once the product is mounted, you are ready to wire the device. Proper wiring, grounding and
shielding are essential for ensuring safe, immune and optimal servo performance of the drive.
The following table legend describes the wiring symbols detailed in all installation guides.
Wiring Symbol Description
Earth connection (PE)
Protective Earth Connection
Common at the Controller
Shielded cable with drain wire.
19
The drain wire is a non-insulated wire
that is in direct contact with the braid
(shielding).
Shielded cable with drain wire
significantly simplifies the wiring and
earthing.
Shielded cable braid only, without
drain wire.
Twisted-pair wires
Encoder Earthing.
The cable`s shield is connected to the
chassis (PE) in the connector.
Earthing the Encoder and connecting
the Earth (PE) to the drive COMRET is
mandatory to insure reliable
operation, high noise immunity and
rejection of voltage common mode
interferences.
||The Gold DC Whistle Connection Diagram|www.elmomc.com
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20
6.1. Basic Recommendations
6.1.1. General
1. Use shielded cables. For best results, the cable should have an aluminum foil shield covered
by copper braid, and should contain a drain wire.
Use 24, 26 or 28 AWG twisted-pair shielded with drain wire cables.
2. Keep the cable as short as possible.
Do not mount the power cables of the motor and power bus in the proximity of the control
and feedback cables.
3. Ensure that in normal operating conditions, the “earth connection” wires and shield of the
control cables carry no current. The only time these conductors carry current is under
abnormal conditions, when electrical equipment has become a potential shock or fire
hazard while conducting external EMI interferences directly to ground, in order to prevent
them from affecting the drive. Failing to meet this requirement might result in
drive/controller/host failure.
4. After completing the wiring, carefully inspect all wires to ensure tightness, good solder of
joints and general safety.
Figure 4: Feedback and Molex Control Cable Assemblies
Note: Please pay attention to the location of PIN 1 in the above connector diagram.
It should be noted that in all Elmo manuals the pinouts are shown differently to Molex’s technical
sheets. Molex shows pin 1 at the bottom-left when looking at the face of the cable-side connector,
tab down (Figure 5).
Figure 5: Molex vs Elmo Technical Diagram Examples Showing Pinout Numbers
However, Elmo specifies pin 1 as the bottom-left of drive-side connector. The result is that Elmo’s
pin designations are mirrored relative to the pinouts as labeled by Molex.
Where there is only one COMRET pin (Common Return) in the connector, which MUST be
connected to the DRAIN WIRE and also to COMRET signal of the cable, it is necessary to connect the
drain wire and COMRET signal to the same pin.
||Basic Recommendations|www.elmomc.com
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6.1.2. Feedback Cable Port A and Port B Connector
1. On the motor side connections, ground the shield to the motor chassis.
2. At least One COMRET (Common Return) must be connected to the PE.
Implement the following steps to connect the COMRET to the PE:
a. At the drive, connect the feedback drain wire to one of the COMRET terminals in the
Molex feedback connector (Figure 5.
b. At the motor, connect the feedback cable drain wire to the GND motor chassis
terminal of the feedback connector (Figure 6).
The drawing displays two earth connections.
21
Figure 6: Feedback Port A and B Cable Assemblies
||Basic Recommendations|www.elmomc.com
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6.1.3. Feedback Cable Port C Connector
1. At the controller side connections, follow the controller manufacturer’s recommendations
concerning the shield.
2. The connection of the Drain wire to the Port C is not mandatory.
22
Figure 7: Feedback Port C Cable Assemblies
6.1.4. IO Cable Connector
It is recommended to use shielded cable, but is not mandatory.
Figure 8: Feedback IO Cable Assemblies
||Basic Recommendations|www.elmomc.com
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6.1.5. STO (Port C) Cable Connector
It is recommended to use shielded cable, but is not mandatory.
Figure 9: STO Cable Assemblies
23
||Basic Recommendations|www.elmomc.com
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6.2. Motor Power Connector Pinouts (J14)
See Chapter 8 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Pin (J14) Signal Function Cable
Brushless Motor Brushed DC Motor
1 PE Protective Earth Motor Motor
2 M1 Motor phase Motor N/C
3 M2 Motor phase Motor Motor
4 M3 Motor phase Motor Motor
24
4-Pin Phoenix 5 mm Pitch ‘HC’
Table 3: Connectors for Motor
4-Pin Phoenix Plug-in
Connector
Figure 10: Brushless Motor Power Connection Diagram
||Motor Power Connector Pinouts (J14)|www.elmomc.com
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Figure 11: Brushed Motor Power Connection Diagram
||Motor Power Connector Pinouts (J14)|www.elmomc.com
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6.3. Main and Auxiliary Power
The Gold DC Whistle receives power from main and auxiliary supplies and delivers power to the
motor.
6.3.1. Description
This section describes the Main and Auxiliary Power for power ratings 200V and 100V, and provides
details for the optional Backup (Auxiliary) Supply.
• The Gold DC Whistle Power rating is 12 to 195 VDC
• There are Two power ratings for Gold DC Whistle; 100V and 200V:
Power rating of 200V
Two power isolated DC power sources are required, main power 12 - 195V and Auxiliary Power
12-95V for the logic.
Power rating of 100V
Single DC Power Supply - Power to the Gold DC Whistle is provided by a 12–95 VDC single
isolated DC power source (not included with the Gold DC Whistle). A “smart” control-supply
algorithm enables the Gold DC Whistle to operate with only one power supply with no need for
an auxiliary power supply for the logic.
Optional Backup (Auxiliary) Supply
If backup functionality is required in case of power loss, e.g., to keep the original position, a
12–95 VDC external isolated supply should be connected (via the Gold DC Whistle’s VL+
terminal). This is more flexible than the requirement for 24 VDC supply.
If backup is not needed, a single power supply is used for both the power and logic circuits.
There are two voltage ratings of the Gold DC Whistle, therefore the correct power supply must
be used, according to the maximum operating voltage of the Gold DC Whistle. Refer to section
4.2 Technical Data.
||Main and Auxiliary Power|www.elmomc.com
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6.3.2. Main Power (J13)
Pin (J13) Signal Function Cable
1 VP+ Positive Power input DC Power
2 PR Power return DC Power
3 PE Protective Earth DC Power
27
3-Pin Phoenix Plug-in
Connector
3-Pin Phoenix 5 mm Pitch ‘HC’
Table 4: Connectors for Main Power
Connect the DC power cable to the VP+ and PR terminals on the Main Power Connector.
To connect the DC power supply:
1. The source of the 12 to 195 VDC power supply must be isolated.
2. For best immunity, it is highly recommended to use twisted and shielded cables for the DC
power supply. A 3-wire shielded cable should be used. The gauge is determined by the
actual current consumption of the motor.
3. Connect the cable shield to the closest ground connection near the power supply.
4. Connect the PE to the closest ground connection near the power supply.
5. Connect the PR to the closest ground connection near the power supply.
6. Before applying power, first verify the polarity of the connection.
||Main and Auxiliary Power|www.elmomc.com
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Caution:
MAN-G-DCWHI IG-EC (Ver. 1.700)
6.3.3. Auxiliary Power Supply (J12)
Pin (J12) Signal Function Cable
1 VL+ Auxiliary Supply Input DC Power
2 PR Auxiliary Supply Return DC Power
28
2-Pin Phoenix Plug-in
Connector
2-Pin Phoenix 3.81 mm Pitch
Table 5: Aux. Power Connector – Pin Assignments
Power from the Gold DC Whistle to the motor must come from the Main Supply
and not from the Auxiliary Supply.
The backup functionality can be used for storing control parameters in case of power-outs,
providing maximum flexibility and backup capability when needed.
Connect the VL+ and PR terminal to the Auxiliary Connector.
To connect the auxiliary supply:
1. The source of the Auxiliary Supply must be isolated.
2. For safety reasons, connect the return (common) of the auxiliary supply source to the
closest ground near the auxiliary supply source
3. Connect the cable shield to the closest ground near the auxiliary supply source
4. Before applying power, first verify the polarity of the connection.
||Main and Auxiliary Power|www.elmomc.com
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MAN-G-DCWHI IG-EC (Ver. 1.700)
6.3.3.1. Power Rating 200 V
For Power Rating 200 V, two power isolated DC power sources are required, main power 12 - 195V
and auxiliary Power 12-95V for the logic.
29
Figure 12: 200 VDC Power Source Connection Diagram
||Main and Auxiliary Power|www.elmomc.com
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6.3.3.2. Power Rating 100 V
6.3.3.2.a Single Power Supply
For power rating 100 V , a single Power Supply is required which contains a “smart” control-supply
algorithm, enabling the Gold DC Whistle to operate with only one power supply with no need for an
auxiliary power supply for the logic.
Figure 13: Main Power Supply Connection Diagram (no Auxiliary Supply)
6.3.3.2.b Optional Backup Supply
Figure 14: Auxiliary Power Supply Connections Diagram
||Main and Auxiliary Power|www.elmomc.com
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6.4. Drive Status Indicator
Figure 15 shows the position of the red/green dual LED, which is used for immediate indication of
the Initiation and Working states. For details refer to Chapter 7 Drive Status Indicator, in the
MAN-G-Panel Mounted Drives Hardware manual.
31
Figure 15: Drive Status Indicator - EtherCAT
Figure 16: Drive Status Indicator - CAN
The red/green dual LED is used for immediate indication of the following states:
• Initiation state: In this state the LED indicates whether the drive is in the boot state
(blinking red) or in the operational state (steady red).
• Working state: In this state the LED indicates whether the drive is in an amplifier failure
state (red) or is ready to enable the motor (green).
||Drive Status Indicator|www.elmomc.com
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6.5. STO (Safe Torque Off) (J11)
See Chapter 9 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Pin (J11) Signal Function
1 STO1 STO1 input (default 24 V)
2 STO2 STO2 input (default 24 V)
3 STO_RET STO signal return
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3-Pin 2.54 mm Pitch Molex
Table 6: STO Input – Pin Assignments
3-Pin Molex Plug
This cable is included in the cable kit
described in Section 3.1.1.
||STO (Safe Torque Off) (J11)|www.elmomc.com
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6.5.1. Source Mode – PLC Voltage Level
Refer to the diagrams below for the PLC Source option connection.
Figure 17: STO Molex Type Input Connection – PLC Source Option
33
6.5.2. TTL Mode – TTL Voltage Level
Refer to the diagrams below for TTL option connection.
Figure 18: STO Input Connection – TTL Option
||STO (Safe Torque Off) (J11)|www.elmomc.com
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6.5.3. Sink Mode – PLC Voltage Level
Refer to the diagrams below for the PLC Sink option connections which is not fully certified for STO.
This option is not recommended for new designs.
Figure 19: STO Input Connection – Sink Option
||STO (Safe Torque Off) (J11)|www.elmomc.com
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6.6. Port A (J1)
See Section 10.3 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Incremental Encoder Absolute Serial Encoder
Pin (J1) Signal Function Signal Function
1 +5V Encoder +5V supply +5V Encoder +5V supply
2 COMRET Common return COMRET Common return
3 PortA_ENC_A+ Channel A + ABS_CLK+ Absolute encoder clock+
4 PortA_ENC_A- Channel A - ABS_CLK- Absolute encoder clock-
5 PortA_ENC_B+ Channel B+ ABS_DATA+ Absolute encoder data+
6 PortA_ENC_B- Channel B - ABS_DATA- Absolute encoder data-
7 PortA_ENC_INDEX+ Index+ Reserved Reserved
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8 PortA_ENC_INDEX- Index - Reserved Reserved
9 HA Hall sensor A HA Hall sensor A
10 HB Hall sensor B HB Hall sensor B
11 HC Hall sensor C HC Hall sensor C
12 COMRET Common Return COMRET Common Return
Pin Positions Cable Connector
12-Pin 2.54 mm Pitch Molex
Table 7: Port A Pin Assignments
||Port A (J1)|www.elmomc.com
12-Pin Molex Plug
This cable is included in
the cable kit described in
Section 3.1.1.
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6.6.1. Incremental Encoder
36
Figure 20: Port A Molex Type Incremental Encoder Input – Recommended Connection Diagram
6.6.2. Halls Sensor
Figure 21: Molex Type Hall Sensors Connection Diagram
||Port A (J1)|www.elmomc.com
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6.6.3. Absolute Serial Encoder
The following figures describe the connections at Port A for the Absolute Serial type encoders.
37
Figure 22: Absolute Serial Encoder – Recommended Connection Diagram for EnDAT, Biss, SSI
Figure 23: Absolute Serial Encoder – Recommended Connection Diagram for Sensors
Supporting Data Line Only (NRZ types, e.g., Panasonic / Mitutoyo / Sanyo Danki / Tamagawa)
||Port A (J1)|www.elmomc.com
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6.6.3.1. Hiperface
The following figure describes the connection diagram.
38
Figure 24: Absolute Serial Encoder – Recommended Molex Type Connection Diagram for
Stegmann Hiperface
||Port A (J1)|www.elmomc.com
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6.7. Port B (J3)
See Section 10.4 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
39
Incremental or
Resolver
Interpolated Analog Encoder
G-DCWHIXXX/YYYYEXX G-DCWHIXXX/YYYYRXX
Pin (J3) Signal Function Signal Function
1 +5V Encoder +5V supply NC
2 COMRET Common return COMRET Common return
3 PortB_ENC_A+/SIN+ Channel A+/Sine+ SIN+ Sine+
4 PortB_ENC_A-/SIN- Channel A -/Sine- SIN- Sine-
5 PortB_ENC_B+/COS+ Channel B+/Cosine+ COS+ Cosine+
6 PortB_ENC_B-/COS- Channel B-/Cosine- COS- Cosine-
7 PortB_ENC_INDEX+/
Analog_Index+
8 PortB_ENC_INDEX-/
Analog_Index-
Channel_Index+/
Analog_Index+
Channel_Index- /
Analog_Index-
RESOLVER_OUT+ Vref f=1/TS, 50 mA
Max.
RESOLVER_OUT- Vref complement
f= 1/TS, 50 mA
Maximum
Pin Positions Cable Connector
8-Pin Molex Plug
This cable is included in
the cable kit described in
Section 3.1.1.
8-Pin 2.54 mm Pitch Molex
Table 8: Port B Pin Assignments
||Port B (J3)|www.elmomc.com
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6.7.1. Incremental Encoder
The following figure describes the connections at Port B for the Incremental encoder.
40
Figure 25: Port B Incremental Encoder Input – Recommended Connection Diagram
||Port B (J3)|www.elmomc.com
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6.7.2. Interpolated Analog Encoder
The following figure describes the connections at Port B for the Interpolated Analog encoder.
41
Figure 26: Port B - Interpolated Analog Encoder Molex Type Connection Diagram
||Port B (J3)|www.elmomc.com
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6.7.3. Resolver
42
Figure 27: Port B – Resolver Molex Type Connection Diagram
||Port B (J3)|www.elmomc.com
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6.8. Port C, Digital I/Os, and Analog Inputs (J2)
The Port C connector includes the following functions:
• Port C: Refer to Sections 10.5 in the in the MAN-G-Panel Mounted Drives Hardware manual
for full details
• I/O: Refer to Chapter 11 in the in the MAN-G-Panel Mounted Drives Hardware manual for full
details.
• Analog input: See Section 11.2 in the in the MAN-G-Panel Mounted Drives Hardware manual
for full details.
Pin (J2) Signal Function
1 PortC_ENCO_A+ Buffered Channel A output
2 PortC_ENCO_A- Buffered Channel A complement output
3 PortC_ENCO_B+ Buffered Channel B output
4 PortC_ENCO_B- Buffered Channel B complement output
5 PortC_ENCO_Index+ Buffered INDEX output
6 PortC_ENCO_Index- Buffered INDEX complement output
7 COMRET Common return
8 COMRET Common return
9 ANALOG1- Analog input complement
10 ANALOG1+ Analog input
11 ANARET Analog return
12 INRET1_6 Programmable input 1 – 6 return
13 IN1 Programmable digital input 1
14 IN2 Programmable digital input 2
15 IN3 Programmable digital input 3
16 IN4 Programmable digital input 4
17 IN5 Programmable digital input 5
18 IN6 Programmable digital input 6
19 OUT4 Programmable output 4
20 OUT3 Programmable output 3
21 OUT2 Programmable output 2
22 OUT1 Programmable output 1
23 VDD VDD supply (5 V up to 30 V)
24 VDDRET VDD supply return
||Port C, Digital I/Os, and Analog Inputs (J2)|www.elmomc.com
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Pin Positions Cable Connector
44
24-Pin 2.54 mm Pitch Molex
Table 9: Port C Feedback Out and I/O
24-Pin Molex Plug
This cable is included in the
cable kit described in
Section 3.1.1.
||Port C, Digital I/Os, and Analog Inputs (J2)|www.elmomc.com
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6.8.1. Port C – Emulated Encoder Output
The following figure describes the connections at Port C for the Emulated Encoder Differential.
45
Figure 28: Emulated Encoder Differential Output – Recommended Connection Diagram
Note that the user is required to connect a 120 Ω termination at the end of each differential line.
||Port C, Digital I/Os, and Analog Inputs (J2)|www.elmomc.com
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6.8.2. Analog Input
The following circuit describes the internal interface of the Analog input.
46
Figure 29: Differential Analog Input
||Port C, Digital I/Os, and Analog Inputs (J2)|www.elmomc.com
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6.8.3. Digital Input and Output TTL Mode
The following figure describes the connections at the I/O Port for the Digital Input and Output TTL
Mode.
47
Figure 30: Digital Input TTL Mode Connection Diagram
||Port C, Digital I/Os, and Analog Inputs (J2)|www.elmomc.com
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48
Figure 31: Digital Output Connection Diagram – TTL Option
||Port C, Digital I/Os, and Analog Inputs (J2)|www.elmomc.com
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6.8.4. Digital Input and Output PLC Source Mode
The following figure describes the connections at the I/O Port for the Digital Input and Output PLC
Mode.
49
Figure 32: Digital Input Connection Diagram – Source PLC Option
||Port C, Digital I/Os, and Analog Inputs (J2)|www.elmomc.com
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Figure 33: Digital Output Connection Diagram – Source PLC Option
||Port C, Digital I/Os, and Analog Inputs (J2)|www.elmomc.com
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6.8.5. Digital Input and Output Sink Mode
The following figure describes the connections at the I/O Port for the Digital Input and Output Sink
Mode.
51
Figure 34: Digital Input Sink Mode – PLC voltage level Molex Type Connection Diagram
||Port C, Digital I/Os, and Analog Inputs (J2)|www.elmomc.com
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Figure 35: Digital Output as Sink Configuration Molex Type Connection Diagram
||Port C, Digital I/Os, and Analog Inputs (J2)|www.elmomc.com
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6.9. USB 2.0 (J9)
See Section 12.1 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Pin (J9) Signal Function
1 USB VBUS USB VBUS 5 V
2 USBD- USB _N line
3 USBD+ USB _P line
5 USB COMRET USB communication return
Pin Positions Cable Connector
53
USB Device Mini-B
Table 10: USB 2.0 Pin Assignments
USB Device Mini-B Plug
Figure 36: USB Network Diagram
||USB 2.0 (J9)|www.elmomc.com
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6.10. EtherCAT Communication Version
Fieldbus communications are industrial network protocols for real-time distributed control that
allows connection of servo drives. The Gold DC Whistle supports the following EtherCAT fieldbus
type industrial network protocol:
Fieldbus Type Product Number
EtherCAT G-DCWHI XX/YYYEXX
6.10.1. EtherCAT IN/Ethernet Pin Assignments (J7)
Refer to section 12.2 in the MAN-G-Panel Mounted Drives Hardware manual for more details.
Pin (J7) Signal Function
1 EtherCAT_IN_TX+/Ethernet_TX+ EtherCAT in/Ethernet transmit +
2 EtherCAT_IN_TX-/Ethernet_TX- EtherCAT in/Ethernet transmit -
3 EtherCAT_IN_RX+/Ethernet_RX+ EtherCAT in/Ethernet receive +
54
4, 5 N/A
6 EtherCAT_IN_RX-/Ethernet_RX- EtherCAT in/Ethernet receive -
7, 8 N/A
Connectors
Standard Ethernet CAT5 Cable
8-Pin RJ-45
||EtherCAT Communication Version|www.elmomc.com
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6.10.2. EtherCAT OUT Pin Assignments (J8)
See Section 12.2 in the MAN-G-Panel Mounted Drives Hardware manual for the electrical diagram.
Pin (J8) Signal Function
1 EtherCAT_OUT_TX+ EtherCAT out transmit +
2 EtherCAT_OUT_TX- EtherCAT out transmit -
3 EtherCAT_OUT_RX+ EtherCAT out receive +
4, 5 N/A
6 EtherCAT_OUT_RX- EtherCAT out receive -
7, 8 N/A
Connectors
55
Standard Ethernet CAT5 Cable
8-Pin RJ-45
6.10.3. EtherCAT Wiring
Figure 37 describes the wiring diagram for the EtherCAT connections.
Figure 37: EtherCAT RJ-45 Connections
||EtherCAT Communication Version|www.elmomc.com
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6.10.4. EtherCAT Status Indicator
56
Figure 38: EtherCAT Status LED
The EtherCAT status indicator is a single red/green dual bi-colored LED that combines the green
RUN indicator and the red ERROR indicator of the EtherCAT state machine. For further details, see
the EtherCAT Application Manual.
Note: There is no Gold DC Whistle ECAT Status indicator equivalent in the CAN version, refer to the
figure below.
Figure 39: Gold DC Whistle Status Indicator - CAN
||EtherCAT Communication Version|www.elmomc.com
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6.11. CAN Communication Version
Fieldbus communications are industrial network protocols for real-time distributed control that
allows connection of servo drives. The Gold DC Whistle supports the following CAN fieldbus type
industrial network protocol:
Fieldbus Type Product Number
CAN G-DCWHI XX/YYYSXX
See Section 12.4 in the MAN-G-Panel Mounted Drives Hardware manual for the electrical diagram.
Pin (J7, J8) Signal Function
1 CAN_H CAN_H bus line (dominant high)
2 CAN_L CAN_L bus line (dominant low)
3 COMRET (CAN_RET) CAN Return
4, 5 N/A —
6 CAN_SHLD Shield, connected to the RJ plug cover
57
7 CAN_RET CAN Return
8 N/A —
Pin Position
Table 11: CAN In/Out Connectors Pin Assignments
Standard CAT5e Ethernet Cable
||CAN Communication Version|www.elmomc.com
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6.11.1. CAN Wiring
58
Caution
When installing the CAN
communications, ensure that each
servo drive is allocated a unique ID.
Otherwise, the CAN network may
hang.
Figure 40: Gold DC Whistle Connection Diagram – CAN
||CAN Communication Version|www.elmomc.com
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6.12. Powering Up
After the Gold DC Whistle 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.
6.13. Initializing the System
After the Gold DC Whistle has been connected and mounted, the system must be set up and
initialized. This is accomplished using the EASII, Elmo’s Windows-based software application. Install
the application and then perform setup and initialization according to the directions in the EASII
User Manual.
||Powering Up|www.elmomc.com
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Chapter 7: Dimensions
MAN-G-DCWHI IG-EC (Ver. 1.700)
This chapter provides detailed technical information regarding the Gold DC Whistle.
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