Page 1
Gold Duo
Digital Servo Drive
Installation Guide
EtherCAT
July 2014 (Ver. 1.500) 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 Duo 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-DUOIG-E (Ver. 1.500)
Copyright 2014
Elmo Motion Control Ltd.
All rights reserved.
Catalog Number
Page 3
Cable Kit
Catalog number: CBL-GDUOKIT01 (can be ordered separately)
For further details, see the MAN-G-DUO-CBLKIT documentation for this cable kit.
Revision History
Version Date Details
Ver. 1.500 July 2014 Initial release in new format
Page 4
Table of Contents
MAN-G-DUOIG-E (V er. 1.500)
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 Per Axis .............................................................................................. 9
4.2.1. Auxiliary Supply ......................................................................................... 10
4.2.2. Product Features Per Axis.......................................................................... 11
4
Chapter 5: Installation ................................................................................................ 12
5.1. Unpacking the Drive Components ........................................................................... 12
5.2. Connectors Types ..................................................................................................... 13
5.3. Mounting the Gold Duo ............................................................................................ 15
5.4. The Gold Duo Connection Diagram .......................................................................... 16
Chapter 6: Wiring ....................................................................................................... 17
6.1. Basic Recommendations .......................................................................................... 18
6.1.1. General ...................................................................................................... 18
6.1.2. Feedback Cable Port A and Port B Connector ........................................... 19
6.1.3. Feedback Cable Port C Connector ............................................................. 20
6.1.4. IO Cable Connector .................................................................................... 20
6.1.5. STO (Port C) Cable Connector .................................................................... 21
6.2. Motor Power Connector Pinouts ............................................................................. 22
6.3. Main and Auxiliary Power ........................................................................................ 25
6.3.1. Description ................................................................................................ 25
6.3.2. Main Power ............................................................................................... 26
6.3.3. Auxiliary Power Supply .............................................................................. 27
6.3.3.1. Power Rating 200 V .................................................................. 28
6.3.3.2. Power Rating 100 V .................................................................. 29
6.4. Drive Status Indicator ............................................................................................... 31
6.5. STO (Safe Torque Off) ............................................................................................... 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
6.6. Feedback Port A Per Axis .......................................................................................... 35
Page 5
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. Feedback Port B Per Axis .......................................................................................... 39
6.7.1. Incremental Encoder ................................................................................. 40
6.7.2. Interpolated Analog Encoder .................................................................... 41
6.7.3. Resolver ..................................................................................................... 42
6.8. Feedback Port C and I/O ........................................................................................... 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 Communication per Axis ............................................................................. 53
6.10. EtherCAT Communication Version ........................................................................... 54
6.10.1. EtherCAT IN/Ethernet Pin Assignments .................................................... 54
6.10.2. EtherCAT OUT Pin Assignments................................................................. 55
6.10.3. EtherCAT Wiring ........................................................................................ 55
6.10.4. EtherCAT Status Indicator ......................................................................... 56
6.11. Powering Up ............................................................................................................. 57
6.12. Initializing the System .............................................................................................. 57
5
Chapter 7: Dimensions ............................................................................................... 58
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Gold Duo Installation Guide
Table of Contents
Chapter 1: This Installation Guide
Chapter 2: Safety Information
Warning:
Caution:
Important:
MAN-G-DUOIG-E (V er. 1.500)
This installation Guide details the technical data, pinouts, and power connectivity of the Gold Duo.
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 Duo, 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 Duo 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.
6
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 Duo 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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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 Duo 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 Duo 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 Duo, 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 Duo 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 Duo 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-DUOIG-E (V er. 1.500)
8
The Gold Duo is an advanced high power density servo drive delivering up to 1.6 kW of continuous
power or 3.2 kW of peak power per axis in a 394 cc (24.0 in³) package (150 x 105 x 25.8 mm or 5.9"
x 4.1" x 1.0"). The Gold Duo is a highly compact integrated solution containing two drives in a single
package. The solution operates under a single power supply and is designed for applications with up
to two axes. The Gold Duo has a fully featured motion controller and local intelligence.
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 Duo is
powered by a single 12 V – 195 V isolated DC power source (not included) and a “smart” controlsupply 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 Duo 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 Duo 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 Duo is available in a variety of options. There are multiple power rating options, a variety
of feedback selections and I/O configuration possibilities.
3.1.1. Accessories
Cable Kit, catalog number: CBL-GDUOKIT01 (can be ordered separately)
For further details, see the MAN-G-DUO-CBLKIT documentation for this cable kit.
||Warranty Information|www.elmomc.com
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Chapter 4: Technical Information
MAN-G-DUOIG-E (V er. 1.500)
4.1. Physical Specifications
Feature Units All Types
Weight g (oz) 479 g (16.9 oz)
Dimensions mm (in) 150 x 105 x 25.8 mm (5.9" x 4.13" x 98")
Mounting method Wall Mount / Book Shelf
4.2. Technical Data Per Axis
Feature Units 5/100 10/100 15/100 20/100
Minimum supply voltage VDC 12
9
Nominal supply voltage VDC 85
Maximum supply voltage VDC 95
Maximum continuous power output W 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
Table 1: Power Ratings
Note on current ratings: The current ratings of the Gold Duo 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.
% > 99
(up to 6 VA inc. 5 V/2 x 200 mA for
encoder)
A 5 10 15 20
A 3.5 7 10.6 14.1
||Physical Specifications|www.elmomc.com
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Elmo now offers a 200 VDC maximum output rating selection of Gold Duo, 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 per axis
≤ 6 VA with full external loading per axis
||Technical Data Per Axis|www.elmomc.com
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4.2.2. Product Features Per Axis
Main Feature Details Presence and No.
11
STO
Digital Input
Digital Output
Analog Input
Feedback
Communication Option
TTL, or √
PLC Source √
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 √
||Technical Data Per Axis|www.elmomc.com
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Chapter 5: Installation
MAN-G-DUOIG-E (V er. 1.500)
The Gold Duo 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 Duo, verify that you have all of its components, as follows:
• The Gold Duo servo drive
• The Elmo Application Studio software and software manual
The Gold Duo is shipped in a cardboard box with Styrofoam protection.
To unpack the Gold Duo:
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 Duo you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Gold Duo. It looks like this:
4. Verify that the Gold Duo 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. Connectors Types
The Gold Duo has 15 connectors.
Connector Pins Type Function
Bottom Connectors
13
J13 5 Phoenix, 5 mm Pitch ‘HC’ Main Power
J12 2 Phoenix 3.81 mm Pitch Auxiliary supply
J14, J15 4 Phoenix 5 mm Pitch ‘HC’ (2) Motor phases
Front Connectors
J2, J5 24 2.54 mm Pitch Molex (2) I/O and Port C
J3, J6 8 2.54 mm Pitch Molex (2) Feedback Port B
J1, J4 12 2.54 mm Pitch Molex (2) Feedback Port A
||Connectors Types|www.elmomc.com
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Connector Pins Type Function
Top Connectors
14
J9, J10 5 USB Device Mini-B (2) USB
J7 8 RJ-45 EtherCAT in
J8 8 RJ-45 EtherCAT out
J11 3 2.54 mm Pitch Molex STO
Table 2: Connector Types
||Connectors Types|www.elmomc.com
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15
5.3. Mounting the Gold Duo
The Gold Duo 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 Duo
(see the diagram below).
Figure 1: Mounting the Gold Duo
||Mounting the Gold Duo|www.elmomc.com
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5.4. The Gold Duo Connection Diagram
16
Figure 2: The Gold Duo Connection Diagram
||The Gold Duo Connection Diagram|www.elmomc.com
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Chapter 6: Wiring
MAN-G-DUOIG-E (V er. 1.500)
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.
The drain wire is a non-insulated wire
that is in direct contact with the braid
(shielding).
17
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 Duo Connection Diagram|www.elmomc.com
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18
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 3: 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 4).
Figure 4: 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 4.
b. At the motor, connect the feedback cable drain wire to the GND motor chassis terminal of the
feedback connector (Figure 5).
The drawing displays two earth connections.
19
Figure 5: 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.
20
Figure 6: Feedback Port C Cable Assemblies
6.1.4. IO Cable Connector
It is recommended to use shielded cable, but is not mandatory.
Figure 7: 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 8: STO Cable Assemblies
21
||Basic Recommendations|www.elmomc.com
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J14/2
J14/3
J14/4
J15/1
J15/2
J15/3
J15/4
MAN-G-DUOIG-E (V er. 1.500)
6.2. Motor Power Connector Pinouts
See Chapter 8 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Pin Signal Function Cable (Wires)
Brushless Motor Brushless DC Motor
J14/1 PE Protective earth Motor Motor
M1 Motor phase Axis 1 Motor N/C
M2 Motor phase Axis 1 Motor Motor
M3 Motor phase Axis 1 Motor Motor
PE Protective earth Motor Motor
M1 Motor phase Axis 2 Motor N/C
M2 Motor phase Axis 2 Motor Motor
M3 Motor phase Axis 2 Motor Motor
22
Axis 1 and Axis 2: 4-Pin Phoenix 5 mm Pitch ‘HC’
Table 3: Motor Power Pin Assignments
4-Pin Phoenix Plug-in
Connector
||Motor Power Connector Pinouts|www.elmomc.com
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See Chapter 8 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Pin Function Cable
Brushless Motor Brushed DC Motor
PE Protective Earth Motor Motor
M1 Motor phase Motor N/C
M2 Motor phase Motor Motor
M3 Motor phase Motor Motor
23
4-Pin Phoenix 5 mm Pitch ‘HC’
Table 4: Connectors for Motor
4-Pin Phoenix Plug-in
Connector
Figure 9: Brushless Motor Power Connection Diagram
||Motor Power Connector Pinouts|www.elmomc.com
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Figure 10: Brushed Motor Power Connection Diagram
||Motor Power Connector Pinouts|www.elmomc.com
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25
6.3. Main and Auxiliary Power
6.3.1. Description
The Gold Duo receives power from main and auxiliary supplies and delivers power to the motor.
Note: There are multiple voltage ratings of the Gold Duo (12 V to 195 V), so you must use the
correct power supply according to the maximum operating voltage of the Gold Duo. Refer to
Chapter 4: Technical Information.
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 Duo Power rating is 12 to 195 VDC
• There are Two power ratings for Gold Duo; 100V and 200V:
For power rating 200V
Two power isolated DC power sources are required, main power 12 - 195V and Auxiliary
Power 12-95V for the logic.
For power rating of 100V
Single DC Power Supply - Power to the Gold Duo is provided by a 12–95 VDC single isolated
DC power source (not included with the Gold Duo). A “smart” control-supply algorithm
enables the Gold Duo 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 Duo’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 Duo, therefore the correct power supply must be used,
according to the maximum operating voltage of the Gold Duo. Refer to section 4.2 Technical Data.
||Main and Auxiliary Power|www.elmomc.com
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J13/2
J13/3
J13/4
J13/5
MAN-G-DUOIG-E (V er. 1.500)
6.3.2. Main Power
Pin Signal Function Cable (Wires)
J13/1 VP+ Pos. Power input DC Power
VP+ Pos. Power input DC Power
PR Power return DC Power
PR Power return DC Power
PE Protective earth DC Power
26
5-Pin Phoenix Plug-in
Connector
5-Pin Phoenix 5 mm Pitch ‘HC’
Table 5: Main Power Pin Assignments
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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6.3.3. Auxiliary Power Supply
Pin Signal Function Cable (Wires)
J12/1 VL+ Auxiliary Supply Input Auxiliary Power
J12/2 PR Auxiliary Supply Return Auxiliary Power
27
2-Pin Phoenix Plug-in
Connector
2-Pin Phoenix 3.81 mm Pitch
Table 6: Auxiliary Supply Pin Assignments
Caution:
Power from the Gold Duo 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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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.
28
Figure 11: 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 Duo to operate with only one power supply with no need for an
auxiliary power supply for the logic.
29
Figure 12: Main Power Supply Connection Diagram
||Main and Auxiliary Power|www.elmomc.com
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6.3.3.2.b Optional Backup Supply
30
Figure 13: Main Power Supply Connection Diagram with Auxiliary Supply
||Main and Auxiliary Power|www.elmomc.com
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6.4. Drive Status Indicator
Figure 14 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 14: Drive Status Indicator - EtherCAT
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)
See Chapter 9 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Pin (J11) Signal Function
J11/1 STO1 STO1 input (default 24 V)
J11/2 STO2 STO2 input (default 24 V)
J11/3 STO_RET STO signal return
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3-Pin 2.54 mm Pitch Molex
Table 7: STO Inputs Pin Assignments
3-Pin Molex Plug
This cable is included in the cable
kit described in Section 3.1.1
||STO (Safe Torque Off)|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 15: STO Molex Type Input Connection – PLC Source Option
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6.5.2. TTL Mode – TTL Voltage Level
Refer to the diagrams below for TTL option connection.
Figure 16: STO Input Connection – TTL Option
||STO (Safe Torque Off)|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 17: STO Input Connection – Sink Option
||STO (Safe Torque Off)|www.elmomc.com
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6.6. Feedback Port A Per Axis
See Section 10.3 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Incremental Encoder Absolute Serial Encoder
Pin 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
8 PortA_ENC_INDEX- Index - Reserved Reserved
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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
12-Pin Molex Plug
12-Pin 2.54 mm Pitch Molex
Table 8: Port A Pin Assignments
||Feedback Port A Per Axis|www.elmomc.com
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 18: Port A Molex Type Incremental Encoder Input – Recommended Connection Diagram
6.6.2. Halls Sensor
Figure 19: Molex Type Hall Sensors Connection Diagram
||Feedback Port A Per Axis|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 20: Absolute Serial Encoder – Recommended Connection Diagram for EnDAT, Biss, SSI
Figure 21: Absolute Serial Encoder – Recommended Connection Diagram for Sensors
Supporting Data Line Only (NRZ types, e.g., Panasonic / Mitutoyo / Sanyo Danki / Tamagawa)
||Feedback Port A Per Axis|www.elmomc.com
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6.6.3.1. Hiperface
The following figure describes the connection diagram.
38
Figure 22: Absolute Serial Encoder – Recommended Molex Type Connection Diagram for
Stegmann Hiperface
||Feedback Port A Per Axis|www.elmomc.com
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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+/
Channel_Index+/
RESOLVER_OUT+
Vref f=1/TS, 50 mA
8
PortB_ENC_INDEX-/
Channel_Index- /
RESOLVER_OUT-
Vref complement
MAN-G-DUOIG-E (V er. 1.500)
6.7. Feedback Port B Per Axis
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-DUOXXXX/YYYYEXX G-DUOXXXX/YYYYRXX
Pin Signal Function Signal Function
Analog_Index+
Analog_Index-
Analog_Index+
Analog_Index-
Max.
f= 1/TS, 50 mA
Maximum
||Feedback Port B Per Axis|www.elmomc.com
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 9: Port B Pin Assignments
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6.7.1. Incremental Encoder
The following figure describes the connections at Port B for the Incremental encoder.
40
Figure 23: Port B Incremental Encoder Input – Recommended Connection Diagram
||Feedback Port B Per Axis|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 24: Port B - Interpolated Analog Encoder Molex Type Connection Diagram
||Feedback Port B Per Axis|www.elmomc.com
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6.7.3. Resolver
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Figure 25: Port B – Resolver Molex Type Connection Diagram
||Feedback Port B Per Axis|www.elmomc.com
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6.8. Feedback Port C and I/O
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 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 input 1 (High speed)
14 IN2 Programmable input 2 (High speed)
15 IN3 Programmable input 3 (High speed)
16 IN4 Programmable input 4 (High speed)
17 IN5 Programmable input 5 (High speed)
18 IN6 Programmable input 6 (High speed)
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
||Feedback Port C and I/O|www.elmomc.com
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Connector Location
44
24-Pin 2.54 mm Pitch Molex
Table 10: 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.
||Feedback Port C and I/O|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 26: 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.
||Feedback Port C and I/O|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 27: Differential Analog Input
||Feedback Port C and I/O|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 28: Digital Input TTL Mode Connection Diagram
||Feedback Port C and I/O|www.elmomc.com
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Figure 29: Digital Output Connection Diagram – TTL Option
||Feedback Port C and I/O|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 30: Digital Input Connection Diagram – Source PLC Option
||Feedback Port C and I/O|www.elmomc.com
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Figure 31: Digital Output Connection Diagram – Source PLC Option
||Feedback Port C and I/O|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 32: Digital Input Sink Mode – PLC voltage level Molex Type Connection Diagram
||Feedback Port C and I/O|www.elmomc.com
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Figure 33: Digital Output as Sink Configuration Molex Type Connection Diagram
||Feedback Port C and I/O|www.elmomc.com
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6.9. USB 2.0 Communication per Axis
See Section 12.1 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Pin (A-2, A-1) 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
Connectors
53
Mini-USB Type B
Table 11: USB 2.0 Pin Assignments
USB Device Mini-B Plug
Figure 34: USB Network Diagram
||USB 2.0 Communication per Axis|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.
6.10.1. EtherCAT IN/Ethernet Pin Assignments
Refer to section 12.2 in the MAN-G-Panel Mounted Drives Hardware manual for more details.
Pin 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 +
4, 5 N/A
6 EtherCAT_IN_RX-/Ethernet_RX- EtherCAT in/Ethernet receive -
7, 8 N/A
54
Connector Location
Standard CAT5e Ethernet Cable
8-Pin RJ-45
||EtherCAT Communication Version|www.elmomc.com
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6.10.2. EtherCAT OUT Pin Assignments
See Section 12.2 in the MAN-G-Panel Mounted Drives Hardware manual for the electrical diagram.
Pin 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
Connector Location
55
Table 12: EtherCAT Pin Assignments
6.10.3. EtherCAT Wiring
Figure 35 describes the wiring diagram for the EtherCAT connections.
Standard CAT5e Ethernet
Cable
Figure 35: EtherCAT RJ-45 Connections
||EtherCAT Communication Version|www.elmomc.com
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6.10.4. EtherCAT Status Indicator
56
Figure 36: 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.
||EtherCAT Communication Version|www.elmomc.com
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6.11. Powering Up
After the Gold Duo 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.
6.12. Initializing the System
After the Gold Duo 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.
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||Powering Up|www.elmomc.com
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Chapter 7: Dimensions
MAN-G-DUOIG-E (V er. 1.500)
This chapter provides detailed technical information regarding the Gold Duo.
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