ElmoMC Gold Hornet User Manual
Gold Hornet
Digital Servo Drive
Installation Guide
EtherCAT and CAN
August 2014 (Ver. 1.007)
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Elmo Motion Control and the Elmo Motion Control logo are
EtherCAT Conformance Tested. EtherCAT® is a registered
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 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.
• Information in this document is subject to change without notice.
registered trademarks of Elmo Motion Control Ltd.
trademark and patented technology, licensed by Beckhoff
Automation GmbH, Germany.
Catalog Number
Document no. MAN-G-HORIG-E (Ver. 1.007)
Copyright 2014
Elmo Motion Control Ltd.
All rights reserved.
Revision History
Version Date Details
Ver. 1.000 Initial release
Ver. 1.001 General document updates
Ver. 1.002 General document updates
Ver. 1.003 January 2013 Added a caution and recommendation on the type of
cleaning solution to use for the Elmo unit.
Ver. 1.004 March 2013 Added Section 3.1: Physical Specifications
Section 3.2: Technical Data- updated the Power Ratings table
for the 200 VDC option.
Ver. 1.005 May 2014 Correction to main drawing
Ver. 1.006 July 2014 General format update
Ver. 1.007 Aug 2014 IG application to EtherCAT and CAN
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
MAN-G-HORIG-E (Ver . 1.007)
Table of Contents
Gold Hornet Installation Guide (EtherCAT and CAN)
Chapter 1: Safety Information ...................................................................................... 8
1.1. Warnings .....................................................................................................................9
1.2. Cautions ......................................................................................................................9
1.3. Directives and Standards ......................................................................................... 10
1.4. CE Marking Conformance ........................................................................................ 10
1.5. Warranty Information ............................................................................................. 10
Chapter 2: Product Description .................................................................................. 11
2.1. Functional Description ............................................................................................. 11
2.2. Product Features ..................................................................................................... 13
2.2.1. High Power Density .................................................................................. 13
2.2.2. Supply Input .............................................................................................. 13
2.2.3. Servo Control ............................................................................................ 13
2.2.4. Advanced Filters and Gain Scheduling...................................................... 14
2.2.5. Motion Control ......................................................................................... 14
2.2.6. Fully Programmable .................................................................................. 15
2.2.7. Feedback Ports Options ............................................................................ 15
2.2.8. Feedback Sensor Specifications ................................................................ 15
2.2.9. Communications ....................................................................................... 16
2.2.10. Safety ........................................................................................................ 17
2.2.11. Outputs ..................................................................................................... 17
2.2.12. Inputs ........................................................................................................ 17
2.2.13. Built-In Protection .................................................................................... 18
2.2.14. Status Indication ....................................................................................... 18
2.2.15. Automatic Procedures .............................................................................. 18
2.3. System Architecture ................................................................................................ 19
2.4. How to Use this Guide ............................................................................................. 20
5
Chapter 3: Technical Information ............................................................................... 21
3.1. Physical Specifications ............................................................................................. 21
3.2. Technical Data ......................................................................................................... 21
3.2.1. Auxiliary Supply ........................................................................................ 22
Chapter 4: Installation ............................................................................................... 23
4.1. Site Requirements ................................................................................................... 23
4.2. Unpacking the Drive Components ........................................................................... 23
4.3. Connectors............................................................................................................... 25
4.3.1. Connector Types ....................................................................................... 25
4.3.2. Pinouts ...................................................................................................... 25
4.3.2.1. Motor Power ............................................................................ 25
4.3.2.2. Main Power .............................................................................. 26
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4.3.2.3. Auxiliary Power Connector ...................................................... 26
4.3.2.4. Connector J2 ............................................................................ 27
4.3.2.5. Connector J1 ............................................................................ 30
4.4. Mounting the Gold Hornet ...................................................................................... 32
4.5. Integrating the Gold Hornet on a PCB ..................................................................... 33
4.5.1. Grounds and Returns ................................................................................ 33
4.6. The Gold Hornet Connection Diagram .................................................................... 35
4.7. Main Power, Auxiliary Power and Motor Power ..................................................... 36
4.7.1. Motor Power............................................................................................. 36
4.7.2. Main and Auxiliary Power ......................................................................... 37
4.7.2.1. Main Power .............................................................................. 37
4.7.2.2. Auxiliary Power Supply (Optional) ........................................... 38
4.7.2.3. Power Rating 200 V ................................................................. 39
4.7.2.4. Power Rating 100 V ................................................................. 40
4.8. STO (Safe Torque Off) Inputs ................................................................................... 42
4.9. Feedback .................................................................................................................. 45
4.9.1. Port A (J2) ................................................................................................. 46
4.9.1.1. Incremental Encoder ............................................................... 47
4.9.1.2. Absolute Serial Encoder ........................................................... 48
4.9.1.3. Hall Sensors.............................................................................. 49
4.9.2. Port B (J2) .................................................................................................. 50
4.9.2.1. Incremental Encoder ............................................................... 51
4.9.2.2. Interpolated Analog Encoder ................................................... 52
4.9.2.3. Resolver ................................................................................... 53
4.9.3. Port C – Emulated Encoder Output (J2) .................................................... 53
4.9.4. Analog Input ............................................................................................. 54
4.10. User I/Os .................................................................................................................. 55
4.10.1. Digital Inputs (J1) ...................................................................................... 55
4.10.2. Digital Outputs (J1) ................................................................................... 58
4.10.3. Analog Input ............................................................................................. 59
4.11. Communications ...................................................................................................... 60
4.11.1. RS-232 Communication (J2) ...................................................................... 60
4.11.2. CAN Communication (J2) .......................................................................... 62
4.11.3. USB 2.0 Communication (J2) .................................................................... 64
4.11.4. EtherCAT Communication (J2) .................................................................. 65
4.11.5. Ethernet Communication (J2) ................................................................... 67
4.11.6. EtherCAT/Ethernet Line Interface ............................................................ 69
4.12. Powering Up ............................................................................................................ 70
4.13. Initializing the System .............................................................................................. 70
4.14. Heat Dissipation....................................................................................................... 71
4.14.1. Thermal Data ............................................................................................ 71
4.14.2. Heat Dissipation Data ............................................................................... 71
4.14.3. How to Use the Charts .............................................................................. 73
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Chapter 5: Technical Specifications ............................................................................ 74
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5.1. Dimensions .............................................................................................................. 74
5.2. Environmental Conditions ....................................................................................... 75
5.3. Control Specifications .............................................................................................. 76
5.3.1. Current Loop ............................................................................................. 76
5.3.2. Velocity Loop ............................................................................................ 77
5.3.3. Position Loop ............................................................................................ 77
5.4. Feedbacks ................................................................................................................ 78
5.4.1. Feedback Supply Voltage .......................................................................... 78
5.4.2. Feedback Options ..................................................................................... 78
5.4.2.1. Incremental Encoder Input ...................................................... 78
5.4.2.2. Digital Halls .............................................................................. 79
5.4.2.3. Interpolated Analog (Sine/Cosine) Encoder ............................ 79
5.4.2.4. Resolver ................................................................................... 80
5.4.2.5. Absolute Serial Encoder ........................................................... 80
5.4.3. Port C Feedback Output ........................................................................... 81
5.5. I/Os .......................................................................................................................... 82
5.5.1. Digital Input Interfaces – TTL Mode ......................................................... 82
5.5.2. Digital Output Interface – TTL Mode ........................................................ 83
5.5.2.1. OUT1 and OUT2 ....................................................................... 83
5.5.2.2. OUT3 and OUT4 ....................................................................... 84
5.5.3. Analog Input ............................................................................................. 84
5.6. Safe Torque Off (STO) .............................................................................................. 85
5.6.1. STO Input Interfaces – TTL Mode ............................................................. 85
5.7. Communications ...................................................................................................... 86
5.8. Pulse-Width Modulation (PWM) ............................................................................. 86
5.9. Compliance with Standards ..................................................................................... 87
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Chapter 1: Safety Information
Warning:
Caution:
Gold Hornet Installation Guide (EtherCAT and CAN) Safety Information
In order to achieve the optimum, safe operation of the Gold 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 Gold Hornet 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 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.
8
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:
This information is needed to avoid a safety hazard, which might cause
bodily injury.
This information is necessary for preventing damage to the product or to
other equipment.
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Gold Hornet Installation Guide (EtherCAT and CAN) 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 Gold Hornet from all voltage sources before it is opened for servicing.
• The Gold 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
9
• The Gold Hornet servo drive contains hot surfaces and electrically-charged components
during operation.
• The maximum DC power supply connected to the instrument must comply with the
parameters outlined in this guide.
• When connecting the Gold Hornet to an approved isolated 12–95 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 Gold 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 Gold 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.com-usa/daten/electronics/Product_TI1s/TI1VIGON_EFM-US.pdf
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Gold Hornet Installation Guide (EtherCAT and CAN) Safety Information
1.3. Directives and Standards
The Gold Hornet conforms to the following industry safety standards:
Safety Standard Item
Approved IEC/EN 61800-5-1, Safety Adjustable speed electrical power drive systems
Recognized UL 508C Power Conversion Equipment
In compliance with UL 840 Insulation Coordination Including Clearances and
Creepage Distances for Electrical Equipment
10
In compliance with UL 60950-1
(formerly UL 1950)
Safety of Information Technology Equipment
Including Electrical Business Equipment
In compliance with EN 60204-1 Low Voltage Directive 73/23/EEC
The Gold 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 Gold 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
Gold Hornet 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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Chapter 2: Product Description
Gold Hornet Installation Guide (EtherCAT and CAN) Product Description
2.1. Functional Description
The Gold Hornet is an advanced high power density servo drive. It provides top servo
performance, advanced networking and built in safety, all in a small PCB mountable package.
The Gold Hornet has a fully featured motion controller and local intelligence.
The Gold 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 Gold Hornet
can operate as a standalone 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 Elmo Application Studio (EAS). This Windowsbased application enables users to quickly and simply configure the servo drive for optimal use
with their motor. For more information about software tools refer to the Elmo Application
Studio Software Manual.
11
The Gold Hornet is available in a variety of models. There are multiple power rating options,
two different communications options, a number of feedback options and different I/O
configuration possibilities. These models are a set of durable motion control products for
applications operating under extreme environmental conditions. They are capable of
withstanding the following extreme conditions:
Feature Operation Conditions Range
Ambient
Temperature
Non-operating
Conditions
-50 °C to +100 °C (-58 °F to 212 °F)
Range
Operating conditions -40 °C to +70 °C (-40 °F to 160 °F)
Temperature
Shock
Altitude
Non-operating
conditions
Non-operating
-40 °C to +70 °C (-40 °F to 160 °F) within 3 min
Unlimited
conditions
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)
Vibration
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)
Operating conditions 20 Hz to 2000 Hz, 14.6g
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Gold Hornet Installation Guide (EtherCAT and CAN) Product Description
Feature Operation Conditions Range
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Mechanical
Shock
Non-operating
conditions
±40g; Half sine, 11 msec
Operating conditions ±20g; Half sine, 11 msec
The Gold Hornet has been tested using methods and procedures specified in a variety of
extended environmental conditions (EEC) standards.
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Gold Hornet Installation Guide (EtherCAT and CAN) Product Description
2.2. Product Features
Note: The features described in this chapter relate to the range of Gold Hornet models.
Depending on the model you have purchased, not all features are available.
To see the features for your model, look at the product label on the Gold Hornet and use the
product catalog number schematic that appears at the beginning of this manual and on
page 24 to determine which specific features are available to you.
2.2.1. High Power Density
The Solo Hornet delivers up to 1600 W of continuous power or 3200 W of peak power in a
38.0 cm
2.2.2. Supply Input
• Gold Hornet Power rating is 12 to 195 VDC
• Two power ratings for Gold Hornet; 100V and 200V:
3
/2.32 in³ (55 x 46 x 15 mm or 2.2" x 1.8" x 0.6") package.
13
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 Hornet is provided by a 12–95 VDC single
isolated DC power source (not included with the Gold Hornet). A “smart” controlsupply algorithm enables the Gold Hornet 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
Hornet’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 Hornet, therefore the correct power supply
must be used, according to the maximum operating voltage of the Gold Hornet. Refer
to Chapter 3: Technical Information.
2.2.3. Servo Control
• Advanced and extremely fast vector control algorithm (current loop bandwidth: 4 kHz)
• Current/Torque sampling rate: up to 25 kHz (40 μs)
• Velocity sampling rate: up to 12.5 kHz (80 μs)
• Position sampling rate: up to 12.5 kHz (80 μs)
• Electrical commutation frequency: up to 4 kHz
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• Current closed loop bandwidth exceeds 4 kHz
• Position/Velocity/Acceleration command range – full 32 bit
• Position over velocity, with full dual loop support
• S-curve Profile Smoothing
14
• Cogging, BEMF and
ωxL compensation
• Dual Loop Operation supported by Auto Tuning
• Fast, easy and efficient advanced Auto Tuning
• Motion profiler numeric range:
9
Position up to ±2 x 10
Velocity up to 2 x 10
Acceleration up to 2 x 10
counts
9
counts/sec
9
counts/sec2
2.2.4. Advanced Filters and Gain Scheduling
• “On-the-Fly” gain scheduling of current and velocity
• Velocity and position with “1-2-2” PIP controllers
• Automatic commutation alignment
• Automatic motor phase sequencing
• Current gain scheduling to compensate for the motor's non-linear characteristics
• Advanced filtering: Low pass, Notch, General Biquad
• Current loop gain scheduling to compensate for bus voltage variations
• Velocity gain scheduling for reliable velocity loop performance
• Gains & filter scheduling vs. position for mechanical coupling optimization, speed and
position tracking errors
• High order filters gain scheduling vs. speed and position
2.2.5. Motion Control
• Motion control programming environment
• Motion modes: PTP, PT, PVT, ECAM, Follower, Dual Loop, Current Follower, Fast event
capturing inputs
• Full DS-402 motion mode support, in both the CAN and CAN over EtherCAT (CoE) protocols,
including Cyclic Position/Velocity modes. Fast (Hardware) event capturing inputs,
supporting < 1 μs latch latency
• Fast (hardware) Output Compare, with < 1 μs latency
• Output compare repetition rate:
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Fixed Gap: Unlimited
Table based: 4 kHz
• Motion Commands: Analog current and velocity, Pulse-Width Modulation (PWM) current
and velocity, digital (software), Pulse and Direction
• Distributed Motion Control
• EAS (Elmo Application Studio) software: an efficient and user friendly auto tuner
2.2.6. Fully Programmable
• Third generation programming structure
• Event capturing interrupts
• Event triggered programming
2.2.7. Feedback Ports Options
• There are Port A and Port B feedback input ports that are flexible and configurable. Each
port can be programmed to serve as:
15
Commutation feedback and/or
Velocity feedback and/or
Position feedback
• Port A supports the following sensors, depending on the specific model:
Incremental encoder
Incremental encoder and digital Hall
Absolute serial encoder
Absolute serial encoder and digital Hall (for dual loop)
• Port B supports the following sensors, depending on the specific model:
Incremental encoder
Analog encoder
Analog Hall
Resolver
Programmable PI and FFW (feed forward) control filters
• Port C is a flexible and configurable feedback output port. It supports the Encoder
emulation outputs of Port A or Port B or internal variables
• Analog input (± 10 V ptp) support:
Velocity feedback (tachometer)
Position feedback (potentiometer)
2.2.8. Feedback Sensor Specifications
• Incremental Quadrature Encoder (with or without commutation halls) up to
75 Megacounts per second (18 MHz PPS (Pulses Per Second))
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• Incremental encoder and digital Halls
• Digital Hall
Up to 4 kHz commutation frequency
5 V logic
Input voltage up to 15 VDC
• Interpolated Analog (Sine/Cosine) Encoder :
Supports 1 V PTP Sine/Cosine
Sin-Cos Frequency: up to 500 kHz
Internal Interpolation: up to ×8192
Automatic Correction of amplitude mismatch, phase mismatch, signal offset
Emulated encoder output of the Analog encoder
• Analog Halls (commutation & position)
One feedback electrical cycle = one motor's electrical cycle
Supports 1 V PTP Sin/Cos
Sin/Cos Frequency: up to 500 kHz
Internal Interpolation: up to ×8192
Automatic correction of amplitude mismatch, phase mismatch, signal offset
16
• Absolute serial encoders:
NRZ (Panasonic, Tamagawa, Mitutoyo, etc.)
EnDAT 2.2
BiSS/SSI
Stegmann Hiperface
• Resolver
14 bit resolution
Up to 512 revolutions per second (RPS)
Emulated encoder outputs of the Resolver
• Auxiliary Encoder inputs (ECAM, follower, etc.) single-ended, unbuffered
• Tachometer (available on request)
• Potentiometer (available on request)
• The Gold Hornet provides 5 V supply voltage (5 V, 2 x 200 mA max) for the encoders,
Resolver or Hall supplies
2.2.9. Communications
• Fast and efficient EtherCAT and CAN networking
• EtherCAT Slave:
CoE (CAN over EtherCAT)
EoE (Ethernet over EtherCAT)
FoE (File over EtherCAT) for firmware download
Supports Distributed Clock
EtherCAT cyclic modes supported down to a cycle time of 250 μs
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• CAN (DS-301, DS-305, DS-402)
• Ethernet TCP/IP
UDP
Telnet
• USB 2.0
• RS-232 (TTL logic level)
2.2.10. Safety
• IEC 61800-5-2, Safe Torque Off (STO)
Two STO (Safe Torque Off) inputs
Optically isolated
TTL Level (5 V logic)
Open collector and open emitter
• UL 508C recognition
17
• UL 60950 compliance
• CE EMC compliance
2.2.11. Outputs
• Two separate programmable digital outputs, optically isolated (open collector) one with
fast output compare (OC)
Output level: up to 30 V
Open collector and open emitter
• Three differential outputs:
Port C EIA-422 differential output line transmitters
Response time < 1 μs
Output current: ± 15 mA
2.2.12. Inputs
• Six separate programmable digital inputs, optically isolated
TTL Level (5 V logic)
Optically isolated
Fast digital capture data <5 μs
• One Analog input: ± 10 V
• Six very fast differential event capture inputs 5 V logic
Via Port A or B (three on each port, depending on model)
EIA-422 Differential input line receiver
Response time < 1 μs
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2.2.13. Built-In Protection
• Software error handling
• Abort (hard stops and soft stops)
• Extensive status reporting
• Protection against:
Shorts between motor power outputs
Shorts between motor power outputs and power input/return
Failure of internal power supplies
Overheating
• Continuous temperature measurement. Temperature can be read on-the-fly; a warning can
be initiated x degrees before temperature disable is activated.
Over/under voltage
Loss of feedback
Following errors
Current limits
18
2.2.14. Status Indication
• Output for a bi-color LED
2.2.15. 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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2.3. System Architecture
19
Figure 1: Gold Hornet System Block Diagram
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2.4. How to Use this Guide
In order to install and operate your Elmo Gold 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 Gold Hornet.
• Chapter 4 - Technical Specifications, lists all the drive ratings and specifications.
Upon completing the instructions in this guide, your Gold 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 Gold Product Line Software Manual, which describes the comprehensive software used
with the Gold Hornet.
• The Gold Product Line Command Reference Manual, which describes, in detail, each
software command used to manipulate the Gold Hornet motion controller.
20
• The Elmo Application Studio Software Manual, which includes explanations of all the
software tools that are part of the Elmo Application Studio software environment.
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Chapter 3: Technical Information
Gold Hornet Installation Guide (EtherCAT and CAN) Technical Information
21
3.1. Physical Specifications
Feature Units All Types
Weight g (oz) 55 g (1.94 oz)
Dimension mm (in) 55 x 46 x 15 mm (2.2" x 1.8" x 0.6")
Mounting method PCB mount
3.2. 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
Efficiency at rated power (at
nominal conditions)
Maximum output voltage > 95% of DC bus voltage at f = 22 kHz
Auxiliary power supply VDC 12 to 95 VDC
Amplitude sinusoidal/DC
continuous current
Sinusoidal continuous RMS
current limit (Ic)
Peak current limit A 2 x Ic
Digital in/Digital out/Analog in 6/2/1
W 80 200 400 800 1200 1600
% > 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 Hornet 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.
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Elmo now offers a 200 VDC maximum output rating selection of Gold Hornet, 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
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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
Digital in/Digital out/Analog in 6/2/1
3.2.1. Auxiliary Supply
Feature Details
Auxiliary power supply Isolated DC source only
Auxiliary supply input voltage 12 to 95 V
Auxiliary supply input power ≤4 VA without external loading
≤6 VA with full external loading
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Chapter 4: Installation
Gold Hornet Installation Guide (EtherCAT and CAN) Installation
The Gold 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 Gold Hornet 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 2,000 m (6562 feet)
Maximum non-condensing humidity 95%
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Operating area atmosphere No flammable gases or vapors permitted in area
Caution:
The Gold Hornet dissipates its heat by convection. The maximum ambient operating
temperature of –40 °C to +70 °C (-40 °F to +160 °F) must not be exceeded.
4.2. Unpacking the Drive Components
Before you begin working with the Gold Hornet, verify that you have all of its components, as
follows:
• The Gold Hornet servo drive
• The Elmo Application Studio (EAS) software and software manual
The Gold Hornet is shipped in a cardboard box with Styrofoam protection.
To unpack the Gold 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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Gold Hornet Installation Guide (EtherCAT and CAN) Installation
3. To ensure that the Gold Hornet you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Gold Hornet. It looks like
this:
4. Verify that the Gold Hornet type is the one that you ordered, and ensure that the voltage
meets your specific requirements.
The part number at the top gives the type designation as follows:
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Gold Hornet Installation Guide (EtherCAT and CAN) Installation
4.3. Connectors
The Gold Hornet has nine connectors.
4.3.1. Connector Types
Port Pins Type Function Connector Location
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J2 2x24
1.27 mm
pitch
Feedbacks, Digital Halls,
Analog Inputs,
Communications
0.41 mm sq
J1 2x12 I/O, LEDs, STO
M3 1x2
Motor power output 3
M2 1x2 Motor power output 2
M1 1x2 Motor power output 1
PE 1x2 Protective earth
2 mm pitch
0.51 mm sq
PR 1x2 Power input return
VP+ 1x2 Positive power input
VL+ 1x1 Auxiliary power input
Table 2: Connector Types
4.3.2. Pinouts
The pinouts in this section describe the function of each pin in the Gold Hornet connectors that
are listed in Table 2.
4.3.2.1. Motor Power
For full details see Section 4.7.1.
Pin Function Cable Pin Positions
PE Protective earth Motor Motor
M1 Motor phase Motor N/C
M2 Motor phase Motor Motor
M3 Motor phase Motor Motor
Connector Type: 2 mm pitch 0.51 mm sq
Brushless
Motor
Brushed DC
Motor
Table 3: Motor Connector
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Gold Hornet Installation Guide (EtherCAT and CAN) Installation
4.3.2.2. Main Power
For full details see Section 4.7.2.
Pin Function Cable Pin Positions
VP+ Pos. Power input Power
PR Power return Power
PE Protective earth Power
Connector Type: 2 mm pitch 0.51 mm sq
Table 4: Connector for Main Power
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4.3.2.3. Auxiliary Power Connector
For full details see Section 4.7.2.2.
Pin Function Pin Positions
VL+ Auxiliary Supply Input
PR Auxiliary Supply Return
Connector Type: 2 mm pitch 0.51 mm sq
Table 5: Auxiliary Supply Pins
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Feedback A/B/C, Digital Halls – see
Gold Hornet Installation Guide (EtherCAT and CAN) Installation
4.3.2.4. Connector J2
27
Section 4.7.
Analog Inputs – see Section 4.9.4.
RS-232, EtherCAT, USB – see Section 4.11.
Connector Type: 1.27 mm pitch 0.41 mm sq
Note regarding the EtherCAT and CAN communication options:
The J2 Connector exports all supported communication links. However, note that CAN and
EtherCAT are not available in the same version of the Gold Hornet and are thus not operational
simultaneously. See the part number diagram in Section 4.2 above for the different Gold
Hornet configurations.
Pin (J2) Signal Function
1 PortA_ENC_A+ /ABS_CLK+ Port A- channel A/ Absolute encoder clock+
2 PortC_ENCO_A- Port C- channel A complement output
3 PortA_ENC_A-/ABS_CLK- Port A- channel A complement / Absolute
4 PortC_ENCO_A+ Port C- channel A output
5 PortA_ENC_B+/ABS_DATA+ Port A - channel B/ Absolute encoder Data+
6 PortC_ENCO_B- Port C - channel B complement output
encoder clock-
7 PortA_ENC_B-/ABS_DATA- Port A - channel B complement / Absolute
encoder Data-
8 PortCENCO_B+ Port C - channel B output
9 PortA_ENC_INDEX+ Port A – index
10 PortC_ENCO_INDEX- Port C - index complement output
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