ElmoMC Gold Hornet User Manual

Gold Hornet

Digital Servo Drive

Installation Guide

EtherCAT and CAN

August 2014 (Ver. 1.007)

www.elmomc.com

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: [phone] • Fax: [phone] •

[e-mail]

North America

Elmo Motion Control Inc.

42 Technology Way, Nashua, NH 03060
USA

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

Europe

Elmo Motion Control GmbH

Hermann-Schwer-Strasse 3, 78048 VS-Villingen
Germany

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

China

Elmo Motion Control Technology (Shanghai) Co. Ltd.

Room 1414, Huawen Plaza, No. 999 Zhongshan West Road, Shanghai (200051)
China

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

Asia Pacific

Elmo Motion Control APAC Ltd.

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

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

MAN-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

6

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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Gold Hornet Installation Guide (EtherCAT and CAN) Product Description

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

22

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%

23

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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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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4.3. Connectors

The Gold Hornet has nine connectors.

4.3.1. Connector Types

Port Pins Type Function Connector Location

25

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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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

26

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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Pin (J2) Signal Function

11 PortA_ENC_INDEX- Port A - index complement

12 PortC_ENCO_INDEX+ Port C - index output

13 PortB_ENC_A+/SIN+ Port B - channel A

14 HC Hall sensor C input

15 PortB_ENC_A-/SIN- Port B - channel A complement

16 HB Hall sensor B input

17 PortB_ENC_B+/COS+ Port B - channel B

18 HA Hall sensor A input

19 PortB_ENC_B-/COS- Port B - channel B complement

20 ANARET Analog return

21 PortB_ENC_INDEX+/ANALOG_I+ Port B – index

28

RESOLVER_OUT+ Vref

22 ANALOG1+ Analog input 1

23 PortB_ENC_INDEX-/ANALOG_I- Port B – index complement

RESOLVER_OUT- Vref complement

24 ANALOG1- Analog input 1 complement

25 COMRET Common return

26 +3.3V 3.3 V supply voltage for EtherCAT LEDs

Note: The pin connector should only be

used for the 3.3V EtherCAT LED and
EtherCAT RJ-45.

27 PHY_IN_RX+ EtherCAT In receive

28 EtherCAT: PHY_OUT_RX+ EtherCAT Out receive

CAN: Reserved Reserved

29 PHY_IN_RX- EtherCAT In receive complement

30 PHY_OUT_RX- EtherCAT Out receive complement

31 COMRET Common return

32 COMRET Common return

33 PHY_IN_TX+ EtherCAT In transmit

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Pin (J2) Signal Function

34 EtherCAT: PHY_OUT_TX+ EtherCAT Out transmit

CAN: Reserved Reserved

35 PHY_IN_TX- EtherCAT In transmit complement

36 EtherCAT: PHY_OUT_TX- EtherCAT Out transmit complement

CAN: Reserved Reserved

37 PHY_IN_LINK_ACT EtherCAT In active LED

38 EtherCAT: PHY_OUT_LINK_ACT EtherCAT Out active LED

CAN: CAN_L CAN_L BUS Line(dominant low)

39 PHY_IN_SPEED EtherCAT In Speed LED

40 EtherCAT: PHY_OUT_SPEED EtherCAT Out Speed LED

CAN: CAN_H CAN_H BUS Line(dominant high)

29

41 USBD- USB data complement

42 USBD+ USB data

43 COMRET Common return

44 USB_VBUS USB VBUS 5V

45 RS232_RX RS232 receive

46 COMRET Common return

47 +5VE Encoder +5 V supply

48 RS232_TX RS232 transmit

Table 6: Connector J2 – Feedback and Analog Input

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4.3.2.5. Connector J1

30

I/O, LEDs, STO (safety)

For full details on user I/Os, see Section

For full details on STO, see Section 4.8.

Connector Type: 1.27 mm pitch 0.41 mm sq

Pin (J1) Signal Function

1 Reserved Reserved

2 Reserved Reserved

4.10.

3 INRET1_6 Programmable digital inputs 1–6 return

4 IN1 Programmable digital input 1 (high speed)

5 IN2 Programmable digital input 2 (high speed)

6 IN3 Programmable digital input 3 (high speed)

7 IN4 Programmable digital input 4 (high speed)

8 IN5 Programmable digital input 5 (high speed)

9 IN6 Programmable digital input 6 (high speed)

10 STO_RET Safety signal return

11 STO2 Safety 2 input

12 STO1 Safety 1 input

13 LED_ETHERCAT ERR LED Status EtherCAT ERR

14 LED_ETHERCAT RUN LED Status EtherCAT RUN

15 OUT2 Programmable output 2

16 OUT1 Programmable output 1

17 OUTRET2 OUT 2 return

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Pin (J1) Signal Function

18 OUTRET1 OUT 1 return

19 LED2 Bi-color indication output 2 (Cathode)

20 LED1 Bi-color indication output 1 (Anode)

21 OUT4 Programmable output 4 not isolated

(3.3V TTL level)

22 OUT3 Programmable output 3 not isolated

(3.3V TTL level)

23 COMRET Common return

24 Reserved Reserved

Table 7: Connector J1 – I/O, LEDs

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4.4. Mounting the Gold Hornet

The Gold Hornet was designed for mounting on a printed circuit board (PCB) via 1.27 mm pitch

0.41 mm square pins and 2 mm pitch 0.51 mm square pins. When integrating the Gold Hornet
into a device, be sure to leave about 1 cm (0.4") outward from the heat sink to enable free air
convection around the drive. We recommend that the Gold Hornet be soldered directly to the
board. Alternatively, though this is not recommended, the Gold Hornet can be attached to
socket connectors mounted on the PCB. If the PCB is enclosed in a metal chassis, we
recommend that the Gold Hornet be screw-mounted to it as well to help with heat dissipation.
The Gold Hornet has screw-mount holes on each corner of the heat sink for this purpose – see
below.

32

All measurements are in mm

Figure 2: Gold Hornet Dimensions

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When the Gold Hornet is not connected to a metal chassis, the application’s thermal profile
may require a solution for heat dissipation due to insufficient air convection. In this case, we
recommend that you connect an external heat sink. Elmo has an external heat sink (Catalog
number: WHI-HEATSINK-2) that can be ordered for this purpose, see Figure 3 below.

Figure 3: Gold Hornet External Heat Sink

33

4.5. Integrating the Gold Hornet on a PCB

The Gold Hornet is designed to be mounted on a PCB, either by soldering its pins directly to the
PCB or by using suitable socket connectors. Refer to the Gold Line Whistle Design Guide MAN­G-WHIIDG for further information.

4.5.1. Grounds and Returns

The returns in each functional block are listed below:

Functional Block Return Pin

Power PR (Power Return)

Internal Switch Mode P.S. PR (Power Return)

Analog input return ANLRET (J2/20)

Common return COMRET (J2/25,31,32,43,46; J1/23)

STO safety signal return STO_RET (J1/10)

Input Return IN_RET (J1/3)

Table 8: Grounds and Returns

The returns above are all shorted within the Gold Hornet in a topology that results in optimum
performance.

Caution:
Follow these instructions to ensure safe and proper implementation. Failure
to meet any of the below-mentioned requirements can result in drive,
controller or host failure.

1. When wiring the traces of the above functions, on the Integration Board, the Returns of
each function must be wired separately to its designated terminal on the Gold Hornet. DO

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NOT USE A COMMON GROUND PLANE. Shorting the commons on the Integration Board
may cause performance degradation (ground loops, etc).

2. Digital Inputs: The six digital inputs are optically isolated from the other parts of the Gold
Hornet. All six inputs share one return line, INRET. To retain isolation, the Input Return pin
and all other conductors on the input circuit must be laid out separately.

3. STO: The two digital STO inputs are optically isolated from the other parts of the Gold
Hornet, and share one return line, STO_RET. To retain isolation, the Input Return pin and all
other conductors on the input circuit must be laid out separately

4. Digital Outputs: The two digital outputs are optically isolated from the other parts of the
Gold Hornet. To retain isolation, all the output circuit conductors must be laid out
separately.

5. Return Traces: The return traces should be as large as possible, but without shorting each
other, and with minimal cross-overs.

6. Main Power Supply and Motor Traces: The power traces must be kept as far away as
possible from the feedback, control and communication traces.

34

7. PE Terminal: The PE (Protective Earth) terminal is connected directly to the Gold Hornet’s
heat-sink which serves as an EMI common plane. The PE terminal should be connected to
the system's Protective Earth. Any other metallic parts (such as the chassis) of the assembly
should be connected to the Protective Earth as well.

8. Under normal operating conditions, the PE trace carries no current. The only time these
traces carry current is under abnormal conditions (such as when the device has become a
potential shock or fire hazard while conducting external EMI interferences directly to
ground). When connected properly the PE trace prevents these hazards from affecting the
drive.

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4.6. The Gold Hornet Connection Diagram

35

Figure 4: The Gold Hornet Connection Diagram

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4.7. Main Power, Auxiliary Power and Motor Power

The Gold Hornet receives power from main and auxiliary supplies and delivers power to the
motor.

4.7.1. Motor Power

Note: When connecting several drives to several similar motors, all should be wired in an

identical manner. This will enable the same settings to run on all drives.

Pin Function Cable Pin Positions

36

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

Table 9: Motor Connector

Connect the M1, M2, M3 and PE pins on the Gold Hornet in the manner described in Section

4.3.2.1. The phase connection is arbitrary as the Elmo Application Software (EAS) will

automatically establish the proper commutation during setup. However, if you plan to copy the
setup to other drives, then the phase order on all the drives must be the same.

Figure 5: Brushless Motor Power Connection Diagram

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Figure 6: DC Brushed Motor Power Connection Diagram

4.7.2. Main and Auxiliary Power

This section describes the Main and Auxiliary Power for power ratings 200V and 100V, and
provides details for the optional Backup (Auxiliary) Supply.

37

4.7.2.1. Main Power

Pin Function Cable Pin Positions

VP+ Pos. Power input Power

PR Power return Power

PE Protective earth Power

Table 10: Connector for Main Power

Power to the Gold Hornet is provided by a 12 to 195 VDC source.

Connect the DC power cable to the VP+ and PR terminals on the Main Power Connector.

Notes for connecting the DC power supply

• The source of the 12 to 195 VDC power supply must be isolated.

• 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.

• Connect the cable shield to the closest ground connection near the power supply.

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• Connect the PE to the closest ground connection near the power supply.

• Connect the PR to the closest ground connection near the power supply.

• Before applying power, first verify the polarity of the connection.

4.7.2.2. Auxiliary Power Supply (Optional)

Note: The source of the Auxiliary Supply must be isolated.

Connect the VL+ and PR pins on the Gold Hornet in the manner described in Section 4.3.2.1.

Pin Function Pin Positions

VL+ Auxiliary Supply Input

PR Auxiliary Supply Return

38

Table 11: Auxiliary Supply Pins

Caution:

Power from the Gold Hornet 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.

Notes for auxiliary supply connections:

• The source of the Auxiliary Supply must be isolated.

• For safety reasons, connect the return (common) of the auxiliary supply source to the

closest ground near the auxiliary supply source

• Connect the cable shield to the closest ground near the auxiliary supply source

• Before applying power, first verify the polarity of the connection.

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4.7.2.3. 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.

39

Figure 7: 200 VDC Power Source Connection Diagram

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4.7.2.4. Power Rating 100 V

4.7.2.4.a Single Power Supply

For power rating 100 V , a single Power Supply is required which contains a “smart” control­supply algorithm, enabling the Gold Hornet to operate with only one power supply with no
need for an auxiliary power supply for the logic.

40

Figure 8: Main Power Supply Connection Diagram (no Auxiliary Supply)

4.7.2.4.b Separate Auxiliary (Backup) Supply

Power to the Auxiliary Supply can be provided by a separate Auxiliary Supply.

Figure 9: Separate Auxiliary Supply Diagram (Backup)

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4.7.2.4.c Shared Optional Backup Supply

A Main DC Power Supply can be designed to supply power to the drive’s logic as well as to the
Main Power (see Figure 8 and the upper portion of Figure 10). If backup functionality is
required for continuous operation of the drive’s logic in the event of a main power-out, a
backup supply can be connected by implementing “diode coupling” (see the Aux. Backup
Supply in Figure 10).

41

Figure 10: Separate Auxiliary Supply Connection Diagram

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4.8. STO (Safe Torque Off) Inputs

Activation of Safe Torque Off causes the drive to stop providing power that can cause rotation
(or motion in the case of a linear motor) to the motor.

This function may be used to prevent unexpected motor rotation (of brushless DC motors)
without disconnecting the drive from the power supply.

The motor is active only as long as 5 V is provided to both STO1 and STO2. Whenever any input
voltage is no longer present, power is not provided to the motor and the motor shaft continues
to rotate to an uncontrolled stop.

The STO inputs are latched which means that the motor can be re-enabled by a software
command only.

In circumstances where external influences (for example, falling of suspended loads) are
present, additional measures such as mechanical brakes are necessary to prevent any hazard.

This function corresponds to an uncontrolled stop in accordance with Stop Category 0 of IEC
60204-1.

42

Note: This function does not protect against electrical shock, and additional measures to

turn the power off are necessary.

The following table defines the behavior of the motor as a function of the state of the STO
inputs:

Signal – STO1 Signal – STO2 Function

Not Active Not Active Motor is disabled

Not Active Active Motor is disabled

Active Not Active Motor is disabled

Active Active Motor can be enabled

Table 12: Motor Behavior According to Safety Inputs

Note : In the Gold Hornet, STO1 also latches a software disable condition.

Pin (J1) Signal Function

12 STO1 Safety 1 input

11 STO2 Safety 2 input

10 STO_RET STO return

Table 13: STO Inputs Pin Assignments

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Figure 11: STO Input Functionality – Schematic Drawing

The figure below is for the TTL level.

43

Figure 12: STO Input Connection – TTL Level

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The figure below is for PLC.

44

Figure 13: STO Input Connection – PLC

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4.9. Feedback

Figure 14: Feedback Ports on J2

The Gold Hornet has two configurable motion sensor input ports, namely, Port A and Port B,
together with the emulated buffered output Port C. Motion sensors from the motor are
controlled from other sources and can be connected to any of the available inputs on Port A or
Port B.

45

The software configuration designates a role to each input, e.g., the incremental encoder on
port B is the controlled motor position feedback, the Hall sensors on port A are commutation
feedback, and the incremental encoder on port A is follower input.

For more information, about sensors and their use, refer to the Gold Line software manuals.

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4.9.1. Port A (J2)

Port A supports the following sensor inputs:

• Digital Hall sensors

• Incremental encoder or absolute serial encoder, depending on the specific model

Differential pulse-width modulation (PWM) signal input can be connected to port A in the
models that support input from an incremental encoder. The PWM signal can be connected to
the applicable pair of matching + and – encoder channels and is configurable by software.

Differential pulse and direction signal inputs can be connected to port A in the models that
support input from an incremental encoder. The signals can be connected to the applicable pair
of matching + and – encoder channels and are configurable by software.

46

Port A - Incremental Encoder

Port A - Absolute Serial Encoder

G-HORXXX/YYYYE/R G-HORXXX/YYYYE/R

Pin (J2) Signal Function Signal Function

47 +5V Encoder +5V

+5V Encoder +5V supply

supply

25 SUPRET Supply return SUPRET Supply return

1

3

5

7

9

11

14

16

PortA_ENC_A+ Channel A+ ABS_CLK+ Abs encoder clock +

PortA_ENC_A- Channel A- ABS_CLK- Abs encoder clock -

PortA_ENC_B+ Channel B+ ABS_DATA+ Abs encoder data +

PortA_ENC_B- Channel B- ABS_DATA- Abs encoder data -

PortA_ENC_Index+ Index+ Reserved Reserved

PortA_ENC_Index- Index- Reserved Reserved

HA Hall sensor A HA Hall sensor A

HB Hall sensor B HB Hall sensor B

18

HC Hall sensor C HC Hall sensor C

Table 14: Port A Pin Assignments

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4.9.1.1. Incremental Encoder

47

Figure 15: Port A Incremental Encoder Input – Recommended Connection Diagram

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4.9.1.2. Absolute Serial Encoder

48

Figure 16: Absolute Serial Encoder – Recommended Connection Diagram for Sensors

Supporting Data/Clock (e.g., Biss/SSI/EnDAT/ etc.)

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Figure 17: Absolute Serial Encoder – Recommended Connection Diagram for Sensors

Supporting Data Line Only (NRZ types, e.g., Panasonic / Mitutoyo / etc.)

4.9.1.3. Hall Sensors

Figure 18: Hall Sensors Connection Diagram

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4.9.2. Port B (J2)

Port B supports any of the following sensors:

• Incremental encoder, interpolated analog encoder or analog Hall sensors

Or:

• Resolver (separate hardware option)

Differential PWM signal input can be connected to port B in the models that support input from
an incremental encoder. The PWM signal can be connected to the applicable pair of matching +
and – encoder channels and is configurable by software.

Differential pulse and direction signal inputs can be connected to port B in the models that
support input from an incremental encoder. The signals can be connected to the applicable pair
of matching + and – encoder channels and are configurable by software.

50

Port B - Incremental or

Port B - Resolver

Interpolated Analog Encoder

G-HOR XXX/YYYYE G-HOR XXX/YYYYR

Pin (J2) Signal Function Signal Function

47 +5V Encoder +5V supply NC

25 SUPRET Supply return SUPRET Supply return

13 PortB_ENC_A+/ SIN+ Channel A+ / Sine+ SIN+ Sine+

15 PortB_ENC_A-/ SIN- Channel A- / Sine- SIN- Sine-

17 PortB_ENC_B+/

Channel B+ / Cosine+ COS+ Cosine+

COS+

19 PortB_ENC_B-/ COS- Channel B - / Cosine - COS- Cosine-

21 PortB_ENC_INDEX+/

Analog_Index+

23 PortB_ENC_INDEX-/

Analog_Index-

Index +/
Analog_Index+

Index -/
Analog_Index-

RESOLVER_OUT+

RESOLVER_OUT-

Vref f=1/TS, 50 mA
Max.

Vref complement
f= 1/TS, 50 mA
Maximum

Table 15: Port B Pin Assignments

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4.9.2.1. Incremental Encoder

51

Figure 19: Port B Incremental Encoder Input – Recommended Connection Diagram

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4.9.2.2. Interpolated Analog Encoder

52

Figure 20: Port B - Interpolated Analog Encoder Connection Diagram

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4.9.2.3. Resolver

53

Figure 21: Port B – Resolver Connection Diagram

4.9.3. Port C – Emulated Encoder Output (J2)

Port C provides emulated encoder output derived from port A or port B feedback inputs, or
from internal variables. The output options are:

• Port A/B daisy chain (1:1) for incremental encoder

• Encoder emulation: Emulate any input sensor, digital or analog, or use to emulate an

internal variable such as virtual profiler.

• PWM output: any pair of outputs that is used as an encoder channel (e.g., channel A+ and
channel A-) can be configured by software to become PWM output.

• Pulse & Direction output: The output pins that are assigned as channel A and channel B
when used as encoder out can be configured by software to become pulse and direction
outputs, respectively.

This port is used when:

• The Gold Hornet is used as a current amplifier to provide position data to the position
controller.

• The Gold Hornet is used in velocity mode to provide position data to the position
controller.

• The Gold Hornet is used as a master in follower or ECAM mode.

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Pin (J2) Signal Function

2 PortC_ENCO_A- Buffered Channel A- output/Pulse-/PWM-

4 PortC_ENCO_A+ Buffered Channel A+ output / Pulse+/PWM+

6 PortC_ENCO_B- Buffered Channel B- output / Dir-

8 PortC_ENCO_B+ Buffered Channel B+ output / Dir+

10 PortC_ENCO_INDEX- Buffered Channel INDEX- output

12 PortC_ENCO_INDEX+ Buffered Channel INDEX+ output

Table 16: Port C Pin Assignment

54

Figure 22: Emulated Encoder Differential Output – Recommended Connection Diagram

4.9.4. Analog Input

An analog user input can be configured by software to be used as either tachometer velocity

sensor input or potentiometer position feedback. For connection diagrams refer to

Section 4.10.3.

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4.10. User I/Os

The Gold Hornet has six programmable digital inputs (J1), four digital outputs (J1) and one
analog input (J2).

4.10.1. Digital Inputs (J1)

Each of the pins below can function as an independent input. The inputs conform to the TTL
level.

Pin (J1) Signal Function

3 INRET1-6 Programmable inputs 1 - 6 return

4 IN1 High speed programmable input 1

(event capture, home, general purpose, RLS, FLS, INH)

5 IN2 High speed programmable input 2

(event capture, home, general purpose, RLS, FLS, INH)

55

6 IN3 High speed programmable input 3

(event capture, home, general purpose, RLS, FLS, INH)

7 IN4 High speed programmable input 4

(event capture, home, general purpose, RLS, FLS, INH)

8 IN5 High speed programmable input 5

(event capture, home, general purpose, RLS, FLS, INH)

9 IN6 High speed programmable input 6

(event capture, home, general purpose, RLS, FLS, INH)

Table 17: Digital Input Pin Assignments

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See Figure 23 for the TTL connection.

56

Figure 23: Digital Input Connection Diagram – TTL Level

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See the figure below for the PLC connection.

57

Figure 24: Digital Input Connection Diagram – PLC

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4.10.2. Digital Outputs (J1)

The outputs conform to the TTL level.

Pin (J1) Signal Function

16 OUT1 High speed programmable digital output 1, output

compare

15 OUT2 High speed programmable digital output 2, output

compare

18 OUTRET1 OUT 1 Return

17 OUTRET2 OUT 2 Return

Table 18: Digital Output Pin Assignment

58

Figure 25: Digital Output Connection Diagram – TTL Connection

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4.10.3. Analog Input

Pin (J2) Signal Function

22 ANALOG1+ Analog input 1+

24 ANALOG1- Analog input 1-

20 ANARET Analog return

Table 19: Analog Input Pin Assignment

59

Figure 26: Analog Input with Single-Ended Source

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4.11. Communications

The communication interface may differ according to the user’s hardware. The Gold Hornet can
communicate using the CAN open option:

Standard EtherCAT

G-HORXXX/YYYSX G-HORXXX/YYYEX

CAN EtherCAT

USB 2.0 USB 2.0

Ethernet RS-232 (TTL Logic Level)

RS-232 (TTL Logic Level)

Table 20: Gold Hornet Communication Option

For ease of setup and diagnostics of CAN communication, RS-232 and CAN may be used
simultaneously.

60

When the EtherCAT is connected, and FoE in operation, the USB cable connection

must be disconnected.

4.11.1. RS-232 Communication (J2)

The Gold Whistle provides RS-232 with TTL voltage level (Refer to the voltage level in the
technical specification in Section 5.7: Communications). Therefore, to implement standard RS-
232, you must add a RS-232 Line Driver/Receiver on the integration board in order to translate
the TTL logic level to the standard RS-232 voltage level.

The following table describes the Gold Whistle RS-232 pinout:

Pin (J2) Signal Function

45 RS232_Rx RS-232 receive (TTL logic level)

48 RS232_Tx RS-232 transmit (TTL logic level)

46 RS232_COMRET Communication return

Table 21: RS-232 Pin Assignments

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Figure 27 describes the RS-232 connection diagram:

Figure 27: RS-232 Connection Diagram

Note that Elmo does not recommend a specific manufacturer. The following is an example of
an RS-232 Line Driver/Receiver. The RS-232 Line Driver/Receiver operates with 3.3 V to 5 V VCC
Supply.

61

Figure 28: RS-232 – Translator Block Diagram

Notes for connecting the RS-232 communication cable:

• Connect the shield to the ground of the host (PC). Usually, this connection is soldered
internally inside the connector at the PC end. You can use the drain wire to facilitate
connection.

• The RS-232 communication port is non-isolated.

Ensure that the shield of the cable is connected to the shield of the connector used for RS-232
communications. The drain wire can be used to facilitate the connection.

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4.11.2. CAN Communication (J2)

Note that CAN functionality is not available if you have the EtherCAT version.

In order to benefit from CAN communication, the user must have an understanding of the basic
programming and timing issues of a CAN network.

Notes for connecting the CAN communication cable:

• Connect the shield to the ground of the host (PC). Usually, this connection is soldered
internally inside the connector at the PC end. You can use the drain wire to facilitate
connection.

• Ensure that the shield of the cable is connected to the shield of the connector used for
communications. The drain wire can be used to facilitate the connection.

• Make sure to have a 120-Ohm resistor termination at each of the two ends of the network
cable.

• The Gold Hornet’s CAN port is non-isolated.

62

Pin (J2) Signal Function

32 CAN_COMRET CAN Communication Return

38 CAN_L CAN_L bus line (dominant low)

40 CAN_H CAN_H bus line (dominant high)

Table 22: CAN Pin Assignments

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63

Figure 29: CAN Network Diagram

Caution: When installing CAN communication, ensure that each servo drive is

allocated a unique ID. Otherwise, the CAN network may “hang”.

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4.11.3. USB 2.0 Communication (J2)

The USB network consists of a Host controller and multiple devices. The Gold Hornet is a USB
device.

Notes for connecting the USB communication cable:

• Connect the shield to the ground of the host (PC). Usually, this connection is soldered
internally inside the connector at the PC end. You can use the drain wire to facilitate
connection.

• Ensure that the shield of the cable is connected to the shield of the connector used for
communications. The drain wire can be used to facilitate the connection.

Pin (J2) Signal Function

41 USBD- USB _N line

42 USBD+ USB _P line

43 USB COMRET USB Communication return

64

44 USB VBUS USB VBUS 5 V

Table 23: USB 2.0 Pin Assignments

Figure 30: USB Network Diagram

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4.11.4. EtherCAT Communication (J2)

To use EtherCAT and Ethernet communication with the Gold Hornet, it is required to use an
isolation transformer. The most common solution is to use RJ-45 connectors that include
transformer isolation.

This section describes how to connect the Gold Hornet’s EtherCAT interface using the above
mentioned connectors.

For other available options, please see Section 4.11.6.

Notes for EtherCAT Communication:

• The EtherCAT IN port can be configured as an Ethernet port for TCP/IP – see the EtherCAT
Manual.

• It is recommended to use CAT5e (or higher) cable. Category 5e cable is a high signal
integrity cable with four twisted pairs.

65

Pin (J2) Signal Function

26 +3.3V 3.3 V for EtherCAT LEDs

27 PHY_IN_RX+ EtherCAT IN RX+ Line

29 PHY_IN_RX- EtherCAT IN RX- Line

31 PHY_IN_COMRET EtherCAT IN Communication Return

33 PHY_IN_TX+ EtherCAT IN TX+ Line

35 PHY_IN_TX- EtherCAT IN TX- Line

37 PHY_IN_LINK_ACT Indicates EtherCAT LINK

39 PHY_IN_SPEED Indicates EtherCAT Speed

28 PHY_OUT_RX+ EtherCAT OUT RX+ Line

30 PHY_OUT_RX- EtherCAT OUT RX- Line

32 PHY_OUT_ COMRET EtherCAT OUT Communication return

34 PHY_OUT_TX+ EtherCAT OUT TX+ Line

36 PHY_OUT_TX- EtherCAT OUT TX- Line

38 PHY_OUT_LINK_ACT Indicates EtherCAT LINK

40 PHY_OUT_SPEED Indicates EtherCAT Speed

Table 24: EtherCAT - Pin Assignments

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66

Figure 31: EtherCAT Connection Schematic Diagram

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The diagram above ignores line interface for simplicity.

When connecting several EtherCAT devices in a network, the EtherCAT master must always be
the first device in the network. The output of each device is connected to the input of the next
device. The output of the last device may remain disconnected. If redundancy is required, the
output of the last device should be connected to the input of the EtherCAT master.

Figure 32: EtherCAT Network with no Redundancy

67

Figure 33: EtherCAT Network with Redundancy

4.11.5. Ethernet Communication (J2)

To use EtherCAT and Ethernet communication with the Gold Hornet, it is required to use an
isolation transformer. The most common solution is to use RJ-45 connectors that include
transformer isolation.

This section describes how to connect the Gold Hornet Ethernet interface using the above
mentioned connectors.

For other available options, please see Section 4.11.6.

Notes for Ethernet Communication:

• The EtherCAT IN port can be configured as an Ethernet port for TCP/IP – see the EtherCAT
Manual.

• It is recommended to use CAT5e (or higher) cable. Category 5e cable is a high signal
integrity cable with four twisted pairs.

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Pin (J2) Signal Function

26 +3.3V 3.3 V supply voltage for LEDs

27 PHY_IN_RX+ Ethernet In receive

29 PHY_IN_RX- Ethernet In receive complement

31 PHY_IN_COMRET Ethernet In Communication return

33 PHY_IN_TX+ Ethernet In transmit

35 PHY_IN_TX- Ethernet In transmit complement

37 PHY_IN_LINK_ACT Ethernet In Link/Active LED

39 PHY_IN_SPEED Ethernet In Speed LED

Table 25: Ethernet - Pin Assignments

68

Figure 34: Ethernet Network Schematic Diagram

The diagram above ignores line interface for simplicity.

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4.11.6. EtherCAT/Ethernet Line Interface

Ethernet transceivers require either isolation transformers or capacitor coupling for proper
functioning. The Gold Hornet unit does not include such isolation, therefore you must take this
into consideration when designing the integration board.

In Sections 4.11.4 and 4.11.5, a schematic connection with a standard RJ-45 connector that
includes transformer isolation is described.

Other recommended connection options are:

• Gold Hornet to an RJ-45 connector without an integrated magnetic isolation (e.g. M12
connectors). An isolation transformer is required.

• Connecting two EtherCAT ports on the same board can be done using capacitive coupling
or transformer coupling.

For more detailed explanations, including layout recommendations and component selection
guidelines contact Elmo’s technical support.

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4.12. Powering Up

After the Gold Hornet is connected to its device, it is ready to be powered up.

Caution:
Before applying power, ensure that the DC supply is within the specified range
and that the proper plus-minus connections are in order.

4.13. Initializing the System

After the Gold Hornet has been connected and mounted, the system must be set up and
initialized. This is accomplished using the EAS, Elmo’s Windows-based software application.
Install the application and then perform setup and initialization according to the directions in
the EAS User Manual.

70

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Whistle

- 60

Series Power Dissipation

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

0

0

.

75

1

.

5

2

.

25

3

3

.

75

4

.

5

5

.

25

6

6

.

75

7

.

5

8

.

25

9

9

.

75

Peak Current (A)

Power Dissipation (Watts

50V
40V
30V
20V

Standard 40 °C Ambient Temp.

External

Heatsink

Gold Hornet

Gold Hornet Installation Guide (EtherCAT and CAN) Installation

4.14. Heat Dissipation

The best way to dissipate heat from the Gold Hornet is to mount it so that its heat sink faces
up. For best results leave approximately 10 mm of space between the Gold Hornet's heat sink
and any other assembly.

4.14.1. Thermal Data

• Heat dissipation capability (θ): Approximately 10 °C/W

• Thermal time constant: Approximately 240 seconds (thermal time constant means that the

Gold Hornet will reach 2/3 of its final temperature after 4 minutes)

• Shut-off temperature: 86 °C to 88 °C (measured on the heat sink)

4.14.2. Heat Dissipation Data

Heat Dissipation is shown in graphically below:

71

Heatsink
Required

not

Required

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100

Series Power Dissipation

0.0

1.0

2.0

3.0

4.0

5.0

6.0

0

0.511.522.5

3

3.5

4

4.5

5

Peak Current (A)

Power Dissipation (W)

85VDC
70VDC
50VDC

Standard 40 °C Ambient Temp.

External

Heatsink

Gold Hornet

Gold Hornet Installation Guide (EtherCAT and CAN) Installation

72

Heatsink

Required

not

Required

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4.14.3. How to Use the Charts

The charts above are based upon theoretical worst-case conditions. Actual test results show
30% to 50% better power dissipation.

To determine if your application needs a heat sink:

1. Allow maximum heat sink temperature to be 80 °C or less.

2. Determine the ambient operating temperature of the Gold Hornet.

3. Calculate the allowable temperature increase as follows:

 for an ambient temperature of 40 °C , ΔT= 80 °C – 40 °C = 40 °C

4. Use the chart to find the actual dissipation power of the drive. Follow the voltage curve to
the desired output current and then find the dissipated power.

5. If the dissipated power is below 4 W the Gold Hornet will need no additional cooling.

Notes:

73

• The chart above shows that no heat sink is needed when the heat sink temperature is
80 °C, ambient temperature is 40 °C and heat dissipated is 4 W.

• When an external heat sink is required, you can use the Elmo external heat sink (Catalog
number: WHI-HEATSINK-2).

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Chapter 5: Technical Specifications

Gold Hornet Installation Guide (EtherCAT and CAN) Technical Specifications

This chapter provides detailed technical information regarding the Gold Hornet. This includes
its dimensions, power ratings, the environmental conditions under which it can be used, the
standards to which it complies and other specifications.

5.1. Dimensions

74

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5.2. Environmental Conditions

Feature Operation Conditions Range

75

Ambient

Non-operating conditions -50 °C to +100 °C (-58 °F to 212 °F)

Temperature
Range

Temperature
Shock

Operating conditions -40 °C to +70 °C (-40 °F to 160 °F)

Non-operating conditions -40 °C to +70 °C (-40 °F to 160 °F)

within 3 min.

Altitude Non-operating conditions Unlimited

Operating conditions -400 m to 12,000 m (-1312 to 39370 feet)

Maximum
Humidity

Non-operating conditions Up to 95% relative humidity non-

condensing at 35 °C (95 °F)

Operating conditions Up to 95% relative humidity non-

condensing at 25 °C (77 °F), up to 90%

relative humidity non-condensing at 42 °C
(108 °F)

Vibration Operating conditions 20 Hz to 2,000 Hz, 14.6g

Mechanical

Non-operating conditions ±40g; Half sine, 11 msec

Shock

Operating conditions ±20g; Half sine, 11 msec

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5.3. Control Specifications

5.3.1. Current Loop

Feature Details

Controller type Vector, digital

76

Compensation for bus voltage

“On-the-fly” automatic gain scheduling

variations

Motor types

• AC brushless (sinusoidal)

• DC brushless (trapezoidal)

• DC brush

• Linear motors

• “Voice” coils

Current control

• Fully digital

• Sinusoidal with vector control

• Programmable PI control filter based on a

pair of PI controls of AC current signals and
constant power at high speed

Current loop bandwidth > 4 kHz closed loop

Current loop sampling time

Programmable 40 to 120 µsec

Current sampling rate Up to 25 kHz; default 20 kHz

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5.3.2. Velocity Loop

Feature Details

Controller type PI + Four advanced filters + Two advanced gain

scheduling filters

77

Velocity control

• Fully digital

• Programmable PI and feed forward control filters

• On-the-fly gain scheduling according to either

speed or position command or feedback

• Automatic, quick, advanced or expert tuning

Velocity and position feedback
options

• Incremental Encoder

• Digital Halls

• Interpolated Analog (sin/cos) Encoder (optional)

• Resolver (optional)

• Absolute serial encoder

Note: With all feedback options, 1/T with automatic

mode switching is activated (gap, frequency and
derivative).

Velocity loop bandwidth < 500 Hz

Velocity loop sampling time

80 to 240 µsec (2x current loop sample time)

Velocity loop sampling rate Up to 12.5 kHz; default 10 kHz

Velocity command options Internally calculated by either jogging or step

Note: All software-calculated profiles support

on-the-fly changes.

5.3.3. Position Loop

Feature Details

Controller type “1-2-2” PIP + three advanced filters + one advanced

gain scheduling filter

Position command options

Position loop bandwidth < 200 Hz

Position loop sampling time

Position loop sampling rate Up to 12.5 kHz; default 10 kHz

• Software

• Pulse and Direction

80 to 240 µsec (2x current loop sample time)

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5.4. Feedbacks

5.4.1. Feedback Supply Voltage

The Gold Hornet has two feedback ports (Main and Auxiliary). The Gold Hornet supplies voltage
only to the main feedback device and to the auxiliary feedback device if needed.

Feature Details

Main encoder supply voltage 5 V +5% @ 200 mA maximum

5.4.2. Feedback Options

The Gold Hornet can receive and process feedback input from diverse types of devices.

5.4.2.1. Incremental Encoder Input

Feature Details

78

Encoder format

• A, B and Index

• Differential

• Quadrature

Interface RS-422

Input resistance

Differential: 120 Ω

Maximum incremental encoder frequency Maximum absolute: 75 Megacounts per

second (18 MHz PPS (Pulses Per Second))

Minimum quadrature input period (PIN) 53 nsec

Minimum quadrature input high/low period

26 nsec

(PHL)

Minimum quadrature phase period (PPH) 13 nsec

Maximum encoder input voltage range

Common mode: ± 7 V
Differential mode: ± 7 V

Figure 35: Main Feedback - Encoder Phase Diagram

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5.4.2.2. Digital Halls

Feature Details

79

Hall inputs

• H

, HB, HC

A

• Single ended inputs

• Built in hysteresis of 1 V for noise

immunity

Input voltage Nominal operating range: 0 V < V

Maximum absolute: -1 V < V
High level input voltage: V
Low level input voltage: V

InLow

In_Hall

InHigh

In_Hall

< 15 V

> 2.5 V

< 1 V

Input current Sink current (when input pulled to the

common): 5 mA

Maximum frequency f

: 4 kHz

MAX

5.4.2.3. Interpolated Analog (Sine/Cosine) Encoder

Feature Details

Analog encoder format Sine and Cosine signals

Analog input signal level

• Offset voltage: 2.2 V to 2.8 V

< 5 V

• Differential, 1 V peak to peak

Input resistance

Maximum analog signal frequency f

Differential: 120 Ω

: 500 kHz

MAX

Interpolation multipliers Programmable: x4 to x8192

Maximum “counts” frequency 2 x 10

Automatic errors correction

9

counts/sec

• Signal amplitudes mismatch

• Signal phase shift

• Signal offsets

Encoder outputs See Port C Encoder Outputs Specifications,

Section 5.4.3.

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5.4.2.4. Resolver

Feature Details

80

Resolver format

• Sine/Cosine

• Differential

Input resistance

Differential 2.49 kΩ

Resolution Programmable: 10 to 15 bits

Maximum electrical frequency (RPS) 512 revolutions/sec

Resolver transfer ratio 0.5

Reference frequency 1/Ts (Ts = sample time in seconds)

Reference voltage Supplied by the Gold Hornet

Reference current up to ±50 mA

Encoder outputs See Port C Encoder Output Specifications,

Section 5.4.3.

5.4.2.5. Absolute Serial Encoder

Feature Details

Encoder format

• NRZ (Panasonic, Tamagawa, Mitutoyo,
etc.)

• EnDAT 2.2

• BiSS/SSI

• Stegmann Hiperface

Interface

• RS-485

• Clock – Differential output line

• Data – Differential bidirectional line

Input Resistance

Differential 120 Ω

Transmission Rate Up to 2.5 MHz

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5.4.3. Port C Feedback Output

Feature Details

81

Emulated output

• A, B, Index

• Differential

Interface

• RS-422

Output current capability Maximum output current: IOH (max) = 2 mA

> 3.0 V

OH

= 2 mA

OL

< 0.4 V

OL

Available as options

High level output voltage: V

Minimum output current: I

Low level output voltage: V

• Emulated encoder output of any sensor
on Port A or Port B

• Daisy chain Port A or Port B

• Emulated encoder output of internal

variables

• Emulated encoder outputs of the
tachometer

• Emulated encoder outputs of the
potentiometer

Maximum frequency f

: 8 MHz pulses/output

MAX

Edge separation between A & B Programmable number of clocks to allow

adequate noise filtering at remote receiver
of emulated encoder signals (default 2 MHz)

Index (marker) Length of pulse is one quadrature (one

quarter of an encoder cycle) and
synchronized to A&B

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5.5. I/Os

The Gold Hornet has:

• 6 Digital Inputs

• 2 Digital Outputs

• 1 Analog Input

5.5.1. Digital Input Interfaces – TTL Mode

Feature Details

Type of input Optically isolated

Input current for all inputs Iin = 3.8 mA @ Vin = 5 V

High-level input voltage 2.4 V < Vin < 15 V, 5 V typical

Low-level input voltage 0 V < Vin < 0.8 V

82

Minimum pulse width

Execution time (all inputs):
the time from application of
voltage on input until execution is
complete

High-speed inputs – 1–6 minimum
pulse width, in high-speed mode

> 250 µsec

0 < T < 250 µsec

T > 5 µsec if the input functionality is set to
latch/capture (index/strobe).

Notes:

• Home mode is high-speed mode and can be used
for fast capture and precise homing.

• Highest speed is achieved when turning on
optocouplers.

Figure 36: Digital Input Schematic

Capture with differential input

Port A, Port B Index

T > 0.1 µsec if the differential input functionality is set
to touch probe/capture (index/strobe).

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5.5.2. Digital Output Interface – TTL Mode

There are 2 types of outputs:

• OUT1 and OUT2 are optically isolated outputs

• OUT3 and OUT4 are TTL 3.3V non isolated outputs

5.5.2.1. OUT1 and OUT2

The following table describes the electrical specification of theOUT1 and OUT2 outputs:

Feature Details

83

Type of output

• Optically isolated

• Source/Sink

Supply output (VCC) 5 V to 30 V

Max. output current
I

(max) (V

out

= Low)

out

VOL at maximum output voltage

7 mA

V

(on) ≤ 0.4 V

out

(low level)

RL The external resistor RL must be selected to limit the

output current to no more than 7 mA.

Executable time

0 < T < 250 µsec

Figure 37: Digital Output Schematic

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5.5.2.2. OUT3 and OUT4

These outputs are 3.3V TTL outputs. The following table describes the electrical specification of
the outputs:

Feature Details

Type of output 3.3V TTL

84

VOL max (low level) V

(on) ≤ 0.4 V

out

VOH min (High level) 2.5V

Max. output current
I

(max)

outH

8 mA

5.5.3. Analog Input

Feature Details

Maximum operating differential voltage ± 10 V

Maximum absolute differential input voltage ± 16 V

Differential input resistance 3.74 kΩ

Analog input command resolution 12-bit

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5.6. Safe Torque Off (STO)

The Gold Whistle has two STO (Safe Torque Off) inputs.

5.6.1. STO Input Interfaces – TTL Mode

Feature Details

Type of input Optically isolated

Input current for all inputs Iin = 3.8 mA @ Vin = 5 V

High-level input voltage 2.4 V < Vin < 15 V, 5 V typical

Low-level input voltage 0 V < Vin < 0.8 V

Minimum pulse width >3 ms

85

Figure 38: STO Input Schematic

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Electrical Characteristic

Min

Type

Max

Unit

VIH

High-level input voltage

2 3.3 V VIL

Low-level input voltage

0.8 V VOH

High-level output voltage

2.4 V VOL

Low-level output voltage

0.4

V

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5.7. Communications

Specification Details

86

RS-232

CAN

Signals:

• RS232_Rx, RS232_Tx COMRET

• Full duplex, serial communication for setup and control

• Baud Rate of 9,600 to 57,600 bit/sec

CAN bus Signals:

• CAN_H, CAN_L, CAN_RET

• Maximum Baud Rate of 1 Mbit/sec.

Version:

• DS 301 v4.01

Layer Setting Service and Protocol Support:

• DS 305

Device Profile (drive and motion control):

• DS 402

EtherCAT

• 100base-T

• Baud Rate: 100 Mbit/sec

• CAT5 Cable

• CoE, FoE, EoE

Ethernet

• 100base-T

• Baud Rate: 100 Mbit/sec

• CAT5 Cable

• UDP, Telnet

USB

• USB 2.0 Device mode

5.8. Pulse-Width Modulation (PWM)

Feature Details

PWM resolution Minimum 10-bit

Default 12-bit

Maximum 14-bit

PWM switching frequency on the load 2/Ts (factory default 40 kHz on the motor)

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5.9. Compliance with Standards

Specification Details

Quality Assurance

ISO 9001:2008 Quality Management

Design

Approved IEC/EN 61800-5-1, Safety Printed wiring for electronic equipment

(clearance, creepage, spacing, conductors
sizing, etc.)

MIL-HDBK- 217F Reliability prediction of electronic equipment

(rating, de-rating, stress, etc.)

Printed wiring for electronic equipment

• IPC-SM-782

• IPC-CM-770

(clearance, creepage, spacing, conductors
sizing, etc.)

87

• UL 508C

• UL 840

• UL 60950

In compliance with VDE0160-7 (IEC 68) Type testing

Safety

Recognized UL 508C Power Conversion Equipment

In compliance with UL 840 Insulation Coordination Including Clearances

and Creepage Distances for Electrical
Equipment

In compliance with UL 60950 Safety of Information Technology Equipment

Including Electrical Business Equipment

Approved IEC/EN 61800-5-1, Safety Adjustable speed electrical power drive

systems

In compliance with EN 60204-1 Low Voltage Directive 73/23/EEC

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Specification Details

EMC

Approved IEC/EN 61800-3, EMC Adjustable speed electrical power drive

systems

88

In compliance with EN 55011 Class A with

Electromagnetic compatibility (EMC)
EN 61000-6-2: Immunity for industrial
environment, according to:

IEC 61000-4-2 / criteria B
IEC 61000-4-3 / criteria A
IEC 61000-4-4 / criteria B
IEC 61000-4-5 / criteria B
IEC 61000-4-6 / criteria A
IEC 61000-4-8 / criteria A
IEC 61000-4-11 / criteria B/C

Workmanship

In compliance with IPC-A-610, level 3 Acceptability of electronic assemblies

PCB

In compliance with IPC-A-600, level 2 Acceptability of printed circuit boards

Packing

In compliance with EN 100015 Protection of electrostatic sensitive devices

Environmental

In compliance with 2002/96/EC Waste Electrical and Electronic Equipment

regulations (WEEE)

Note: Out-of-service Elmo drives should be

sent to the nearest Elmo sales office.

In compliance with 2002/95/EC
(effective July 2006)

Restrictions on Application of Hazardous

Substances in Electric and Electronic

Equipment (RoHS)

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