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 Whistle servo
drive in its installation.
• The text and graphics included in this manual are for the purpose of illustration and
reference only. The specifications on which they are based are subject to change without
notice.
• Information in this document is subject to change without notice.
registered trademarks of Elmo Motion Control Ltd.
trademark and patented technology, licensed by Beckhoff
Automation GmbH, Germany.
Catalog Number
Document no. MAN-G-WHIIG (Ver. 1.208)
Copyright 2014
Elmo Motion Control Ltd.
All rights reserved.
Page 3
Revision History
Version Date Details
Ver. 1.0 September 2010 Initial release
Ver. 1.1 January 2010Several updates throughout the manual
Ver. 1.2 September 2012 Several corrections and updates to manual
Ver. 1.201 Several corrections and updates to manual
Ver. 1.202 Several corrections and updates to manual
Ver. 1.203 July 2012Several corrections and updates to manual
Ver. 1.204 January 2013Several corrections and updates to manual
Ver. 1.205 January 2013Added a caution and recommendation on the type of
cleaning solution to use for the Elmo unit.
Updated the supply output (VDD) voltage range value of
the Digital Output Interface for the TTL mode.
Updated Section 4.3.2.5: Connector J1 - table.
Added Section 3.1: Physical Specifications.
Ver. 1.206 March 2013 Section 3.2: Technical Data- updated the Power Ratings
table for the 200 VDC option.
Ver. 1.207 March 2014 Correction of diagram in section 4.4 Mounting the Gold
Whistle.
Ver. 1.208 July 2014 General format updates
Page 4
Elmo Worldwide
Head Office
Elmo Motion Control Ltd.
60 Amal St., P.O. Box 3078, Petach Tikva 49516
Israel
5.9. Compliance with Standards .......................................................................................... 84
7
Page 8
MAN-G-WHIIG (Ver . 1.208)
Chapter 1: Safety Information
Warning:
Caution:
Gold Whistle Installation Guide
In order to achieve the optimum, safe operation of the Gold Whistle 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 Whistle and accompanying equipment.
Please read this chapter carefully before you begin the installation process.
Before you start, ensure that all system components are connected to earth ground. Electrical
safety is provided through a low-resistance earth connection.
Only qualified personnel may install, adjust, maintain and repair the servo drive. A qualified
person has the knowledge and authorization to perform tasks such as transporting, assembling,
installing, commissioning and operating motors.
The Gold Whistle 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.
www.elmomc.com
Page 9
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideSafety 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 Whistle from all voltage sources before it is opened for servicing.
• The Gold Whistle 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 Whistle 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 Whistle 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 Whistle, 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 Whistle 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:
The Gold Whistle 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 508CPower Conversion Equipment
In compliance with UL 840Insulation 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 Whistle 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 Whistle 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 Whistle 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.
www.elmomc.com
Page 11
MAN-G-WHIIG (Ver . 1.208)
Chapter 2: Product Description
Gold Whistle Installation Guide
2.1. Functional Description
The Gold Whistle 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 Whistle has a fully featured motion controller and local intelligence.
The Gold Whistle operates from a DC power source. The drive can operate as a stand-alone
device or as part of a multi-axis system in a distributed configuration on a real-time network.
The Gold Whistle drive is easily set up and tuned using the Elmo Application Studio (EAS)
software tools. As part of the Gold product line, it is fully programmable with the Elmo motion
control language. For more information about software tools refer to the Elmo Application
Studio Software Manual.
The Gold Whistle 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.
11
2.2. Product Features
Note: The features described in this chapter relate to the range of Gold Whistle 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 Whistle and use the
product catalog number schematic that appears at the beginning of this manual and on
page 23 to determine which specific features are available to you.
2.2.1. High Power Density
The Gold Whistle delivers up to 1.6 kW of continuous power or 3.2 kW of peak power in a
38.0 cc (2.32 in³) package (55 x 46 x 15 mm or 2.2" x 1.8" x 0.6").
2.2.2. Supply Input
• Gold Whistle Power rating is 12 to 195 VDC
• Two power ratings for Gold Whistle; 100V and 200V:
For power rating 200V
Two power isolated DC power sources are required, main power 12 - 195V and
Auxiliary Power 12-95V for the logic.
For power rating of 100V
Single DC Power Supply - Power to the Gold Whistle is provided by a 12–95 VDC single
isolated DC power source (not included with the Gold Whistle). A “smart” control-
supply algorithm enables the Gold Whistle to operate with only one power supply with
no need for an auxiliary power supply for the logic.
Optional Backup (Auxiliary) Supply
If backup functionality is required in case of power loss, e.g., to keep the original
position, a 12–95 VDC external isolated supply should be connected (via the Gold
Whistle’s VL+ terminal). This is more flexible than the requirement for 24 VDC supply.
If backup is not needed, a single power supply is used for both the power and logic
circuits.
There are two voltage ratings of the Gold Whistle, therefore the correct power supply
must be used, according to the maximum operating voltage of the Gold Whistle. 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)
12
• Position sampling rate: up to 12.5 kHz (80 μs)
• Electrical commutation frequency: up to 4 kHz
• 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
• 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
• 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
14
• 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))
• 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
• The Gold Whistle 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 (CANopen 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
Shorts between motor power outputs
Shorts between motor power outputs and power input/return
Failure of internal power supplies
Over-heating
• 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 error
Current limits
In order to install and operate your Elmo Gold Whistle 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 Whistle.
• Chapter 4 - Technical Specifications, lists all the drive ratings and specifications.
Upon completing the instructions in this guide, your Gold Whistle 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 Whistle.
• The Gold Product Line Command Reference Manual, which describes, in detail, each
software command used to manipulate the Gold Whistle motion controller.
19
• The Elmo Application Studio Software Manual, which includes explanations of all the
software tools that are part of the Elmo Application Studio software environment.
www.elmomc.com
Page 20
MAN-G-WHIIG (Ver . 1.208)
Chapter 3: Technical Information
Gold Whistle Installation Guide
20
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: Technical Data
Note on current ratings: The current ratings of the Gold Whistle are given in units of DC
amperes (ratings that are used for trapezoidal commutation or DC motors). The RMS
(sinusoidal commutation) value is the DC value divided by 1.41.
www.elmomc.com
Page 21
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideTechnical Information
Elmo now offers a 200 VDC maximum output rating selection of Gold Whistle, according to the
following technical data:
Feature Units 3/200 6/200 9/200
Minimum supply voltage VDC 12
Nominal supply voltage VDC 170
Maximum supply voltage VDC 195
Maximum continuous power output W 480 960 1450
21
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
www.elmomc.com
Page 22
MAN-G-WHIIG (Ver . 1.208)
Chapter 4: Installation
Gold Whistle Installation Guide
The Gold Whistle 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 Whistle by ensuring that it is installed in an
appropriate environment.
Feature Value
22
Ambient operating temperature
Maximum non-condensing humidity 90%
Operating area atmosphere No flammable gases or vapors permitted in area
Models for extended environmental conditions are available.
Caution:
The Gold Whistle dissipates its heat by convection. The maximum ambient
operating temperature of 40 °C (104 °F) must not be exceeded.
0 °C to 40 °C (32 °F to 104 °F)
4.2. Unpacking the Drive Components
Before you begin working with the Gold Whistle, verify that you have all of its components, as
follows:
• The Gold Whistle servo drive
• The Elmo Application Studio (EAS) software and software manual
The Gold Whistle is shipped in a cardboard box with Styrofoam protection.
To unpack the Gold Whistle:
1. Carefully remove the servo drive from the box and the Styrofoam.
2. Check the drive to ensure that there is no visible damage to the instrument. If any damage
has occurred, report it immediately to the carrier that delivered your drive.
www.elmomc.com
Page 23
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
3. To ensure that the Gold Whistle you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Gold Whistle. It looks like
this:
4. Verify that the Gold Whistle 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:
23
www.elmomc.com
Page 24
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
4.3. Connectors
The Gold Whistle has nine connectors.
4.3.1. Connector Types
Port Pins Type Function Connector Location
24
J2 2x24 1.27 mm
pitch
0.41 mm sq
Feedbacks, Digital Halls,
Analog Inputs,
Communications
J1 2x12 I/O, LEDs, STO
M3 1x2 2 mm pitch
M2 1x2 Motor power output 2
0.51 mm sq
Motor power output 3
M1 1x2 Motor power output 1
PE 1x2 Protective earth
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 Whistle 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
www.elmomc.com
Page 25
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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
25
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
www.elmomc.com
Page 26
MAN-G-WHIIG (Ver . 1.208)
Feedback A/B/C, Digital Halls – see
Gold Whistle Installation Guide Installation
4.3.2.4. Connector J2
26
Section 4.9.
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 Whistle and are thus not
operational simultaneously. See the part number diagram in Section 4.2 above for the different
Gold Whistle 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
www.elmomc.com
Page 27
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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
27
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
www.elmomc.com
Page 28
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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)
28
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
www.elmomc.com
Page 29
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
4.3.2.5. Connector J1
29
I/O, LEDs, STO (safety)
For full details on user I/Os, see Section
4.10.
For full details on STO, see Section
Connector Type: 1.27 mm pitch 0.41 mm sq
Pin (J1) Signal Function
1 Reserved Reserved
2 Reserved Reserved
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)
4.8.
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
18 OUTRET1 OUT 1 return
www.elmomc.com
Page 30
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
Pin (J1) Signal Function
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
30
www.elmomc.com
Page 31
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
4.4. Mounting the Gold Whistle
The Gold Whistle 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 Whistle
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 Whistle be soldered directly to the
board. Alternatively, though this is not recommended, the Gold Whistle can be attached to
socket connectors mounted on the PCB. If the PCB is enclosed in a metal chassis, we
recommend that the Gold Whistle be screw-mounted to it as well to help with heat dissipation.
The Gold Whistle has screw-mount holes on each corner of the heat-sink for this purpose – see
below.
31
All measurements are in mm
Figure 2: Gold Whistle Dimensions
www.elmomc.com
Page 32
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
When the Gold Whistle 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 Whistle External Heat Sink
32
4.5. Integrating the Gold Whistle on a PCB
The Gold Whistle 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
MAN-G-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 Whistle 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 Whistle. DO
www.elmomc.com
Page 33
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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
Whistle. 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
Whistle, 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 Whistle. 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.
33
7. PE Terminal: The PE (Protective Earth) terminal is connected directly to the Gold Whistle’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.
www.elmomc.com
Page 34
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
4.6. The Gold Whistle Connection Diagram
34
Figure 4: The Gold Whistle Connection Diagram
www.elmomc.com
Page 35
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
4.7. Main Power, Auxiliary Power and Motor Power
The Gold Whistle 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
35
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 Whistle 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
www.elmomc.com
Page 36
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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.
4.7.2.1. Main Power
36
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 Whistle 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.
• 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.
www.elmomc.com
Page 37
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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 Whistle in the manner described in Section 4.3.2.1.
Pin Function Pin Positions
VL+ Auxiliary Supply Input
PR Auxiliary Supply Return
Table 11: Auxiliary Supply Pins
37
Caution:
Power from the Gold Whistle to the motor must come from the Main Supply
and not from the Auxiliary Supply.
The backup functionality can be used for storing control parameters in case of power-outs,
providing maximum flexibility and backup capability when needed.
Connect the VL+ and PR terminal to the Auxiliary Connector.
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.
www.elmomc.com
Page 38
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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.
38
Figure 7: 200 VDC Power Source Connection Diagram
www.elmomc.com
Page 39
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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 Whistle to operate with only one power supply with no
need for an auxiliary power supply for the logic.
39
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)
www.elmomc.com
Page 40
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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.
40
Figure 10: Separate Auxiliary Supply Connection Diagram
www.elmomc.com
Page 41
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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.
41
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 Whistle, 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
www.elmomc.com
Page 42
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
Figure 11: STO Input Functionality – Schematic Drawing
The figure below is for the TTL level.
42
Figure 12: STO Input Connection – TTL Level
www.elmomc.com
Page 43
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
The figure below is for PLC.
43
Figure 13: STO Input Connection – PLC
www.elmomc.com
Page 44
MAN-G-WHIIG (Ver . 1.208)
Port A
Port B
Port C
Gold Whistle Installation Guide Installation
4.9. Feedback
Figure 14: Feedback Ports on J2
The Gold Whistle 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.
44
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 Manual.
www.elmomc.com
Page 45
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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.
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
HC Hall sensor C HC Hall sensor C
HB Hall sensor B HB Hall sensor B
18
HA Hall sensor A HA Hall sensor A
Table 14: Port A Pin Assignments
www.elmomc.com
Page 46
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
4.9.1.1. Incremental Encoder
46
Figure 15: Port A Incremental Encoder Input – Recommended Connection Diagram
www.elmomc.com
Page 47
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
4.9.1.2. Absolute Serial Encoder
47
Figure 16: Absolute Serial Encoder – Recommended Connection Diagram for Sensors
Supporting Data/Clock (e.g., Biss / SSI / EnDAT, etc.)
www.elmomc.com
Page 48
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
48
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
www.elmomc.com
Page 49
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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.
Figure 19: Port B Incremental Encoder Input – Recommended Connection Diagram
www.elmomc.com
Page 51
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
4.9.2.2. Interpolated Analog Encoder
51
Figure 20: Port B - Interpolated Analog Encoder Connection Diagram
www.elmomc.com
Page 52
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
4.9.2.3. Resolver
52
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 Whistle is used as a current amplifier to provide position data to the position
controller.
• The Gold Whistle is used in velocity mode to provide position data to the position
controller.
• The Gold Whistle is used as a master in follower or ECAM mode.
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.
www.elmomc.com
Page 54
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
4.10. User I/Os
The Gold Whistle 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)
54
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
See Figure 23 for the TTL connection.
www.elmomc.com
Page 55
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
55
Figure 23: Digital Input Connection Diagram – TTL Level
See the figure below for the PLC connection.
www.elmomc.com
Page 56
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
56
Figure 24: Digital Input Connection Diagram – PLC
www.elmomc.com
Page 57
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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
57
Figure 25: Digital Output Connection Diagram – TTL Connection
www.elmomc.com
Page 58
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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
58
Figure 26: Analog Input with Single-Ended Source
www.elmomc.com
Page 59
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
4.11. Communications
The communication interface may differ according to the user’s hardware. The Gold Whistle
can communicate using the following options:
Standard EtherCAT
G-WHIXXX/YYYSXG-WHIXXX/YYYEX
CAN EtherCAT
USB 2.0 USB 2.0
Ethernet RS-232 (TTL Logic Level)
RS-232 (TTL Logic Level)
Table 20: Gold Whistle Communication Options
For ease of setup and diagnostics of CAN communication, RS-232 and CAN can be used
simultaneously.
59
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 RS232, 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
www.elmomc.com
Page 60
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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.
60
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.
www.elmomc.com
Page 61
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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 Ohms resistor termination at each of the two ends of the network
cable.
• The Gold Whistle’s CAN port is non-isolated.
61
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
www.elmomc.com
Page 62
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
62
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”.
www.elmomc.com
Page 63
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
4.11.3. USB 2.0 Communication (J2)
The USB network consists of a Host controller and multiple devices. The Gold Whistle 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
63
44 USB VBUS USB VBUS 5 V
Table 23: USB 2.0 Pin Assignments
Figure 30: USB Network Diagram
www.elmomc.com
Page 64
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
4.11.4. EtherCAT Communication (J2)
To use EtherCAT and Ethernet communication with the Gold Whistle, 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 Whistle’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.
64
Pin (J/2) 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
www.elmomc.com
Page 65
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
65
Figure 31: EtherCAT Connection Schematic Diagram
www.elmomc.com
Page 66
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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
66
Figure 33: EtherCAT Network with Redundancy
4.11.5. Ethernet Communication (J2)
To use EtherCAT and Ethernet communication with the Gold Whistle, 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 Whistle 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.
www.elmomc.com
Page 67
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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
67
Figure 34: Ethernet Network Schematic Diagram
The diagram above ignores line interface for simplicity.
www.elmomc.com
Page 68
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
4.11.6. EtherCAT/Ethernet Line Interface
Ethernet transceivers require either isolation transformers or capacitor coupling for proper
functioning. The Gold Whistle 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 Whistle 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.
4.12. Powering Up
68
After the Gold Whistle is connected to its device, it is ready to be powered up.
Caution:
Before applying power, ensure that the DC supply is within the specified range
and that the proper plus-minus connections are in order.
4.13. Initializing the System
After the Gold Whistle has been connected and mounted, the system must be set up and
initialized. This is accomplished using the Composer, Elmo’s Windows-based software
application. Install the application and then perform setup and initialization according to the
directions in the ComposerSoftware Manual.
4.14. Heat Dissipation
The best way to dissipate heat from the Gold Whistle is to mount it so that its heatsink faces
up. For best results leave approximately 10 mm of space between the Gold Whistle's heatsink
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 Whistle will reach 2/3 of its final temperature after 4 minutes)
• Shut-off temperature: 86 °C to 88 °C (measured on the heat sink)
www.elmomc.com
Page 69
MAN-G-WHIIG (Ver . 1.208)
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
Whistle 100
Series Power Dissipation
0.0
1.0
2.0
3.0
4.0
5.0
6.0
0
0.511.522.533.544.5
5
Peak Current (A)
Power Dissipation (W)
85VDC
70VDC
50VDC
Standard 40 °C Ambient Temp.
External
Heatsink
Gold
Gold Whistle Installation Guide Installation
4.14.2. Heat Dissipation Data
Heat Dissipation is shown in graphically below:
69
Heatsink
Required
not
Required
Heatsink
Required
not
Required
www.elmomc.com
Page 70
MAN-G-WHIIG (Ver . 1.208)
Gold Whistle Installation GuideInstallation
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 heatsink:
1. Allow maximum heatsink temperature to be 80 °C or less.
2. Determine the ambient operating temperature of the Gold Whistle.
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 Whistle will need no additional cooling.
Notes:
70
• The chart above shows that no heatsink is needed when the heatsink temperature is 80 °C,
ambient temperature is 40 °C and heat dissipated is 4 W.
• When an external heatsink is required, you can use the Elmo external heatsink (Catalog
number: WHI-HEATSINK-2).
www.elmomc.com
Page 71
MAN-G-WHIIG (Ver . 1.208)
Chapter 5: Technical Specifications
Gold Whistle Installation Guide
This chapter provides detailed technical information regarding the Gold Whistle. This includes
its dimensions, power ratings, the environmental conditions under which it can be used, the
standards to which it complies and other specifications.
The Gold Whistle has two feedback ports (Main and Auxiliary). The Gold Whistle supplies
voltage only to the main feedback device and to the auxiliary feedback device if needed
Feature Details
Encoder supply voltage 5 V ± 5% @ 2 x 200 mA (maximum)
5.4.2. Feedback Options
The Gold Whistle can receive and process feedback input from diverse types of devices.
5.4.2.1. Incremental Encoder Input
Feature Details
74
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