ElmoMC Gold Line User Manual

Gold Whistle

Digital Servo Drive

Installation Guide

July 2014 (Ver. 1.208)

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 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.

Revision History

Version Date Details

Ver. 1.0 September 2010 Initial release

Ver. 1.1 January 2010 Several 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 2012 Several corrections and updates to manual

Ver. 1.204 January 2013 Several corrections and updates to manual

Ver. 1.205 January 2013 Added 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

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-WHIIG (Ver . 1.208)

Table of Contents

Gold Whistle Installation Guide

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 .......................................................................................................... 11

2.2.1. High Power Density ....................................................................................... 11

2.2.2. Supply Input ................................................................................................... 11

2.2.3. Servo Control ................................................................................................. 12

2.2.4. Advanced Filters and Gain Scheduling........................................................... 13

2.2.5. Motion Control .............................................................................................. 13

2.2.6. Fully Programmable ....................................................................................... 13

2.2.7. Feedback Ports Options ................................................................................. 14

2.2.8. Feedback Sensor Specifications ..................................................................... 14

2.2.9. Communications ............................................................................................ 15

2.2.10. Safety ............................................................................................................. 16

2.2.11. Outputs .......................................................................................................... 16

2.2.12. Inputs ............................................................................................................. 16

2.2.13. Built-In Protection ......................................................................................... 17

2.2.14. Status Indication ............................................................................................ 17

2.2.15. Automatic Procedures ................................................................................... 17

2.3. System Architecture ..................................................................................................... 18

2.4. How to Use this Guide .................................................................................................. 19

5

Chapter 3: Technical Information ................................................................................... 20

3.1. Physical Specifications .................................................................................................. 20

3.2. Technical Data .............................................................................................................. 20

3.2.1. Auxiliary Supply ............................................................................................. 21

Chapter 4: Installation ................................................................................................... 22

4.1. Site Requirements ........................................................................................................ 22

4.2. Unpacking the Drive Components ................................................................................ 22

4.3. Connectors.................................................................................................................... 24

4.3.1. Connector Types ............................................................................................ 24

4.3.2. Pinouts ........................................................................................................... 24

4.3.2.1. Motor Power ................................................................................. 24

4.3.2.2. Main Power ................................................................................... 25

MAN-G-WHIIG (Ver . 1.208)

Gold Whistle Installation Guide Table of Contents

4.3.2.3. Auxiliary Power Connector ........................................................... 25

4.3.2.4. Connector J2 ................................................................................. 26

4.3.2.5. Connector J1 ................................................................................. 29

4.4. Mounting the Gold Whistle .......................................................................................... 31

4.5. Integrating the Gold Whistle on a PCB ......................................................................... 32

4.5.1. Grounds and Returns ..................................................................................... 32

4.6. The Gold Whistle Connection Diagram ........................................................................ 34

4.7. Main Power, Auxiliary Power and Motor Power .......................................................... 35

4.7.1. Motor Power.................................................................................................. 35

4.7.2. Main and Auxiliary Power .............................................................................. 36

4.7.2.1. Main Power ................................................................................... 36

4.7.2.2. Auxiliary Power Supply (Optional) ................................................ 37

4.7.2.3. Power Rating 200 V ...................................................................... 38

4.7.2.4. Power Rating 100 V ...................................................................... 39

4.8. STO (Safe Torque Off) Inputs ........................................................................................ 41

4.9. Feedback ....................................................................................................................... 44

4.9.1. Port A (J2) ...................................................................................................... 45

4.9.1.1. Incremental Encoder .................................................................... 46

4.9.1.2. Absolute Serial Encoder ................................................................ 47

4.9.1.3. Hall Sensors................................................................................... 48

4.9.2. Port B (J2) ....................................................................................................... 49

4.9.2.1. Incremental Encoder .................................................................... 50

4.9.2.2. Interpolated Analog Encoder ........................................................ 51

4.9.2.3. Resolver ........................................................................................ 52

4.9.3. Port C – Emulated Encoder Output (J2) ......................................................... 52

4.9.4. Analog Input .................................................................................................. 53

4.10. User I/Os ....................................................................................................................... 54

4.10.1. Digital Inputs (J1) ........................................................................................... 54

4.10.2. Digital Outputs (J1) ........................................................................................ 57

4.10.3. Analog Input .................................................................................................. 58

4.11. Communications ........................................................................................................... 59

4.11.1. RS-232 Communication (J2) ........................................................................... 59

4.11.2. CAN Communication (J2) ............................................................................... 61

4.11.3. USB 2.0 Communication (J2) ......................................................................... 63

4.11.4. EtherCAT Communication (J2) ....................................................................... 64

4.11.5. Ethernet Communication (J2) ........................................................................ 66

4.11.6. EtherCAT/Ethernet Line Interface ................................................................. 68

4.12. Powering Up ................................................................................................................. 68

4.13. Initializing the System

................................................................................................... 68

4.14. Heat Dissipation............................................................................................................ 68

4.14.1. Thermal Data ................................................................................................. 68

4.14.2. Heat Dissipation Data .................................................................................... 69

4.14.3. How to Use the Charts ................................................................................... 70

6

Chapter 5: Technical Specifications ................................................................................ 71

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5.1. Dimensions ................................................................................................................... 71

5.2. Environmental Conditions ............................................................................................ 72

5.3. Control Specifications ................................................................................................... 72

5.3.1. Current Loop .................................................................................................. 72

5.3.2. Velocity Loop ................................................................................................. 73

5.3.3. Position Loop ................................................................................................. 73

5.4. Feedbacks ..................................................................................................................... 74

5.4.1. Feedback Supply Voltage ............................................................................... 74

5.4.2. Feedback Options .......................................................................................... 74

5.4.2.1. Incremental Encoder Input ........................................................... 74

5.4.2.2. Digital Halls ................................................................................... 75

5.4.2.3. Interpolated Analog (Sine/Cosine) Encoder ................................. 75

5.4.2.4. Resolver ........................................................................................ 76

5.4.2.5. Absolute Serial Encoder ................................................................ 76

5.4.3. Port C Feedback Output ................................................................................ 77

5.5. I/Os ............................................................................................................................... 78

5.5.1. Digital Input Interfaces – TTL Mode .............................................................. 78

5.5.2. Digital Output Interface – TTL Mode ............................................................. 79

5.5.2.1. OUT1 and OUT2 ............................................................................ 79

5.5.2.2. OUT3 and OUT4 ............................................................................ 80

5.5.3. Analog Input .................................................................................................. 80

5.6. Safe Torque Off (STO) ................................................................................................... 81

5.6.1. STO Input Interfaces – TTL Mode .................................................................. 81

5.7. Communications ........................................................................................................... 82

5.8. Pulse-Width Modulation (PWM) .................................................................................. 83

5.9. Compliance with Standards .......................................................................................... 84

7

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.

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MAN-G-WHIIG (Ver . 1.208)

Gold Whistle Installation Guide 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 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:

http://www.zestron.com/fileadmin/zestron.com-usa/daten/electronics/Product_TI1s/TI1­VIGON_EFM-US.pdf

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MAN-G-WHIIG (Ver . 1.208)

Gold Whistle Installation Guide Safety Information

1.3. Directives and Standards

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 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 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.

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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-

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MAN-G-WHIIG (Ver . 1.208)

Gold Whistle Installation Guide Product Description

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

counts

9

counts/sec

9

counts/sec2

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MAN-G-WHIIG (Ver . 1.208)

Gold Whistle Installation Guide Product Description

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 ultimate velocity loop performance

• Gains and filter scheduling vs. position for mechanical coupling optimization, speed and

position tracking errors

• High order filters gain scheduling vs. speed and position

13

2.2.5. Motion Control

• Motion control programming environment

• Motion modes: PTP, PT, PVT, ECAM, Follower

• Full DS-402 motion mode support, in both the CANopen and CANopen 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:

 Fixed Gap: Unlimited
 Table based: 4 kHz

• Motion Commands: Analog current and velocity, pulse-width modulation (PWM) current
and velocity, digital (SW) and 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

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MAN-G-WHIIG (Ver . 1.208)

Gold Whistle Installation Guide Product Description

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:

 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

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

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 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

• 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)

15

• Potentiometer (available on request)

• 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

• CANopen (DS-301, DS-305, DS-402)

• Ethernet TCP/IP

 UDP
 Telnet

• USB 2.0

• RS-232 (TTL logic level)

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MAN-G-WHIIG (Ver . 1.208)

Gold Whistle Installation Guide Product Description

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

• UL 60950 compliance

• CE EMC compliance

2.2.11. Outputs

• Two Digital Outputs

 Optically isolated
 Output level: up to 30 V
 Open collector and open emitter

16

• Three differential outputs:

 Port C EIA-422 differential output line transmitters
 Response time < 1 μs
 Output current: ± 15 mA.

2.2.12. Inputs

• Six digital inputs

 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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Gold Whistle Installation Guide Product Description

2.2.13. Built-In Protection

• Software error handling

• Abort (hard stops and soft stops)

• Status reporting

• Protection against:

 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

17

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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MAN-G-WHIIG (Ver . 1.208)

Gold Whistle Installation Guide Product Description

2.3. System Architecture

18

Figure 1: Gold Whistle System Block Diagram

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MAN-G-WHIIG (Ver . 1.208)

Gold Whistle Installation Guide Product Description

2.4. How to Use this Guide

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.

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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.

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MAN-G-WHIIG (Ver . 1.208)

Gold Whistle Installation Guide Technical 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

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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.

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MAN-G-WHIIG (Ver . 1.208)

Gold Whistle Installation Guide Installation

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

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MAN-G-WHIIG (Ver . 1.208)

Gold Whistle Installation Guide Installation

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

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MAN-G-WHIIG (Ver . 1.208)

Gold Whistle Installation Guide Installation

4.3.2.2. Main Power

For full details see Section 4.7.2.

Pin Function Cable Pin Positions

VP+ Pos. Power input Power

PR Power return Power

PE Protective earth Power

Connector Type: 2 mm pitch 0.51 mm sq

Table 4: Connector for Main Power

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

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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

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