ElmoMC Gold Solo Hornet User Manual

Gold Solo Hornet

Digital Servo Drive

Installation Guide

EtherCAT and CAN

July 2014 (Ver. 1.009)

www.elmomc.com

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 Solo Hornet
servo drive in its installation.

• The text and graphics included in this manual are for the purpose of illustration and

reference only. The specifications on which they are based are subject to change
without notice.

• Information in this document is subject to change without notice.

Elmo Motion Control and the Elmo Motion Control logo are
registered trademarks of Elmo Motion Control Ltd.

EtherCAT Conformance Tested. EtherCAT® is a registered
trademark and patented technology, licensed by Beckhoff
Automation GmbH, Germany.

Catalog Number

Document no. MAN-G-SOLHORIG-EC (Ver. 1.009)

Copyright  2014

Elmo Motion Control Ltd.

All rights reserved.

Notes

• The part number of the Gold Solo Hornet (EtherCAT version) has an E, for example,

G-SOLHOR1/100E whereas the CAN version has an S, for example G-SOLHOR1/100S.

• There are two models of the Gold Solo Hornet: connectors only (for currents of 10 A or

less) and wires only (for currents of 15 A or more). On request, the wires model may be
ordered for currents of 10 A or less.

Cable Kit

• Catalog number: CBL-GSOLHORKIT01 (can be ordered separately)

• For further details, see the documentation for this cable kit (TBD).

Revision History

Version Date Details

1.000 December 2012 Initial release

1.001 December 2012 General corrections

1.002 December 2012 General corrections

1.003 December 2012 General corrections

1.004 December 2012 General corrections

1.005 December 2012 General corrections

Added Section 3.1: Physical Specifications

1.006 March 2013 General corrections

1.007 March 2013 Section 3.2: Technical Data- updated the Power Ratings

table for the 200 VDC option.

1.008 April 2014 Corrections to sections 4.6, 4.7.2.3, 4.7.2.4, and 5.5.2

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-SOLHORI G-EC (Ver. 1.009)

Table of Contents

Gold Solo Hornet Installation Guide (EtherCAT and CAN)

Chapter 1: Safety Information .......................................................................................... 8

1.1. Warnings ......................................................................................................................... 9

1.2. Cautions .......................................................................................................................... 9

1.3. Directives and Standards .............................................................................................. 10

1.4. CE Marking Conformance ............................................................................................. 10

1.5. Warranty Information .................................................................................................. 10

Chapter 2: Product Description ...................................................................................... 11

2.1. Functional Description .................................................................................................. 11

2.2. Product Features .......................................................................................................... 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. Differential Outputs ....................................................................................... 16

2.2.13. Inputs ............................................................................................................. 16

2.2.14. Differential Inputs .......................................................................................... 16

2.2.15. Analog Input .................................................................................................. 16

2.2.16. Built-In Protection ......................................................................................... 17

2.2.17. Status Indication ............................................................................................ 17

2.2.18. Automatic Procedures ................................................................................... 17

2.2.19. Accessories .................................................................................................... 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 and Indicators ............................................................................................ 24

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Gold Solo Hornet Installation Guide (EtherCAT and CAN) Table of Contents

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

4.3.2. Pinouts ........................................................................................................... 25

4.3.2.1. Power, Motor, Control and Port B Connector (J1) ....................... 25

4.3.2.2. Auxiliary Feedback and IO (J2) ...................................................... 27

4.3.2.3. Communication Connector (J3) .................................................... 29

4.3.3. EtherCAT Indicators ....................................................................................... 30

4.3.3.1. EtherCAT Link Indicators ............................................................... 30

4.3.3.2. EtherCAT Status Indicator ............................................................. 30

4.3.4. Drive Status Indicator .................................................................................... 31

4.4. Mounting the Gold Solo Hornet ................................................................................... 32

4.5. Wiring the Gold Solo Hornet ........................................................................................ 33

4.6. The Gold Solo Hornet Connection Diagrams ................................................................ 34

4.7. Main, Auxiliary and Motor Power ................................................................................ 36

4.7.1. Motor Power (J1) ........................................................................................... 36

4.7.2. Main and Auxiliary Power .............................................................................. 38

4.7.2.1. Main Power (J1) ............................................................................ 38

4.7.2.2. Auxiliary Power Supply (J2) (Optional) ......................................... 39

4.7.2.3. Power Rating 200 V ...................................................................... 40

4.7.2.4. Power Rating 100 V ...................................................................... 41

4.8. STO (Safe Torque Off) Inputs (J2) ................................................................................. 43

4.9. Feedback and Analog Input .......................................................................................... 46

4.9.1. Feedback Port A (J2) ...................................................................................... 46

4.9.1.1. Incremental Encoder .................................................................... 49

4.9.1.2. Absolute Serial Encoder ................................................................ 49

4.9.1.3. Hall Sensors................................................................................... 50

4.9.2. Feedback Port B (J1) ...................................................................................... 51

4.9.2.1. Incremental Encoder .................................................................... 52

4.9.2.2. Interpolated Analog Encoder ........................................................ 53

4.9.2.3. Resolver Connection ..................................................................... 53

4.9.3. Port C – Emulated Encoder Output (J2) ......................................................... 54

4.10. User I/Os (J2) ................................................................................................................ 57

4.10.1. Digital Inputs (J2) ........................................................................................... 57

4.10.2. Digital Output (J2) .......................................................................................... 60

4.10.3. Analog Input (J2) ............................................................................................ 62

4.11. Communications ........................................................................................................... 63

4.11.1. RS-232 (J3) ..................................................................................................... 63

4.11.2. Differential RS-232 Communication (RS-422) – J3 ........................................ 65

4.11.3. USB 2.0 Communication (J3) ......................................................................... 66

4.11.4. EtherCAT Communications Version ............................................................... 67

4.11.4.1. EtherCAT Communication (J3) ...................................................... 67

4.11.4.2. Ethernet Communication (J3) ....................................................... 69

4.11.5. CAN Communications Version ....................................................................... 70

4.12. Powering Up ................................................................................................................. 72

4.13. Initializing the System ................................................................................................... 72

4.14. Heat Dissipation............................................................................................................ 72

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Gold Solo Hornet Installation Guide (EtherCAT and CAN) Table of Contents

4.14.1. Thermal Data ................................................................................................. 72

4.14.2. Heat Dissipation Data .................................................................................... 73

4.14.3. How to Use the Charts ................................................................................... 74

Chapter 5: Technical Specifications ................................................................................ 75

5.1. Dimension ..................................................................................................................... 75

5.2. Environmental Conditions ............................................................................................ 76

5.3. Control Specifications ................................................................................................... 77

5.3.1. Current Loop .................................................................................................. 77

5.3.2. Velocity Loop ................................................................................................. 78

5.3.3. Position Loop ................................................................................................. 78

5.4. Feedbacks ..................................................................................................................... 79

5.4.1. Feedback Supply Voltage ............................................................................... 79

5.4.2. Feedback Options .......................................................................................... 79

5.4.2.1. Incremental Encoder Input ........................................................... 79

5.4.2.2. Digital Halls ................................................................................... 80

5.4.2.3. Interpolated Analog (Sine/Cosine) Encoder ................................. 80

5.4.2.4. Resolver ........................................................................................ 81

5.4.2.5. Absolute Serial Encoder ................................................................ 81

5.4.3. Port C Feedback Output ................................................................................ 82

5.5. I/Os ............................................................................................................................... 83

5.5.1. Digital Input Interfaces – TTL Mode .............................................................. 83

5.5.2. Digital Input Interfaces – PLC Mode .............................................................. 84

5.5.3. Digital Output Interface ................................................................................. 85

5.5.4. Analog Input .................................................................................................. 85

5.6. Safe Torque Off (STO) ................................................................................................... 86

5.6.1. STO Input Interfaces – TTL Mode .................................................................. 86

5.6.2. STO Input Interfaces – PLC Mode .................................................................. 86

5.7. EtherCAT Communications Version ............................................................................. 87

5.8. CAN Communications Version ...................................................................................... 88

5.9. Pulse-Width Modulation (PWM) .................................................................................. 88

5.10. Compliance with Standards .......................................................................................... 89

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Table of Contents

Chapter 1: Safety Information

Warning:

Caution:

Gold Solo Hornet Installation Guide (EtherCAT and CAN)

In order to achieve the optimum, safe operation of the Gold Solo Hornet servo drive, it is
imperative that you implement the safety procedures included in this installation guide. This
information is provided to protect you and to keep your work area safe when operating the
Gold Solo Hornet and accompanying equipment.

Please read this chapter carefully before you begin the installation process.

Before you start, ensure that all system components are connected to earth ground. Electrical
safety is provided through a low-resistance earth connection.

Only qualified personnel may install, adjust, maintain and repair the servo drive. A qualified
person has the knowledge and authorization to perform tasks such as transporting, assembling,
installing, commissioning and operating motors.

The Gold Solo Hornet servo drive contains electrostatic-sensitive components that can be
damaged if handled incorrectly. To prevent any electrostatic damage, avoid contact with highly
insulating materials, such as plastic film and synthetic fabrics. Place the product on a
conductive surface and ground yourself in order to discharge any possible static electricity
build-up.

8

To avoid any potential hazards that may cause severe personal injury or damage to the product
during operation, keep all covers and cabinet doors shut.

The following safety symbols are used in this manual:

This information is needed to avoid a safety hazard, which might cause
bodily injury.

This information is necessary for preventing damage to the product or to
other equipment.

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Table of Contents

Gold Solo Hornet Installation Guide (EtherCAT and CAN) Safety Information

1.1. Warnings

• To avoid electric arcing and hazards to personnel and electrical contacts, never

connect/disconnect the servo drive while the power source is on.

• Power cables can carry a high voltage, even when the motor is not in motion. Disconnect

the Gold Solo Hornet from all voltage sources before it is opened for servicing.

• The Gold Solo Hornet servo drive contains grounding conduits for electric current

protection. Any disruption to these conduits may cause the instrument to become hot (live)
and dangerous.

• After shutting off the power and removing the power source from your equipment, wait at

least 1 minute before touching or disconnecting parts of the equipment that are normally
loaded with electrical charges (such as capacitors or contacts). Measuring the electrical
contact points with a meter, before touching the equipment, is recommended.

1.2. Cautions

• The Gold Solo Hornet servo drive contains hot surfaces and electrically-charged

components during operation.

9

• The maximum DC power supply connected to the instrument must comply with the

parameters outlined in this guide.

• When connecting the Gold Solo Hornet to an approved isolated 12 to 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 Solo Hornet, verify that all safety precautions have been

observed and that the installation procedures in this manual have been followed.

• Do not clean any of the Gold Solo Hornet drive's soldering with solvent cleaning fluids of pH

greater than 7 (8 to 14). The solvent corrodes the plastic cover causing cracks and eventual
damage to the drive's PCBs.

Elmo recommends using the cleaning fluid Vigon-EFM which is pH Neutral (7).

For further technical information on this recommended cleaning fluid, select the link:

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

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Table of Contents

Gold Solo Hornet Installation Guide (EtherCAT and CAN) Safety Information

1.3. Directives and Standards

The Gold Solo Hornet conforms to the following industry safety standards:

Safety Standard Item

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

Recognized UL 508C Power Conversion Equipment

In compliance with UL 840 Insulation Coordination Including Clearances and

Creepage Distances for Electrical Equipment

10

In compliance with UL 60950-1
(formerly UL 1950)

Safety of Information Technology Equipment
Including Electrical Business Equipment

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

The Gold Solo Hornet servo drive has been developed, produced, tested and documented in
accordance with the relevant standards. Elmo Motion Control is not responsible for any
deviation from the configuration and installation described in this documentation.
Furthermore, Elmo is not responsible for the performance of new measurements or ensuring
that regulatory requirements are met.

1.4. CE Marking Conformance

The Gold Solo Hornet servo drive is intended for incorporation in a machine or end product.
The actual end product must comply with all safety aspects of the relevant requirements of the
European Safety of Machinery Directive 98/37/EC as amended, and with those of the most
recent versions of standards EN 60204-1 and EN 292-2 at the least.

According to Annex III of Article 13 of Council Directive 93/68/EEC, amending Council Directive
73/23/EEC concerning electrical equipment designed for use within certain voltage limits, the
Gold Solo Hornet meets the provisions outlined in Council Directive 73/23/EEC. The party
responsible for ensuring that the equipment meets the limits required by EMC regulations is
the manufacturer of the end product.

1.5. Warranty Information

The products covered in this manual are warranted to be free of defects in material and
workmanship and conform to the specifications stated either within this document or in the
product catalog description. All Elmo drives are warranted for a period of 12 months from the
time of installation, or 18 months from time of shipment, whichever comes first. No other
warranties, expressed or implied — and including a warranty of merchantability and fitness for
a particular purpose — extend beyond this warranty.

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Table of Contents

Chapter 2: Product Description

Gold Solo Hornet Installation Guide (EtherCAT and CAN)

2.1. Functional Description

The Gold Solo Hornet is an integrated solution designed to simply and efficiently connect
Elmo’s Gold Hornet servo drive directly to the application. The solution consists of the Gold
Hornet together with a convenient connection interface which either eliminates or reduces
development time and resources when designing an application’s PCB board.

The Gold Solo Hornet is an advanced high power density servo drive. It provides top servo
performance, advanced networking and built in safety, all in a small PCB mountable package.
Gold Solo Hornet has a fully featured motion controller and local intelligence.

The Gold Solo Hornet operates from a DC power source. The drive can operate as a standalone
device or as part of a multi-axis system in a distributed configuration on a real-time network.

The Gold Solo Hornet drive is easily set up and tuned using Elmo Application Studio (EAS)
software tools. As part of the Gold product line, it is fully programmable with the Elmo motion
control language. For more about software tools refer to the Elmo Application Studio Software
Manual.

11

The Gold Solo Hornet is available in a variety of options. There are multiple power rating
options, two different communications options – Standard (S suffix in the part number) or
EtherCAT (E suffix in the part number), a variety of feedback selections and I/O configuration
possibilities.

2.2. Product Features

Note: The features described in this chapter relate to the range of Gold Solo Hornet models.

Depending on the model you have purchased, not all features are available.

To see the features for your model, look at the product label on the Gold Solo Hornet 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 Solo Hornet delivers up to 1.6 kW of continuous power or 3.2 kW of peak power in a
compact package (73.4 x 46.5 x 35.8 mm or 2.89" x 1.8" x 1.4").

2.2.2. Supply Input

• Gold Solo Hornet Power rating is 12 to 195 VDC

• Two power ratings for Gold Solo Hornet; 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.

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Table of Contents

Gold Solo Hornet Installation Guide (EtherCAT and CAN) Product Description

 For power rating of 100V

Single DC Power Supply - Power to the Gold Solo Hornet is provided by a 12–95 VDC
single isolated DC power source (not included with the Gold Solo Hornet). A “smart”
control-supply algorithm enables the Gold Solo Hornet to operate with only one power
supply with no need for an auxiliary power supply for the logic.
Optional Backup (Auxiliary) Supply
If backup functionality is required in case of power loss, e.g., to keep the original
position, a 12–95 VDC external isolated supply should be connected (via the Gold Solo
Hornet’s VL+ terminal). This is more flexible than the requirement for 24 VDC supply.
If backup is not needed, a single power supply is used for both the power and logic
circuits.
There are two voltage ratings of the Gold Solo Hornet, therefore the correct power
supply must be used, according to the maximum operating voltage of the Gold Solo
Hornet. Refer to Chapter 3: Technical Information.

2.2.3. Servo Control

• Advanced and extremely fast vector control algorithm (current loop bandwidth: 4 kHz)

12

• Current/Torque sampling rate: up to 25 kHz (40 μs)

• Velocity sampling rate: up to 12.5 kHz (80 μs)

• Position sampling rate: up to 12.5 kHz (80 μs)

• Electrical commutation frequency: up to 4 kHz

• Current closed loop bandwidth exceeds 4 kHz

• Position/Velocity/Acceleration command range – full 32 bit

• Position over velocity, with full dual loop support

• 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

• S-curve Profile Smoothing

• Cogging, BEMF and ωxL compensation

• Dual Loop Operation supported by Auto Tuning

• Fast, easy and efficient advanced Auto Tuning

• Incremental encoder frequency of up to 75 Megacounts/sec

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Gold Solo Hornet Installation Guide (EtherCAT and CAN) Product Description

• Motion profiler numeric range:

9

 Position up to ±2 x 10
 Velocity up to 2 x 10
 Acceleration up to 2 x 10

counts

9

counts/sec

9

counts/sec2

2.2.4. Advanced Filters and Gain Scheduling

• “On-the-Fly” gain scheduling of current and velocity

• Velocity and position with “1-2-2” PIP controllers

• Automatic commutation alignment

• Automatic motor phase sequencing

• Current gain scheduling to compensate for the motor’s non-linear characteristics

• Advanced filtering: Low pass, Notch, General Biquad

• Current loop gain scheduling to compensate for bus voltage variations

• Velocity gain scheduling for ultimate velocity loop performance

13

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

position tracking errors

• High order filters gain scheduling vs. speed and position

2.2.5. Motion Control

• Motion control programming environment

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

• Full DS-402 motion mode support, in both the CAN and CAN over EtherCAT (CoE) protocols,

including Cyclic Position/Velocity modes. Fast (Hardware) event capturing inputs,
supporting < 1 μs latch latency

• Fast (hardware) Output Compare, with < 1 μs latency

• Output compare repetition rate:

 Fixed Gap: Unlimited
 Table based: 4 kHz

• Motion Commands: Analog, Pulse-Width Modulation (PWM), Software, Pulse and Direction

• Distributed Motion Control

• EAS (Elmo Application Studio) software: an efficient and user friendly auto tuner

2.2.6. Fully Programmable

• Third generation programming structure

• Event capturing interrupts

• Event triggered programming

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Gold Solo Hornet Installation Guide (EtherCAT and CAN) 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

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Table of Contents

Gold Solo Hornet Installation Guide (EtherCAT and CAN) Product Description

• 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

• 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

15

• Auxiliary Encoder inputs (ECAM, follower, etc.) single-ended, unbuffered

• Tachometer (available on request)

• Potentiometer (available on request)

• The Gold Solo Hornet provides 5 V supply voltage (5 V, 2 x 200 mA max) for the encoders,

Resolver or Hall supplies

2.2.9. Communications

• Fast and efficient EtherCAT and CAN networking

• EtherCAT Slave:

 CoE (CAN over EtherCAT)
 EoE (Ethernet over EtherCAT)
 FoE (File over EtherCAT) for firmware download
 Supports Distributed Clock
 EtherCAT cyclic modes supported down to a cycle time of 250 μs

• CAN (DS-301, DS-305, DS-402)

• Ethernet TCP/IP

 UDP
 Telnet

• USB 2.0

• RS-232

• RS-422

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Gold Solo Hornet Installation Guide (EtherCAT and CAN) Product Description

2.2.10. Safety

• IEC 61800-5-2, Safe Torque Off (STO)

• Two STO (Safe Torque Off) inputs PLC level which can be configured to 5 V logic (available

on request)

 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 isolated output

2.2.12. Differential Outputs

16

• Three differential outputs:

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

2.2.13. Inputs

• Six digital inputs – conforms to PLC Standard

 TTL Level (5 V logic)
 Optically isolated
 Fast digital capture data <5 μs

• The six digital inputs can be configured to TTL mode (available on request, see

Section 5.5.1)

2.2.14. Differential Inputs

• 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

2.2.15. Analog Input

• One Analog Input – up to 14-bit resolution

• One Analog input: ±10 V

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Gold Solo Hornet Installation Guide (EtherCAT and CAN) Product Description

2.2.16. Built-In Protection

Built-in Protection & Diagnostics:

• Software error handling

• Abort (hard stops and soft stops)

• Extensive status reporting

• Protection against:

 Shorts between motor power outputs and power return

 Failure of internal power supplies
 Over-heating

 Overtemperature

• Continuous temperature measurement. Temperature can be read on the fly; a warning can

be initiated x degrees before temperature disable is activated.

 Overvoltage/undervoltage
 Loss of feedback
 Current limits
 Following errors
 i

2

t motor current

17

2.2.17. Status Indication

• Output for a bi-color LED

2.2.18. 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

2.2.19. Accessories

Cable Kit, catalog number: CBL-GSOLHORKIT01 (can be ordered separately)

For further details, see the documentation for this cable kit (TBD).

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Power Stage

Feedback

Port A

Feedback

Port B

Feedback Out

Port C

Communication

User I/O Interface

Motion

Control Logic

Incremental

Encoder,

Hall Sensors

(Options E, R)

Serial Encoder,

Hall Sensors

(Options A, M)

Incremental

Encoder

or

Analog Encoder

(Options E, A)

Resolver

(Options R, M)

Encoder

Emulation,

PWM

Digital
Inputs

Digital
Outputs

Analog
Input

CANopen, USB,
RS-232, RS-422

(Option S)

EtherCAT, USB,
RS-232, RS-422

(Option E)

Main DC Power

Supply

Optional DC

Auxiliary Supply

Motor

PWM

Current
Feedback,
Protection

STO1,
STO2

Or

Or

Or

STO2

Gold Solo Hornet Installation Guide (EtherCAT and CAN) Product Description

2.3. System Architecture

18

Figure 1: Gold Solo Hornet System Block Diagram

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2.4. How to Use this Guide

In order to install and operate your Elmo Gold Solo Hornet servo drive, you will use this manual
in conjunction with a set of Elmo documentation. Installation is your first step; after carefully
reading the safety instructions in the first chapter, the following chapters provide you with
installation instructions as follows:

• Chapter 3 - Installation, provides step-by-step instructions for unpacking, mounting,

connecting and powering up the Gold Solo Hornet.

• Chapter 4 - Technical Specifications, lists all the drive ratings and specifications.

Upon completing the instructions in this guide, your Gold Solo Hornet servo drive should be
successfully mounted and installed. From this stage, you need to consult higher-level Elmo
documentation in order to set up and fine-tune the system for optimal operation.

• The Gold Product Line Software Manual, which describes the comprehensive software used

with the Gold Solo Hornet

• The Gold Product Line Command Reference Manual, which describes, in detail, each

software command used to manipulate the Gold Solo Hornet motion controller

• The Elmo Application Studio Software Manual, which includes explanations of all the

software tools that are part of the Elmo Application Studio software environment.

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Chapter 3: Technical Information

Gold Solo Hornet Installation Guide (EtherCAT and CAN) Technical Information

3.1. Physical Specifications

Feature Units All Types

Weight g (oz) 106 g (3.74 oz)

Dimensions mm (in) 73.4 x 46.5 x 35.8 mm (2.89" x 1.8" x 1.4")

Mounting method PCB mount

3.2. Technical Data

Feature Units 2.5/100 5/100 10/100 15/100 20/100

Minimum supply voltage VDC 12

Nominal supply voltage VDC 85

20

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

Note on current ratings: The current ratings of the Gold Solo Hornet are given in units of DC

amperes (ratings that are used for trapezoidal commutation or DC motors). The RMS
(sinusoidal commutation) value is the DC value divided by 1.41.

W 200 400 800 1200 1600

% > 99

(up to 6 VA inc. 5 V/2 x 200 mA for encoder)

A 2.5 5 10 15 20

A 1.8 3.5 7 10.6 14.1

Table 1: Power Rating

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Elmo now offers a 200 VDC maximum output rating selection of Gold Solo Hornet, according to
the following technical data:

Feature Units 3/200 6/200 9/200

Minimum supply voltage VDC 12

Nominal supply voltage VDC 170

Maximum supply voltage VDC 195

Maximum continuous power output W 480 960 1450

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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Chapter 4: Installation

Gold Solo Hornet Installation Guide (EtherCAT and CAN)

The Gold Solo Hornet must be installed in a suitable environment and properly connected to its
voltage supplies and the motor.

4.1. Site Requirements

You can guarantee the safe operation of the Gold Solo Hornet by ensuring that it is installed in
an appropriate environment.

Feature Value

Ambient operating temperature -40 °C to +70 °C (-40 °F to 160 °F)

Maximum operating altitude 2,000 m (6562 feet)

Maximum non-condensing humidity 95%

22

Operating area atmosphere No flammable gases or vapors permitted in area

Caution: The Gold Solo Hornet dissipates its heat by convection. The maximum

ambient operating temperature of 40 °C (104 °F) must not be exceeded.

4.2. Unpacking the Drive Components

Before you begin working with the Gold Solo Hornet, verify that you have all of its components,
as follows:

• The Gold Solo Hornet servo drive

• The Elmo Application Studio software and software manual

The Gold Solo Hornet is shipped in a cardboard box with Styrofoam protection.

To unpack the Gold Solo Hornet:

1. Carefully remove the servo drive from the box and the Styrofoam.

2. Check the drive to ensure that there is no visible damage to the instrument. If any damage

has occurred, report it immediately to the carrier that delivered your drive.

3. To ensure that the Gold Solo Hornet you have unpacked is the appropriate type for your

requirements, locate the part number sticker on the side of the Gold Solo Hornet. It looks
like this:

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4. Verify that the Gold Solo Hornet type is the one that you ordered, and ensure that the

voltage meets your specific requirements.

The part number at the top gives the type designation as follows:

23

Notes:

• This manual is the EtherCAT version – for CAN functionality see the CAN version of this

manual. The part number of the Gold Solo Hornet (EtherCAT version) has an E, for example,
G-SOLHOR10/100E whereas the CAN version has an S, for example G- SOLHOR10/100S.

• There are two models of the Gold Solo Hornet: connectors only (for currents of 10 A or

less) and wires only (for currents of 15 A or more). On request, the wires model may be
ordered for currents of 10 A or less.

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4.3. Connectors and Indicators

The Gold Solo Hornet has 3 connectors (connectors version).

4.3.1. Connector Types

Port No. Pins Type Function

24

J1 6/12 Nicomatic CMM 220

6 HP/12 P

J2 30 Nicomatic CMM 220

2 x 15P

J3 20 Nicomatic CMM 220

2 x 10P

Motor, Power, Port B, Hall Phases

I/O, Auxiliary Feedback

Communication

Figure 2: Connector Locations

Table 2: Connector Types

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4.3.2. Pinouts

The pinouts in this section describe the function of each pin in the Gold Solo Hornet connectors
that are listed in Table 2.

4.3.2.1. Power, Motor, Control and Port B Connector (J1)

J1 consists of a Power, Motor and Control connector (6 pins) and Port B connector (12 pins),
see Section 4.7 for more details.

4.3.2.1.a Power, Motor, and Control Connector (J1)

See Section 4.7.1 for more details.

Pin Signal Function Cable

P1 VP+ Positive Power Input Power

P2 PR Power Return Power

P3 PE Protective Erath Power

25

AC Motor DC Motor

P4 M1 Motor Phase Motor N/C

P5 M2 Motor Phase Motor Motor

P6 M3 Motor Phase Motor Motor

Pin Positions

Table 3: Power, Motor, and Control Connections

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4.3.2.1.b Port B Connector (J1)

See Section 4.7.1 for for more details.

Incremental Encoder Absolute Serial Encoder

Pin (J1) Signal Function Signal Function

1 +5V Encoder +5V Supply +5V Encoder +5V Supply

2 COMRET Supply Return SUPRET Supply Return

3 PORTB_ENC_A+/SIN+ Channel A+/Sine+ SIN+ Sine+

4 PORTB_ENC_A-/SIN- Channel A -/Sine- SIN- Sine-

5 PORTB_ENC_B+/COS+ Channel B+/Cosine+ COS+ Cosine+

6 PORTB_ENC_B-/COS- Channel B-/Cosine- COS- Cosine-

26

7 PORTB_ENC_INDEX+/

ANALOG_INDEX+

8 PORTB_ENC_INDEX-/

ANALOG_INDEX-

9 HA Hall Sensor A HA Hall Sensor A

10 HB Hall Sensor B HB Hall Sensor B

11 HC Hall Sensor C HC Hall Sensor C

12 PE Protective Earth PE Protective Earth

Channel_Index+/
Analog_Index+

Channel_Index- /
Analog_Index-

RESOLVER_OUT+ Vref f=1/TS, 50 mA

Max.

RESOLVER_OUT- Vref Complement

f= 1/TS, 50 mA
Maximum

Pin Positions

Table 4: Port B Pin Assignments

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4.3.2.2. Auxiliary Feedback and IO (J2)

See Section 4.9.1 for more details.

27

Incremental or Interpolated Analog

Resolver

Encoder

G-SOLHOR XXX/YYYYEX G-SOLHOR XXX/YYYYRX

Pin (J2) Signal Function Signal Function

4 PORTA_ENC_A+ Channel A + ABS_CLK+ Absolute Encoder

Clock+

5 PORTA_ENC_A- Channel A - ABS_CLK- Absolute Encoder

Clock-

6 PORTA_ENC_B+ Channel B+ ABS_DATA+ Absolute Encoder

Data+

7 PORTA_ENC_B- Channel B - ABS_DATA- Absolute Encoder

Data-

8 PORTA_ENC_INDEX+ Index+ RESERVED Reserved

9 PORTA_ENC_INDEX- Index- RESERVED Reserved

10 PORTC_ENCO_A- Buffered Channel A Complement Output

11 PORTC_ENCO_A+ Buffered Channel A Output

12 PORTC_ENCO_B- Buffered Channel B Complement Output

13 PORTC_ENCO_B+ Buffered Channel B Output

14 PORTC_ENCO_INDEX- Buffered INDEX Complement Output

15 PORTC_ENCO_INDEX+ Buffered INDEX Output

16 COMRET Common Return

17 ANALOG1- Analog Input Complement

18 ANALOG1+ Analog Input

19 ANLRET Analog Return

20 INRET Programmable Input 1 – 6 Return

21 IN1 Programmable Input 1 (High Speed)

22 IN2 Programmable Input 2 (High Speed)

23 IN3 Programmable Input 3 (High Speed)

IN4 Programmable Input 4

24

STO1 ST01 Input (Default 24 V)

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28

Incremental or Interpolated Analog

Resolver

Encoder

G-SOLHOR XXX/YYYYEX G-SOLHOR XXX/YYYYRX

Pin (J2) Signal Function Signal Function

IN5 Programmable Input 5

25

STO2 ST02 Input (Default 24 V))

IN6 Programmable Input 6

26

STO_RET ST0_RET

27 OUT2RET Programmable Digital Output Return 2

28 OUT2 Programmable Digital Output 1

29 OUT1RET Programmable Digital Output Return 1

30 OUT1 Programmable Digital Output 2

Pin Positions

Table 5: Auxiliary Feedback Pin Assignments

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4.3.2.3. Communication Connector (J3)

See Section 4.9.1 for more details.

Pin (J3) Signal Function

RS-232_TX RS-232 Transmit

1

RS-422 RX+ Differential RS-232 Receive

RS-232_RX RS-232 Receive

2

RS-422_RX- Differential RS-232 Receive Complement

3 USBD+ USB Data

4 USBD- USB Data Complement

5 USB_VBUS USB VBUS 5V

6 USB_GND USB COM RET

7 COMRET Common Return

29

8 ECAT_TX+ IN EtherCAT In Transmit

9 ECAT_TX- IN EtherCAT In Transmit Complement

10 RS422_TX+ Differential RS-232 Transmit

11 ECAT_RX+ IN EtherCAT In Receive

12 ECAT_RX- IN EtherCAT In Receive Complement

13 COMRET Common Return

ECAT_TX+ OUT EtherCAT Out Transmit

14

CANH CAN_H Bus Line (Dominant High)

ECAT_TX- OUT EtherCAT Out Transmit Complement

15

CANL CAN_L Bus Line (Dominant Low)

ECAT_RX+ OUT EtherCAT Out Receive

16

CANH CAN_H Bus Line (Dominant High)

ECAT_RX- OUT EtherCAT Out Receive Complement

17

CANL CAN_L Bus Line (Dominant Low)

18 COMRET Common Return

19 PE Protective Earth

20 RS422_TX- Differential RS-232 Transmit Complement

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Pin (J3) Signal Function

Pin Positions

30

Table 6: Communications Pin Assignments

4.3.3. EtherCAT Indicators

4.3.3.1. EtherCAT Link Indicators

The Gold Solo Hornet can serve as an EtherCAT slave device.

The green LED is the link/activity indicator. It shows the state of the applicable physical link and
the activity on that link.

The possible states of these LEDs are summarized in Table 7.

LED State Meaning

Link/Activity Off No link is established.

On A link is established.

Blinking There is data transmission activity.

Table 7: LED States

4.3.3.2. EtherCAT Status Indicator

The EtherCAT status indicator is a red/green dual LED. It combines run indication (when it is
green) and error indication (when it is red) of the EtherCAT device. For further details, see the
EtherCAT Manual.

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4.3.4. Drive Status Indicator

This red/green dual LED is used for immediate indication of the following states:

• Initiation state: In this state the LED indicates whether the drive is in the boot state

(blinking red) or in the operational state (steady red).

• Working state: In this state the LED indicates whether the drive is in an amplifier failure

state (red) or is ready to enable the motor (green).

31

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4.4. Mounting the Gold Solo Hornet

The Gold Solo Hornet was designed for mounting on a surface. When integrating the Gold Solo
Hornet into a device, be sure to leave about 1 cm (0.4") outward from the heatsink to enable
free air convection around the drive. If the Gold Solo Hornet is enclosed in a metal chassis, we
recommend that the Gold Solo Hornet be screw-mounted to it to help with heat dissipation.
The Gold Solo Hornet has screw-mount holes on each corner of the heatsink for this purpose –
see below.

32

Figure 3: Mounting the Gold Solo Hornet

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

Figure 4: Gold Solo Hornet External Heatsink

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4.5. Wiring the Gold Solo Hornet

Once the Gold Solo Hornet is mounted, you are ready to wire the device. Proper wiring,
grounding and shielding are essential for ensuring safe, immune and optimal servo
performance of the Gold Solo Hornet.

Caution: Perform the following instructions to ensure safe and proper wiring.

To ensure safe and proper wiring:

1. Use twisted pair shielded cables for control, feedback and communication connections. For

best results, the cable should have an aluminum foil shield covered by copper braid, and
should contain a drain wire.

2. The drain wire is a non-insulated wire that is in contact with parts of the cable, usually the

shield. It is used to terminate the shield and as a grounding connection.

3. The impedance of the wire must be as low as possible. The size of the wire must be thicker

than actually required by the carrying current. A 24, 26 or 28 AWG wire for control and
feedback cables is satisfactory although 24 AWG is recommended.

33

4. Use shielded wires for motor connections as well. If the wires are long, ensure that the

capacitance between the wires is not too high: C < 30 nF is satisfactory for most
applications.

5. Keep all wires and cables as short as possible.

6. Keep the motor wires as far away as possible from the feedback, control and

communication cables.

7. Ensure that in normal operating conditions, the shielded wires and drain carry no current.

The only time these conductors carry current is under abnormal conditions, when electrical
equipment has become a potential shock or fire hazard while conducting external EMI
interferences directly to ground, in order to prevent them from affecting the drive. Failing
to meet this requirement can result in drive/controller/host failure.

8. After completing the wiring, carefully inspect all wires to ensure tightness, good solder

joints and general safety.

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4.6. The Gold Solo Hornet Connection Diagrams

34

Figure 5: The Gold Solo Hornet Connection Diagram - EtherCAT

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35

Figure 6: The Gold Solo Hornet Connection Diagram - CAN

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4.7. Main, Auxiliary and Motor Power

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

4.7.1. Motor Power (J1)

The Gold Solo Hornet Motor Power is part of the J1 connector, see Section 4.3.2.1 for more
details.

Pin Function Cable

Brushless Motor Brushed DC Motor

PE Protective Earth Motor Motor

M1 Motor Phase Motor N/C

M2 Motor Phase Motor Motor

M3 Motor Phase Motor Motor

36

Pin Positions

Table 8: Main Power and Motor Connections

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.

Connect the M1, M2, M3 and PE pins on the Gold Solo Hornet. 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.

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37

Figure 7: Brushless Motor Power Connection Diagram

Figure 8: DC Brushed Motor Power Connection Diagram

Notes

• For best immunity, it is highly recommended to use a 4-wire shielded (not twisted) cable

for the motor connection. The gauge is determined by the actual current consumption of
the motor.

• Connect the cable shield to the closest ground connection at the motor end.

• Connect the cable shield to the PE terminal of the Gold Solo Hornet.

• Ensure that the motor chassis is properly grounded.

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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 (J1)

The Gold Solo Hornet Main Power is part of the J1 connector, see Section 4.3.2.1 for more
details.

Pin Function Cable

PE Protective Earth Power

PR Power Return Power

VP+ Positive Power Input Power

Pin Positions

38

Table 9: Main Power and Motor Connections

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

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

Notes for connecting the DC power supply

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

• For best immunity, it is highly recommended to use twisted and shielded cables for the DC

power supply. A 3-wire shielded cable should be used. The gauge is determined by the
actual current consumption of the motor.

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

• 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.

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4.7.2.2. Auxiliary Power Supply (J2) (Optional)

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

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

The Gold Solo Hornet Auxiliary Power is part of the J2 connector, see Section 4.3.2.2 for more
details.

Pin (J2) Signal Function

2 PR Auxiliary Supply Return

1 VL+ Auxiliary Power Input

Pin Positions

39

Table 10: Auxiliary Supply Pins

Caution: Power from the Gold Solo Hornet to the motor must come from the

Main Supply and NOT from the Auxiliary Supply.

The backup functionality can be used for storing control parameters in case of power-outs,
providing maximum flexibility and backup capability when needed.

Connect the VL+ and PR terminal to the Auxiliary Connector.

Note 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.

A cable kit containing a cable that connects to the auxiliary supply connector (J2) is available,
see Section 2.2.19 for more details.

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4.7.2.3. Power Rating 200 V

For Power Rating 200 V, two power isolated DC power sources are required, main power
12 - 195V and auxiliary Power 12-95V for the logic.

40

Figure 9: 200 VDC Power Source Connection Diagram

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4.7.2.4. Power Rating 100 V

4.7.2.4.a Single Power Supply

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

41

Figure 10: 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 11: Separate Auxiliary Supply Diagram (Backup)

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4.7.2.4.c Shared Optional Backup Supply

A Main DC Power Supply can be designed to supply power to the drive’s logic as well as to the
Main Power (see Figure 10 and the upper portion of Figure 12). 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 12).

42

Figure 12: Separate Auxiliary Supply Connection Diagram

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4.8. STO (Safe Torque Off) Inputs (J2)

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 24 VDC (or 5 V for the TTL option) 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.

43

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 11: Motor Behavior According to STO Inputs

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

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The Gold Solo Hornet STO inputs are part of the J2 connector, see Section 4.3.2.2 for more
details.

Pin (J2) Signal Function

IN4 Programmable Input 4

24

STO1 ST01 Input

IN5 Programmable Input 5

25

STO2 ST02 Input

IN6 Programmable Input 6

26

STO_RET ST0_RET

Pin Positions

44

Table 12: STO Inputs Pin Assignments

A cable kit containing a cable that connects to the STO connector (J2) is available, see
Section 2.2.19.

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Figure 13: STO Input Functionality – Schematic Drawing

See Figure 14 for the PLC option connection and Figure 15 for the TTL option connection.

45

Figure 14: STO Input Connection – PLC Option

Figure 15: STO Input Connection – TTL Option

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4.9. Feedback and Analog Input

The Gold Solo Hornet has two configurable motion sensor input ports and one output port:
Port A and port B are input ports, port C is the feedback output port. Motion sensors from the
controlled motor and from other sources can be connected to any of the available inputs on
either port A or B. Software configuration designates each input a role, 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.

4.9.1. Feedback 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.

46

Differential Pulse & 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.

A cable kit containing a cable that connects to port A is available, see Section 2.2.19.

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6
8

Gold Solo Hornet Installation Guide (EtherCAT and CAN) Installation

The Gold Solo Hornet Feedback Port A is part of the J2 connector, see Section 4.3.2.2 for more
details.

Incremental Encoder Absolute Serial Encoder

47

Pin

Signal Function Signal Function

(J2)

16

COMRET Common

PORTA_ENC_A+ Channel A + ABS_CLK+ Absolute Encoder Clock+

5

PORTA_ENC_A- Channel A - ABS_CLK- Absolute Encoder Clock-

PORTA_ENC_B+ Channel B+ ABS_DATA+ Absolute Encoder Data+

7

PORTA_ENC_B- Channel B - ABS_DATA- Absolute Encoder Data -

PORTA_ENC_INDEX+ Index+ RESERVED Reserved

9

PORTA_ENC_INDEX- Index - RESERVED Reserved

Pin Positions

COMRET Common Return

Return

Table 13: Feedback Port A Pin Assignments

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The following are Hall Sensors pin assignments for the Gold Solo Hornet. The Hall Sensor is part
of the J1 connector, see Section 4.3.2.1 for more details.

Pin (J1) Incremental Encoder Absolute Serial Encoder

48

9

10

11

12

Pin Positions

HA Hall Sensor A HA Hall Sensor A

HB Hall Sensor B HB Hall Sensor B

HC Hall Sensor C HC Hall Sensor C

PE Protective Earth PE Protective Earth

Table 14: Hall Sensor Pin Assignments

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4.9.1.1. Incremental Encoder

49

Figure 16: Port A Incremental Encoder Input – Recommended Connection Diagram

4.9.1.2. Absolute Serial Encoder

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

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

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Figure 18: Absolute Serial Encoder – Recommended Connection Diagram for Sensors

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

50

4.9.1.3. Hall Sensors

Figure 19: Hall Sensors Connection Diagram

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4.9.2. Feedback Port B (J1)

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 & 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.

A cable kit containing a cable that connects to the port B is available, see Section 2.2.19.

The Gold Solo Hornet Motor Power is part of the J1 connector, see Section 4.3.2.1 for more
details.

51

Incremental Encoder Absolute Serial Encoder

G-SOLHORXXX/YYYYEX G-SOLHORXXX/YYYYRX

Pin (J1) Signal Function Signal Function

1 +5V Encoder +5V

+5V Encoder +5V Supply

Supply

2 COMRET Supply Return COMRET Supply Return

3 PORTB_ENC_A+/SIN+ Channel A+/Sine+ SIN+ Sine+

4 PORTB_ENC_A-/SIN- Channel A -/Sine- SIN- Sine-

5 PORTB_ENC_B+/COS+ Channel B+/

COS+ Cosine+

Cosine+

6 PORTB_ENC_B-/COS- Channel B-/Cosine- COS- Cosine-

7 PORTB_ENC_INDEX+/

ANALOG_INDEX+

8 PORTB_ENC_INDEX-/

ANALOG_INDEX-

Channel_Index+/
Analog_Index+

Channel_Index- /
Analog_Index-

RESOLVER_OUT+ Vref f=1/TS, 50 mA

Max.

RESOLVER_OUT- Vref complement

f= 1/TS, 50 mA
Maximum

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Incremental Encoder Absolute Serial Encoder

Pin Positions

52

Table 15: Port B Pin Assignments

4.9.2.1. Incremental Encoder

Figure 20: Port B Incremental Encoder Input – Recommended Connection Diagram

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4.9.2.2. Interpolated Analog Encoder

53

Figure 21: Port B - Interpolated Analog Encoder Connection Diagram

4.9.2.3. Resolver Connection

Figure 22: Port B – Resolver Connection Diagram

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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 Solo Hornet is used:

• as a current amplifier to provide position data to the position controller

• in velocity mode, to provide position data to the position controller

• as a master in follower or ECAM mode

54

A cable kit containing a cable that connects to port C is available, see Section 2.2.19.

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The Gold Solo Hornet Port C – Emulated Encoder Output are part of the J2 connector, see
Section 4.3.2.2 for more details.

Pin (J2) Signal Function

10 PORTC_ENCO_A- Buffered Channel A complement Output

11 PORTC_ENCO_A+ Buffered Channel A Output

12 PORTC_ENCO_B- Buffered Channel B complement Output

13 PORTC_ENCO_B+ Buffered Channel B Output

14 PORTC_ENCO_INDEX- Buffered INDEX complement Output

15 PORTC_ENCO_INDEX+ Buffered INDEX Output

16 COMRET Common Return

3 PE Protective Earth

Pin Positions

55

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56

Figure 23: Emulated Encoder Differential Output – Recommended Connection Diagram

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4.10. User I/Os (J2)

The Gold Solo Hornet has six programmable digital inputs, two digital outputs and one analog
input.

4.10.1. Digital Inputs (J2)

Each of the pins below can function as an independent input. The inputs conform to the PLC
standard. TTL configuration is available upon request.

The Gold Solo Hornet Digital Inputs are part of the J2 connector, see Section 4.3.2.2 for more
details.

Pin (J2) Signal Function

20 INRET Programmable Input 1 – 6 Return

21 IN1 Programmable Input 1

22 IN2 Programmable Input

23 IN3 Programmable Input 3

57

IN4 Programmable Input 4

24

STO1 ST01 Input

IN5 Programmable Input 5

25

STO2 ST02 Input

IN6 Programmable Input 6

26

STO_RET ST0_RET

Pin Positions

Table 16: Connector J2 – Digital Input

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Figure 24: Digital Input PLC Mode Connection Diagram

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59

Figure 25: Digital Input TTL Mode Connection Diagram

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4.10.2. Digital Output (J2)

There are two isolated outputs.

The Gold Solo Hornet Digital Outputs are part of the J2 connector, see Section 4.3.2.2 for more
details.

Pin (J2) Signal Function

27 OUT2RET Programmable Digital Output Return 2

28 OUT2 Programmable Digital Output 1

29 OUT1RET Programmable Digital Output Return 1

30 OUT1 Programmable Digital Output 2

Pin Positions

60

Table 17: Connector J2 – Digital Output

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Figure 26: Digital Output Connection Diagram – TTL Option

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4.10.3. Analog Input (J2)

Analog user inputs can be configured by software to be used as either tachometer velocity
sensor input or potentiometer position feedback.

The Gold Solo Hornet Analog Inputs are part of the J2 connector, see Section 4.3.2.2 for more
details.

Pin (J2) Signal Function

17 ANALOG1- Analog Input Complement

18 ANALOG1+ Analog Input

19 ANLRET Analog Return

Pin Positions

62

Figure 27: Analog Input with Single-Ended Source

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4.11. Communications

The communication interface may differ according to the user’s hardware. The Gold Solo
Hornet can communicate using the following options:

• EtherCAT or Ethernet

• CAN

• USB 2.0

• RS-232

• RS-422

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

must be disconnected.

4.11.1. RS-232 (J3)

RS-232 communication requires a cable connected from the Gold Solo Hornet to a serial
interface on the PC. The interface is selected and set up in the Elmo Application Studio (EAS)
software.

63

To connect the RS-232 communication cable:

1. 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.

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

3. Ensure that the shield of the cable is connected to the shield of the connector used for

RS-232 communications. The drain wire can be used to facilitate the connection.

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The Gold Solo Hornet RS-232 pins are part of the J3 connector, see Section 4.3.2.3 for more
details.

Pin (J3) Signal Function

2 RS-232_RX RS-232 Receive

1 RS-232_TX RS-232 Transmit

7 COMRET RS-232 Communication Return

Pin Positions

64

Table 18: RS-232 Pin Assignments

Figure 28: RS-232 Connection Diagram

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4.11.2. Differential RS-232 Communication (RS-422) – J3

Note for connecting the RS-232 communication cable:

• This is Differential RS-232 Communication based on RS-422. Connect the shield to the

ground of the Controller. Usually, this connection is soldered internally inside the
connector at the PC end. You can use the drain wire to facilitate connection.

The Gold Solo Hornet RS-422 pins are part of the J3 connector, see Section 4.3.2.3 for more
details.

Pin (J3) Signal Function

65

10 RS422_TX+

20 RS422_TX-

2 RS422_RX-

1 RS422_RX+

18 COMRET

Differential RS-232 Transmit

Differential RS-232 Transmit Complement

Differential RS-232 Receive

Differential RS-232 Receive Complement

Common Return

Figure 29: Differential RS-232 Communication

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4.11.3. USB 2.0 Communication (J3)

The USB Network consists of Host controller and multiple devices. The Gold Solo Hornet is a
USB Device.

To connect the USB communication cable:

1. Connect a standard USB cable.

2. D+ and D- comprise a twisted pair in the cable.

3. The maximum cable length is 5 m.

4. The cable shield should only be connected to Ground at the host.

5. The shield of the cable is connected to the shield of the connector used for

communications.

The Gold Solo Hornet USB 2.0 communication pins are part of the J3 connector, see Section

4.3.2.3 for more details.

Pin (J3) Signal Function

66

3

4

5

6

Pin Positions

USBD+

USBD-

USB_VBUS

USB_GND

USB Data

USB Data Complement

USB VBUS 5V

USB COM RET

Table 19: USB 2.0 - Pin Assignments

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Figure 30: USB Network Diagram

4.11.4. EtherCAT Communications Version

67

4.11.4.1. EtherCAT Communication (J3)

Notes:

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

Manual.

• It is recommended to use shielded CAT5e (or higher) cable. Category 5e cable is a high

signal integrity cable with four twisted pairs.

The Gold Solo Hornet USB 2.0 communication pins are part of the J3 connector, see Section

4.3.2.3 for more details.

Pin (J3) Signal Function

8 ECAT_ TX+ IN EtherCAT In Transmit +

9 ECAT_ TX- IN EtherCAT In Transmit -

11 ECAT_ RX+ IN EtherCAT In Receive +

12 ECAT_ RX- IN EtherCAT In Receive -

13 COMRET Common Return

14 ECAT_TX+ OUT EtherCAT Out Transmit

15 ECAT_TX- OUT EtherCAT Out Transmit Complement

16 ECAT_RX+ OUT EtherCAT Out Receive

17 ECAT_RX- OUT EtherCAT Out Receive Complement

18 COMRET Common Return

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Pin (J3) Signal Function

Pin Positions

68

Table 20: EtherCAT - Pin Assignments

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 31: EtherCAT Network with no Redundancy

Figure 32: EtherCAT Network with Redundancy

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4.11.4.2. Ethernet Communication (J3)

Notes:

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

Manual.

• It is recommended to use shielded CAT5e (or higher) cable. Category 5e cable is a high

signal integrity cable with four twisted pairs.

The Gold Solo Hornet Ethernet communication pins are part of the J3 connector, see Section

4.3.2.3 for more details.

Pin (J3) Signal Function

69

8

Ethernet In Transmit

9 TX- Ethernet In Transmit Complement

11 RX+ Ethernet In Receive

12 RX- Ethernet In Receive Complement

13 COMRET Common Return

19 PE Protective Earth

Pin Positions

Table 21: Ethernet - Pin Assignments

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4.11.5. CAN Communications Version

Notes for connecting the CAN communication cable:

• Use 26 or 28 AWG twisted pair shielded cables. For best results, the shield should have

aluminum foil and covered by copper braid with a drain wire

• 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 PE pin. The drain wire can be used to

facilitate the connection.

• Connect a termination 120-Ohms resistor at each of the two ends of the network cable.

The Gold Solo Hornet CAN communication pins are part of the J3 connector, see Section 4.3.2.3
for more details.

Pin Signal Function

70

14

15

16

17

CANH CAN_H Bus Line (Dominant High)

CANL CAN_L Bus Line (Dominant Low)

CANH CAN_H Bus Line (Dominant High)

CANL CAN_L Bus Line (Dominant Low)

Pin Positions

Table 22: CAN Connectors - Pin Assignments

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71

Figure 33: CAN - Connection Diagram

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4.12. Powering Up

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

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

4.13. Initializing the System

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

4.14. Heat Dissipation

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

72

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

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

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4.14.2. Heat Dissipation Data

Heat dissipation is shown in graphically below:

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4.14.3. How to Use the Charts

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

To determine if your application needs a heat sink:

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

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

3. Calculate the allowable temperature increase as follows:

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

4. Use the chart to find the actual dissipation power of the drive. Follow the voltage curve to

the desired output current and then find the dissipated power.

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

Note: The chart above shows that no heat sink is needed when the heat sink temperature

is 80 °C, ambient temperature is 40 °C and heat dissipated is 4 Watts.

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Chapter 5: Technical Specifications

Gold Solo Hornet Installation Guide (EtherCAT and CAN)

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

5.1. Dimension

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5.2. Environmental Conditions

Feature Operation Conditions Range

76

Ambient

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

Temperature
Range

Temperature
Shock

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

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

within 3 min.

Altitude Non-operating conditions Unlimited

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

Maximum
Humidity

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

at 35 °C (95 °F)

Operating conditions Up to 95% relative humidity non-condensing

at 25 °C (77 °F), up to 90% relative humidity
non-condensing at 42 °C (108 °F)

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

Mechanical

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

Shock

Operating conditions ±20g; Half sine, 11 msec

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5.3. Control Specifications

5.3.1. Current Loop

Feature Details

Controller type Vector, digital

77

Compensation for bus voltage

“On-the-fly” automatic gain scheduling

variations

Motor types

• AC brushless (sinusoidal)

• DC brushless (trapezoidal)

• DC brush

• Linear motors

• “Voice” coils

Current control

• Fully digital

• Sinusoidal with vector control

• Programmable PI control filter based on a

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

Current loop bandwidth > 4 kHz closed loop

Current sampling time

Programmable 40 to 120 µsec

Current sampling rate Up to 25 kHz; default 20 kHz

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5.3.2. Velocity Loop

Feature Details

Controller type PI + Four advanced filters + Two advanced gain

scheduling filters

78

Velocity control

• Fully digital

• Programmable PI and feed forward control

filters

• On-the-fly gain scheduling according to either

speed or position command or feedback.

• Automatic, quick, advanced or expert tuning

Velocity and position feedback options

• Incremental Encoder

• Digital Halls

• Interpolated Analog (sin/cos) Encoder

(optional)

• Resolver (optional)

• Absolute serial encoder

Note: With all feedback options, 1/T with

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

Velocity loop bandwidth < 500 Hz

Velocity sampling time

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

Velocity sampling rate Up to 12.5 kHz; default 10 kHz

Velocity command options Internally calculated by either jogging or step

Note: All software-calculated profiles support

on-the-fly changes.

5.3.3. Position Loop

Feature Details

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

advanced gain scheduling filter

Position command options

Position loop bandwidth < 200 Hz

Position sampling time

Position sampling rate Up to 12.5 kHz; default 10 kHz

• Software

• Pulse and Direction

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

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5.4. Feedbacks

5.4.1. Feedback Supply Voltage

The Gold Solo Hornet has two feedback ports (Main and Auxiliary). The Gold Solo Hornet
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 Solo Hornet can receive and process feedback input from diverse types of devices.

5.4.2.1. Incremental Encoder Input

Feature Details

79

Encoder format

• A, B and Index

• Differential

•

Interface RS-422

Input resistance

Differential: 120 Ω

Maximum incremental encoder frequency Maximum absolute: 75 Megacounts

per second (18 MHz on A/B)

Minimum quadrature input period (PIN) 53 nsec

Minimum quadrature input high/low period (PHL) 26 nsec

Minimum quadrature phase period (PPH) 13 nsec

Maximum encoder input voltage range

Common mode: ±7 V

Differential mode: ±7 V

Figure 34: Main Feedback - Encoder Phase Diagram

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5.4.2.2. Digital Halls

Feature Details

80

Halls inputs

• H

, HB, HC.

A

• Single ended inputs

• Built in hysteresis of 1 V for noise immunity

Input voltage Nominal operating range: 0 V < V

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

In_Hall

InHigh

InLow

< 1 V

In_Hall

< 15 V

> 2.5 V

< 5 V

Input current Sink current (when input pulled to the common): 5

mA

Maximum frequency f

MAX

: 4 kHz

5.4.2.3. Interpolated Analog (Sine/Cosine) Encoder

Feature Details

Analog encoder format Sine and Cosine signals

Analog input signal level

• Offset voltage: 2.2 V to 2.8 V

• Differential, 1 V peak to peak

Input resistance

Maximum analog signal frequency f

Differential: 120 Ω

: 500 kHz

MAX

Interpolation multipliers Programmable: x4 to x8192

Maximum “counts” frequency 2 x 10

Automatic error correction

9

counts/sec

• Signal amplitudes mismatch

• Signal phase shift

• Signal offsets

Encoder outputs See Port C Encoder Outputs specifications,

Section 5.4.3.

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5.4.2.4. Resolver

Feature Details

81

Resolver format

• Sine/Cosine

• Differential

Input resistance

Differential 2.49 kΩ

Resolution Programmable: 10 to 15 bits

Maximum electrical frequency (RPS) 512 revolutions/sec

Resolver transfer ratio 0.5

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

Reference voltage Supplied by the Gold Solo Hornet

Reference current up to ±50 mA

Encoder outputs See Port C Encoder Outputs specifications,

Section 5.4.3.

5.4.2.5. Absolute Serial Encoder

Feature Details

Encoder format

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

• EnDAT 2.2

• BiSS/SSI

• Stegmann Hiperface

Interface

• RS-485

• Clock – Differential output line

• Data – Differential bidirectional line

Input Resistance

Differential 120 Ω

Transmission Rate Up to 2.5 MHz

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5.4.3. Port C Feedback Output

Feature Details

82

Emulated output

• A, B, Index

• Differential

Interface

• RS-422

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

Available as options

High level output voltage: V

Minimum output current: I

Low level output voltage: V

• Emulated encoder output of any sensor on

> 3.0 V

OH

= 2 mA

OL

< 0.4 V

OL

Port A or Port B

• Daisy chain Port A or Port B

• Emulated encoder output of internal

variables

• Emulated encoder outputs of the tachometer

• Emulated encoder outputs of the

potentiometer

Maximum frequency f

: 8 MHz pulses/output

MAX

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

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

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

an encoder cycle) and synchronized to A&B

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5.5. I/Os

The Gold Solo Hornet has:

• 6 Digital Inputs

• 2 Digital Outputs

• 1 Analog Input

5.5.1. Digital Input Interfaces – TTL Mode

Feature Details

Type of input Optically isolated

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

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

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

83

Minimum pulse width

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

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

Figure 35: Digital Input Schematic

>250 µsec

0 < T < 250 µsec

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

Notes:

• Home mode is high-speed mode and can be used

for fast capture and precise homing.

• Highest speed is achieved when turning on

optocouplers.

Capture with differential input

Port A, Port B Index

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

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5.5.2. Digital Input Interfaces – PLC Mode

Feature Details

Type of input Optically isolated

Input current for all inputs Iin = 2 mA @ Vin = 12 V

High-level input voltage 12 V < Vin < 30 V

Low-level input voltage 0 V < Vin < 7 V

84

Minimum pulse width

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

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

Figure 36: Digital Input Schematic

>250 µsec

0<T< 250 µsec

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

Notes:

• Home mode is high-speed mode and can be

used for fast capture and precise homing.

• Highest speed is achieved when turning on

optocouplers.

Capture with differential input

Port A, Port B Index

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

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5.5.3. Digital Output Interface

Feature Details

85

Type of output

• Optically isolated

• Source/Sink

Maximum supply output (Vcc) 30 V

Max. output current
I

(max) (V

out

= Low)

out

VOL at maximum output voltage

7 mA

V

(on) ≤ 0.4 V

out

(low level)

RL The external resistor RL must be selected to

limit the output current to no more than
7 mA.

Executable time

0 < T < 250 µsec

Figure 37: Digital Output Schematic

5.5.4. Analog Input

Feature Details

Maximum operating differential voltage ± 10 V

Maximum absolute differential input
voltage

Differential input resistance 3.74 kΩ

Analog input command resolution 14-bit

± 16 V

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5.6. Safe Torque Off (STO)

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

5.6.1. STO Input Interfaces – TTL Mode

Feature Details

Type of input Optically isolated

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

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

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

Minimum pulse width >3 ms

86

Figure 38: STO Input Schematic

5.6.2. STO Input Interfaces – PLC Mode

Feature Details

Type of input Optically isolated

Input current for all inputs Iin = 2 mA @ Vin = 12 V

High-level input voltage 12 V < Vin < 30 V

Low-level input voltage 0 V < Vin < 7 V

Minimum pulse width >3 ms

Figure 39: STO Input Schematic

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Signals:

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5.7. EtherCAT Communications Version

Specification Details

87

EtherCAT

• 100base-T

• Baud Rate: 100 Mbit/sec

• CAT5 Cable

• CoE, FoE, EoE

Ethernet

• 100base-T

• Baud Rate: 100 Mbit/sec

• CAT5 Cable

• UDP, Telnet

USB USB 2.0 Device mode

RS-232

• RxD , TxD , GND

• Full duplex, serial communication for setup and control.

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

Differential RS-232
(RS-422)

• Rx+,RX- , Tx+ ,TX- GND

• Full duplex, serial communication for setup and control.

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

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5.8. CAN Communications Version

Specification Details

88

CAN

USB

RS-232

Differential RS-232

(RS-422)

CAN-bus Signals:

• CAN_H, CAN_L, CAN_RET

• Maximum Baud Rate of 1 Mbit/sec.

Version:

• DS 301 v4.01

Layer Setting Service and Protocol Support:

• DS 305

Device. Profile (drive and motion control):

• DS 402

• USB 2.0 Device mode

• RxD , TxD , GND

• Full duplex, serial communication for setup and control.

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

• Rx+,RX- , Tx+ ,TX- GND

• Full duplex, serial communication for setup and control.

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

5.9. Pulse-Width Modulation (PWM)

Feature Details

PWM resolution Minimum 10-bit

Default 12-bit

Maximum 14-bit

PWM switching frequency
on the load

2/Ts (factory default 40 kHz on the motor)

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5.10. Compliance with Standards

Specification Details

Quality Assurance

ISO 9001:2008 Quality Management

Design

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

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

MIL-HDBK- 217F Reliability prediction of electronic equipment

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

89

• IPC-D-275

• IPC-SM-782

• IPC-CM-770

Printed wiring for electronic equipment
(clearance, creepage, spacing, conductors
sizing, etc.)

• UL 508C

• UL 840

• UL 60950

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

Safety

Recognized UL 508C Power Conversion Equipment

In compliance with UL 840 Insulation Coordination Including Clearances

and Creepage Distances for Electrical
Equipment

In compliance with UL 60950 Safety of Information Technology Equipment

Including Electrical Business Equipment

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

systems

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

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Specification Details

EMC

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

systems

90

In compliance with EN 55011 Class A with

Electromagnetic compatibility (EMC)

EN 61000-6-2: Immunity for industrial
environment, according to:

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

Workmanship

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

PCB

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

Packing

In compliance with EN 100015 Protection of electrostatic sensitive devices

Environmental

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

regulations (WEEE)

Note: Out-of-service Elmo drives should be

sent to the nearest Elmo sales office.

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

Restrictions on Application of Hazardous
Substances in Electric and Electronic
Equipment (RoHS)

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