Gold Solo Whistle
Digital Servo Drive
Installation Guide
EtherCAT and CAN
July 2014 (Ver. 1.500) 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 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.
Document no. MAN-G-SOLWHIIG-EC (Ver. 1.500)
Copyright 2014
Elmo Motion Control Ltd.
All rights reserved.
Catalog Number
Notes
• The part number of the Gold Solo Whistle (EtherCAT version) has an E, for example, G-
SOLWHI1/100E whereas the CAN version has an S, for example G-SOLWHI1/100S.
• There are two models of the Gold Solo Whistle: 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-GSOLWHIKIT01 (can be ordered separately)
• For further details, see the documentation for this cable kit (MAN-CBLKIT-GSOLWHI.pdf).
Revision History
Version Date Details
Ver. 1.500 July 2014 New template and new format
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
Chapter 1: This Installation Guide ..................................................................................... 6
Chapter 2: Safety Information .......................................................................................... 6
2.1. Warnings ........................................................................................................................ 7
2.2. Cautions .......................................................................................................................... 7
2.3. CE Marking Conformance ............................................................................................... 7
2.4. Warranty Information .................................................................................................... 7
Chapter 3: Product Description ......................................................................................... 8
3.1.1. Accessories ...................................................................................................... 8
Chapter 4: Technical Information ...................................................................................... 9
4.1. Physical Specification ..................................................................................................... 9
4.2. Technical Data ................................................................................................................ 9
4.2.1. Auxiliary Supply ............................................................................................. 10
4.2.2. Product Features ........................................................................................... 11
4
Chapter 5: Installation .................................................................................................... 12
5.1. Unpacking the Drive Components ............................................................................... 12
5.2. Connector Types ........................................................................................................... 13
5.2.1. Connector Types ............................................................................................ 13
5.3. Mounting the Gold Solo Whistle .................................................................................. 15
5.4. The Gold Solo Whistle Connection Diagrams ............................................................... 16
Chapter 6: Wiring ........................................................................................................... 18
6.1. Basic Recommendations .............................................................................................. 19
6.1.1. General .......................................................................................................... 19
6.1.2. Feedback Cable Port A and Port B Connector ............................................... 20
6.1.3. Feedback Cable Port C Connector ................................................................. 21
6.1.4. IO Cable Connector ........................................................................................ 21
6.1.5. STO (Port C) Cable Connector ........................................................................ 22
6.2. Motor Power Connector Pinouts (J28) ......................................................................... 23
6.3. Main and Auxiliary Power ............................................................................................ 25
6.3.1. Description .................................................................................................... 25
6.3.2. Main Power (J29) ........................................................................................... 26
6.3.3. Auxiliary Power Supply (J30) ......................................................................... 27
6.3.3.1. Power Rating 200 V ...................................................................... 28
6.3.3.2. Power Rating 100 V ...................................................................... 29
6.4. Drive Status Indicator ................................................................................................... 31
6.5. STO (Safe Torque Off) (J26) .......................................................................................... 32
6.5.1. Source Mode – PLC Voltage Level ................................................................. 33
6.5.2. TTL Mode – TTL Voltage Level ....................................................................... 33
6.6. Port A Connector (J4) ................................................................................................
... 34
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.6.1. Incremental Encoder ..................................................................................... 35
6.6.2. Halls Sensor ................................................................................................... 35
6.6.3. Absolute Serial Encoder ................................................................................. 36
6.6.3.1. Hiperface ...................................................................................... 37
6.7. Port B Connector (J5) ................................................................................................... 38
6.7.1. Incremental Encoder ..................................................................................... 39
6.7.2. Interpolated Analog Encoder ........................................................................ 40
6.7.3. Resolver ......................................................................................................... 41
6.8. Port C, Digital I/Os, and Analog Inputs (J6) .................................................................. 42
6.8.1. Port C – Emulated Encoder Output ............................................................... 44
6.8.2. Analog Input .................................................................................................. 45
6.8.3. Digital Input and Output TTL Mode ............................................................... 46
6.8.4. Digital Input and Output PLC Source Mode .................................................. 48
6.9. USB 2.0 (J9) ................................................................................................................... 50
6.10. RS-232 Connector (J21) ................................................................................................ 51
6.11. EtherCAT Communications Version ............................................................................. 52
6.11.1. EtherCAT IN/Ethernet Connector (J7) ........................................................... 52
6.11.1.1. EtherCAT OUT Connector (J8) ...................................................... 53
6.11.2. EtherCAT Wiring ............................................................................................ 53
6.11.3. EtherCAT Status Indicator ............................................................................. 54
6.12. CAN Communications Version ..................................................................................... 55
6.12.1. CAN Wiring .................................................................................................... 56
6.13. Powering Up ................................................................................................................. 57
6.14. Initializing the System .................................................................................................. 57
6.15. Heat Dissipation ........................................................................................................... 58
6.15.1. Thermal Data ................................................................................................. 58
6.15.2. Heat Dissipation Data .................................................................................... 58
6.15.3. How to Use the Charts ................................................................................... 59
5
Chapter 7: Dimensions ................................................................................................... 60
Gold Solo Whistle Installation Guide
Table of Contents
Chapter 1:
This Installation Guide
Chapter 2: Safety Information
Warning:
Caution:
Important:
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6
This installation Guide details the technical data, pinouts, and power connectivity of the Gold Solo
Whistle. For a comprehensive detailed description of the functions refer to the
MAN-G-Panel Mounted Drives Hardware manual which describes Panel Mounted products.
In order to achieve the optimum, safe operation of the Gold Solo Whistle, 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 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 Solo Whistle 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.
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 and all Elmo Motion Control manuals:
This information is needed to avoid a safety hazard, which might cause bodily injury
or death as a result of incorrect operation.
This information is necessary to prevent bodily injury, damage to the product or to
other equipment.
Identifies information that is critical for successful application and understanding of
the product.
||Warnings|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
2.1. 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 Whistle from all voltage sources before servicing.
• The high voltage products within the Gold Line range contain 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.
2.2. Cautions
• The maximum DC power supply connected to the instrument must comply with the
parameters outlined in this guide.
7
• When connecting the Gold Solo Whistle to an approved isolated 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 Whistle, verify that all safety precautions have been
observed and that the installation procedures in this manual have been followed.
• Make sure that the Safe Torque Off is operational
2.3. CE Marking Conformance
The Gold Solo Whistle 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 2006/42/EC as amended, and with those of the most recent versions of
standards EN 60204-1 and
Concerning electrical equipment designed for use within certain voltage limits, the Gold Solo
Whistle meets the provisions outlined in 2006/95/EC. The party responsible for ensuring that the
equipment meets the limits required by EMC regulations is the manufacturer of the end product.
EN ISO 12100 at the least, and in accordance with 2006/95/EC.
2.4. 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.
|Warnings|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
Chapter 3: Product Description
MAN-G-SOLWHIIG-EC (Ver. 1.500)
The Gold Solo Whistle is an integrated solution delivering 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 36.22 mm or 2.89" x 1.83" x 1.425"), and
designed to simply and efficiently connect Elmo’s Gold Whistle servo drive directly to the
application. The solution consists of the Gold Whistle together with a convenient connection
interface which either eliminates or reduces development time and resources when designing an
application’s PCB board.
This advanced, high power density servo drive provides top performance, advanced networking and
built-in safety, as well as a fully featured motion controller and local intelligence. The Gold Solo
Whistle is powered by a single 12 V – 195 V isolated DC power source (not included) and a “smart”
control-supply algorithm enables the drive to operate up to 95V with only one power supply with
no need for an auxiliary power supply for the logic.
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 Solo Whistle drive is easily set up and tuned using Elmo Application Studio (EASIi) 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.
8
The Gold Solo Whistle 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.
3.1.1. Accessories
Cable Kit, catalog number: CBL-GSOLWHIKIT01 (can be ordered separately)
For further details, see the documentation for this cable kit (MAN-CBLKIT-GSOLWHI.pdf).
|Warranty Information|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
Chapter 4: Technical Information
MAN-G-SOLWHIIG-EC (Ver. 1.500)
9
4.1. Physical Specification
Feature Units All Types
Weight g (oz) 106 g (3.74 oz)
Dimension mm (in) 73.4 x 46.5 x 36.22 mm (2.89" x 1.83" x 1.425")
Mounting method Panel Mounted
4.2. 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
Note on current ratings: The current ratings of the Gold Solo 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.
W 80 200 400 800 1200 1600
% > 99
(up to 6 VA inc. 5 V/2 x 200 mA for encoder)
A 1.0 2.5 5 10 15 20
A 0.7 1.8 3.5 7 10.6 14.1
Table 1: Power Rating
|Physical Specification|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
Elmo now offers a 200 VDC maximum output rating selection of Gold Solo 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
10
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
4.2.1. 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
|Technical Data|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
4.2.2. Product Features
11
Main Feature
STO
Digital Input
Digital Output
Analog Input
Feedback
Communication
Option
Details Presence and No.
TTL, or √
PLC Source √
TTL
, or 6
PLC Source 6
TTL
, or 2
PLC Source 2
Differential ±10V 1
Standard Port A, B, & C √
USB √
EtherCAT √
CAN √
RS-232 √
|Technical Data|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
Chapter 5: Installation
MAN-G-SOLWHIIG-EC (Ver. 1.500)
The Gold Solo Whistle must be installed in a suitable environment and properly connected to its
voltage supplies and the motor.
5.1. Unpacking the Drive Components
Before you begin working with the Gold Solo Whistle, verify that you have all of its components, as
follows:
• The Gold Solo Whistle servo drive
• The Elmo Application Studio software and software manual
The Gold Solo Whistle is shipped in a cardboard box with Styrofoam protection.
To unpack the Gold Solo Whistle:
1. Carefully remove the servo drive from the box and the Styrofoam.
12
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 Whistle you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Gold Solo Whistle. It looks
like this:
4. Verify that the Gold Solo Whistle type is the one that you ordered, and ensure that the
voltage meets your specific requirements.
The part number at the top provides the type designation. Refer to the appropriate part
number in the section Catalog Number at the beginning of the installation guide.
The part number of the Gold Solo Whistle (EtherCAT version) has an E, for example, GSOLWHI10/100E whereas the CAN version has an S, for example G- SOLWHI10/100S.
There are two models of the Gold Solo Whistle: 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.
||Unpacking the Drive Components|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
5.2. Connector Types
The Gold Solo Whistle has twelve connectors (connectors version).
5.2.1. Connector Types
Port No. Pins Type Function
13
M1, M2, M3,
PE
4 5.08 mm pitch Motor phases
(Connectors version)
VP+, PR, PE 3 5.08 mm pitch Power (Connectors version)
Wires 7 14 AWG
(M1,M2,M3,PR,VP+)
Main Power and Motor Power
(Wires version)
16 AWG (PE)
J4 2x6 2.0 mm pitch Feedback port A
J5 2x4 2.0 mm pitch Feedback port B
J6 2x12 2.0 mm pitch I/O and port C
J9 5 USB Device Mini-B Mini-USB type B
J21 3 2.0 mm pitch RS-232 communication
J26 3 2.0 mm pitch STO
J27 2 2.0 mm pitch PTC - External Temperature Sensor
J30 (PR, VL) 2 2.0 mm pitch Auxiliary supply input
EtherCAT Version
J7 8 RJ-45 EtherCAT in
J8 8 RJ-45 EtherCAT out
CAN Version
J22 4 2.0 mm pitch CAN
J23 4 2.0 mm pitch CAN
|Connector Types|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
14
Figure 1: Connector Locations – EtherCAT
Figure 2: Connector Locations – CAN
Table 2: Connector Types
The pinouts in Chapter 6: Wiring describe the function of each pin in the Gold Solo Whistle
connectors that are listed in Table 2.
|Connector Types|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
5.3. Mounting the Gold Solo Whistle
The Gold Solo Whistle was designed for mounting on a surface. When integrating the Gold Solo
Whistle into a device, be sure to leave about 1 cm (0.4") outward from the heat-sink to enable free
air convection around the drive. If the Gold Solo Whistle is enclosed in a metal chassis, we
recommend that the Gold Solo Whistle be screw-mounted to it to help with heat dissipation. The
Gold Solo Whistle has screw-mount holes on each corner of the heat-sink for this purpose – see
below.
15
Figure 3: Mounting the Gold Solo Whistle
When the Gold Solo Whistle is not connected to a metal chassis, the application’s thermal profile
may require a solution for heat dissipation due to insufficient air convection. In this case, we
recommend that you connect an external heat-sink. Elmo has an external heat-sink (Catalog
number: WHI-HEATSINK-2) that can be ordered for this purpose – see below.
Figure 4: Gold Solo Whistle External Heat-sink
|Mounting the Gold Solo Whistle|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
5.4. The Gold Solo Whistle Connection Diagrams
16
Figure 5: The Gold Solo Whistle Connection Diagram - EtherCAT
|The Gold Solo Whistle Connection Diagrams|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
17
Figure 6: The Gold Solo Whistle Connection Diagram – CAN
|The Gold Solo Whistle Connection Diagrams|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
Chapter 6: Wiring
MAN-G-SOLWHIIG-EC (Ver. 1.500)
Once the product 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 drive.
The following table legend describes the wiring symbols detailed in all installation guides.
Wiring Symbol Description
Earth connection (PE)
Protective Earth Connection
Common at the Controller
Shielded cable with drain wire.
The drain wire is a non-insulated wire
that is in direct contact with the braid
(shielding).
18
Shielded cable with drain wire
significantly simplifies the wiring and
earthing.
Shielded cable braid only, without
drain wire.
Twisted-pair wires
Encoder Earthing.
The cable`s shield is connected to the
chassis (PE) in the connector.
Earthing the Encoder and connecting
the Earth (PE) to the drive COMRET is
mandatory to insure reliable
operation, high noise immunity and
rejection of voltage common mode
interferences.
|The Gold Solo Whistle Connection Diagrams|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.1. Basic Recommendations
6.1.1. General
1. Use shielded cables. For best results, the cable should have an aluminum foil shield covered
by copper braid, and should contain a drain wire.
Use 24, 26 or 28 AWG twisted-pair shielded with drain wire cables.
2. Keep the cable as short as possible.
Do not mount the power cables of the motor and power bus in the proximity of the control
and feedback cables.
3. Ensure that in normal operating conditions, the “earth connection” wires and shield of the
control cables 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 might result in
drive/controller/host failure.
19
4. After completing the wiring, carefully inspect all wires to ensure tightness, good solder of
joints and general safety.
Figure 7: Feedback and Shrouded Control Cable Assemblies – Example
5. Where there is only one COMRET pin (Common Return) in the connector, which MUST be
connected to the DRAIN WIRE and also to COMRET signal of the cable, it is necessary to
connect the drain wire and COMRET signal to the same pin.
|Basic Recommendations|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.1.2. Feedback Cable Port A and Port B Connector
1. On the motor side connections, ground the shield to the motor chassis.
2. At least One COMRET (Common Return) must be connected to the PE.
Implement the following steps to connect the COMRET to the PE:
a. At the drive, connect the feedback drain wire to one of the COMRET terminals in the
Shrouded feedback connector (Figure 8).
b. At the motor, connect the feedback cable drain wire to the GND motor chassis
terminal of the feedback connector (Figure 8).
The drawing displays two earth connections.
20
Figure 8: Feedback Port A and B Cable Assemblies
|Basic Recommendations|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.1.3. Feedback Cable Port C Connector
1. At the controller side connections, follow the controller manufacturer’s recommendations
concerning the shield.
2. The connection of the Drain wire to the Port C is not mandatory.
21
Figure 9: Feedback Port C Cable Assemblies
6.1.4. IO Cable Connector
It is recommended to use shielded cable, but is not mandatory.
Figure 10: Feedback IO Cable Assemblies
|Basic Recommendations|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.1.5. STO (Port C) Cable Connector
It is recommended to use shielded cable, but is not mandatory.
Figure 11: STO Cable Assemblies
22
|Basic Recommendations|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.2. Motor Power Connector Pinouts (J28)
See Chapter 8 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Pin (J28) Signal Function Cable – Wires
Brushless Motor Brushed DC Motor
4 PE Protective earth Motor Motor
3 M1 Motor phase Motor N/C
2 M2 Motor phase Motor Motor
1 M3 Motor phase Motor Motor
Pin Positions
23
Table 3: 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.
|Motor Power Connector Pinouts (J28)|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
Figure 12: Brushless Motor Power Connection Diagram
24
Figure 13: Brushed Motor Power Connection Diagram
|Motor Power Connector Pinouts (J28)|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.3. Main and Auxiliary Power
The Gold Solo Whistle receives power from main and auxiliary supplies and delivers power to the
motor.
6.3.1. Description
This section describes the Main and Auxiliary Power for power ratings 200V and 100V, and provides
details for the optional Backup (Auxiliary) Supply.
The Gold Solo Whistle Power rating is 12 to 195 VDC
There are Two power ratings for Gold Solo 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 Solo Whistle is provided by a 12–95 VDC single
isolated DC power source (not included with the Gold Solo Whistle). A “smart” control-supply
algorithm enables the Gold Solo Whistle to operate with only one power supply with no need
for an auxiliary power supply for the logic.
25
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 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 Solo Whistle, therefore the correct power supply
must be used, according to the maximum operating voltage of the Gold Solo Whistle. Refer to
section 4.2 Technical Data.
|Main and Auxiliary Power|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.3.2. Main Power (J29)
Pin (J29) Signal Function Cable
1 PE Protective Earth DC Power
2 PR Power Return DC Power
3 VP+ Positive Power Input DC Power
Pin Positions
26
Table 4: Main Power and Motor Connections
Power to the Gold Solo Whistle is provided by a 12 to 195 VDC source.
Connect the DC power cable to the VP+ and PR terminals on the Main Power Connector.
To connect the DC power supply:
1. The source of the 12 to 195 VDC power supply must be isolated.
2. 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.
3. Connect the cable shield to the closest ground connection near the power supply.
4. Connect the PE to the closest ground connection near the power supply.
5. Connect the PR to the closest ground connection near the power supply.
6. Before applying power, first verify the polarity of the connection.
|Main and Auxiliary Power|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.3.3. Auxiliary Power Supply (J30)
Pin (J30) Signal Function
1 PR Auxiliary Supply Return
2 VL+ Auxiliary Supply Input
Pin Positions Cable Connector
2-Pin Tyco Plug
27
This cable is included in the
cable kit described in Section
3.1.1.
Table 5: Auxiliary Supply Pins
Caution: Power from the Gold Solo Whistle to the motor must come from the
Main Supply and NOT from the Auxiliary Supply.
The backup functionality can be used for storing control parameters in case of power-outs,
providing maximum flexibility and backup capability when needed.
Connect the VL+ and PR terminal to the Auxiliary Connector.
To connect the auxiliary supply:
1. The source of the Auxiliary Supply must be isolated.
2. For safety reasons, connect the return (common) of the auxiliary supply source to the
closest ground near the auxiliary supply source.
3. Connect the cable shield to the closest ground near the auxiliary supply source.
A cable kit containing a cable that connects to the auxiliary supply connector (J30) is
available. See Section 3.1.1.
4. Before applying power, first verify the polarity of the connection.
|Main and Auxiliary Power|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.3.3.1. 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.
28
Figure 14: 200 VDC Power Source Connection Diagram
|Main and Auxiliary Power|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.3.3.2. Power Rating 100 V
6.3.3.2.a Single Power Supply
For power rating 100 V , a single Power Supply is required which contains a “smart” control-supply
algorithm, enabling the Gold Solo Whistle to operate with only one power supply with no need for
an auxiliary power supply for the logic.
29
Figure 15: Main Power Supply Connection Diagram (No Auxiliary Supply)
|Main and Auxiliary Power|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.3.3.2.b Optional Backup Supply
30
Figure 16: Auxiliary Supply Connection Diagram
|Main and Auxiliary Power|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.4. Drive Status Indicator
Figure 17 shows the position of the red/green dual LED, which is used for immediate indication of
the Initiation and Working states. For details refer to Chapter 7 Drive Status Indicator, in the
MAN-G-Panel Mounted Drives Hardware manual.
31
Drive Status Indicator - EtherCAT
Figure 17: Drive Status Indicator - CAN
The 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).
|Drive Status Indicator|www.elmomc.com
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.5. STO (Safe Torque Off) (J26)
See Chapter 9 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Pin (J26) Signal Function
1 STO1 STO 1 input (default 24 V)
2 STO2 STO 2 input (default 24 V)
3 STO_RET STO signal return
Pin Positions Cable Connector
32
Table 6: STO Input Pin Assignments
3-Pin Tyco Plug
This cable is included in the
cable kit described in
Section 3.1.1.
|STO (Safe Torque Off) (J26)|www.elmomc.com
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.5.1. Source Mode – PLC Voltage Level
Refer to the diagrams below for the PLC Source option connection.
Figure 18: STO Shrouded Type Input Connection – PLC Source Option
33
6.5.2. TTL Mode – TTL Voltage Level
Refer to the diagrams below for TTL option connection.
Figure 19: STO Input Connection – TTL Option
|STO (Safe Torque Off) (J26)|www.elmomc.com
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.6. Port A Connector (J4)
See Section 10.3 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Incremental Encoder Absolute Serial Encoder
Pin (J4) Signal Function Signal Function
34
1 +5V Encoder +5V
+5V Encoder +5V supply
supply
2 COMRET Common
COMRET Common Return
Return
3 PortA_ENC_A+ Channel A + ABS_CLK+ Absolute encoder clock+
4 PortA_ENC_A- Channel A - ABS_CLK- Absolute encoder clock-
5 PortA_ENC_B+ Channel B+ ABS_DATA+ Absolute encoder data+
6 PortA_ENC_B- Channel B - ABS_DATA- Absolute encoder data -
7 PortA_ENC_INDEX+ Index+ Reserved Reserved
8 PortA_ENC_INDEX- Index - Reserved Reserved
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
COMRET Common Return COMRET Common Return
Pin Positions Cable Connector
12-Pin Tyco Plug
This cable is included
in the cable kit
described in Section
3.1.1.
Table 7: Port A Pin Assignments
|Port A Connector (J4)|www.elmomc.com
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Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.6.1. Incremental Encoder
35
Figure 20: Port A Shrouded Type Incremental Encoder Input – Recommended Connection Diagram
6.6.2. Halls Sensor
Figure 21: Shrouded Type Hall Sensors Connection Diagram
|Port A Connector (J4)|www.elmomc.com
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Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.6.3. Absolute Serial Encoder
The following figures describe the connections at Port A for the Absolute Serial type encoders.
36
Figure 22: Absolute Serial Encoder – Recommended Connection Diagram for EnDAT, Biss, SSI
Figure 23: Absolute Serial Encoder – Recommended Connection Diagram for Sensors
Supporting Data Line Only (NRZ types, e.g., Panasonic / Mitutoyo / Sanyo Danki / Tamagawa)
|Port A Connector (J4)|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.6.3.1. Hiperface
The following figure describes the connection diagram.
37
Figure 24: Absolute Serial Encoder – Recommended Shrouded Type Connection Diagram for
Stegmann Hiperface
Note: When the Hiperface protocol is used, the RS-232 connection is not available
|Port A Connector (J4)|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.7. Port B Connector (J5)
See Section 10.4 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
38
Incremental or
Resolver
Interpolated Analog Encoder
G-SOLWHIXXX/YYYYEX G-SOLWHIXXX/YYYYRX
Pin (J5) Signal Function Signal Function
1 +5V Encoder +5V supply NC
2 COMRET Common Return COMRET Common 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
COS+ Cosine+
B+/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 Max.
Pin Positions Cable Connector
8-Pin Tyco Plug
This cable is included in
the cable kit described in
Section 3.1.1.
Table 8: Port B Pin Assignments
|Port B Connector (J5)|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.7.1. Incremental Encoder
The following figure describes the connections at Port B for the Incremental encoder.
39
Figure 25: Port B Incremental Encoder Input – Recommended Connection Diagram
|Port B Connector (J5)|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.7.2. Interpolated Analog Encoder
The following figure describes the connections at Port B for the Interpolated Analog encoder.
40
Figure 26: Port B - Interpolated Analog Encoder Shrouded Type Connection Diagram
|Port B Connector (J5)|www.elmomc.com
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.7.3. Resolver
41
Figure 27: Port B – Resolver Shrouded Type Connection Diagram
|Port B Connector (J5)|www.elmomc.com
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.8. Port C, Digital I/Os, and Analog Inputs (J6)
The Port C connector includes the following functions:
• Port C: Refer to Sections 10.5 in the in the MAN-G-Panel Mounted Drives Hardware manual
for full details
• I/O: Refer to Chapter 11 in the in the MAN-G-Panel Mounted Drives Hardware manual for full
details.
• Analog input: See Section 11.2 in the in the MAN-G-Panel Mounted Drives Hardware manual
for full details.
Pin (J6) Signal Function
1 PortC_ENCO_A+ Buffered Channel A output
2 PortC_ENCO_A- Buffered Channel A complement output
3 PortC_ENCO_B+ Buffered Channel B output
4 PortC_ENCO_B- Buffered Channel B complement output
42
5 PortC_ENCO_Index+ Buffered INDEX output
6 PortC_ENCO_Index- Buffered INDEX complement output
7 COMRET Common return
8 COMRET Common return
9 ANALOG1- Analog input complement
10 ANALOG1+ Analog input
11 ANARET Analog return
12 INRET1_6 Programmable input 1 – 6 return
13 IN1 Programmable input 1 (High speed)
14 IN2 Programmable input 2 (High speed)
15 IN3 Programmable input 3 (High speed)
16 IN4 Programmable input 4 (High speed)
17 IN5 Programmable input 5 (High speed)
18 IN6 Programmable input 6 (High speed)
19 Reserved Reserved
20 Reserved Reserved
21 OUT2 Programmable output 2
22 OUT1 Programmable output 1
23 VDD VDD supply (5 V up to 30 V)
24 VDDRET VDD supply return
|Port C, Digital I/Os, and Analog Inputs (J6)|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
Pin Positions Cable Connector
24-Pin Tyco Plug
This cable is included in
the cable kit described
in Section 3.1.1.
43
Table 9: Port C Feedback Out and I/O
|Port C, Digital I/Os, and Analog Inputs (J6)|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.8.1. Port C – Emulated Encoder Output
The following figure describes the connections at Port C for the Emulated Encoder Differential.
44
Figure 28: Emulated Encoder Differential Output – Recommended Connection Diagram
Note that the user is required to connect a 120 Ω termination at the end of each differential line.
|Port C, Digital I/Os, and Analog Inputs (J6)|www.elmomc.com
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Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.8.2. Analog Input
The following circuit describes the internal interface of the Analog input.
45
Figure 29: Differential Analog Input
|Port C, Digital I/Os, and Analog Inputs (J6)|www.elmomc.com
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.8.3. Digital Input and Output TTL Mode
The following figure describes the connections at the I/O Port for the Digital Input and Output TTL
Mode.
46
Figure 30: Digital Input TTL Mode Connection Diagram
|Port C, Digital I/Os, and Analog Inputs (J6)|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
47
Figure 31: Digital Output Connection Diagram – TTL Option
|Port C, Digital I/Os, and Analog Inputs (J6)|www.elmomc.com
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.8.4. Digital Input and Output PLC Source Mode
The following figure describes the connections at the I/O Port for the Digital Input and Output PLC
Mode.
48
Figure 32: Digital Input Connection Diagram – Source PLC Option
|Port C, Digital I/Os, and Analog Inputs (J6)|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
49
Figure 33: Digital Output Connection Diagram – Source PLC Option
|Port C, Digital I/Os, and Analog Inputs (J6)|www.elmomc.com
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.9. USB 2.0 (J9)
See Section 12.1 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Pin (J9) Signal Function
1 USB VBUS USB VBUS 5 V
2 USBD- USB _N line
3 USBD+ USB _P line
5 USB COMRET USB communication return
Pin Positions Cable Connector
50
Table 9: USB Device Mini-B - Pin Assignments
USB Device Mini-B Plug
Figure 34: USB Network Diagram
|USB 2.0 (J9)|www.elmomc.com
Gold Solo Whistle Installation Guide
Table of Contents
MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.10. RS-232 Connector (J21)
See section 12.5 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Pin (J21) Signal Function
1 RS232_Rx RS-232 receive
2 RS232_Tx RS-232 transmit
3 RS232_COMRET RS-232 communication return
Pin Positions Cable Connector
51
Table 10: RS-232 Pin Assignments
3-Pin Tyco Plug
Figure 35: RS-232 Connection Diagram
|RS-232 Connector (J21)|www.elmomc.com
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.11. EtherCAT Communications Version
Fieldbus communications are industrial network protocols for real-time distributed control that
allows connection of servo drives. The Gold Solo Whistle supports the following EtherCAT fieldbus
type industrial network protocol:
Fieldbus Type Product Number
EtherCAT G-SOLWHI XX/YYYEXX
6.11.1. EtherCAT IN/Ethernet Connector (J7)
Refer to section 12.2 in the MAN-G-Panel Mounted Drives Hardware manual for more details.
Pin (J7) Signal Function
1 EtherCAT_IN_TX+/Ethernet_TX+ EtherCAT in/Ethernet transmit +
2 EtherCAT_IN_TX-/Ethernet_TX- EtherCAT in/Ethernet transmit -
3 EtherCAT_IN_RX+/Ethernet_RX+ EtherCAT in/Ethernet receive +
52
4, 5 N/A
6 EtherCAT_IN_RX-/Ethernet_RX- EtherCAT in/Ethernet receive -
7, 8 N/A
Pin Positions Cable Connector
Standard CAT5e Ethernet
Cable
Table 11: EtherCAT IN - Pin Assignments
|EtherCAT Communications Version|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.11.1.1. EtherCAT OUT Connector (J8)
See Section 12.2 in the MAN-G-Panel Mounted Drives Hardware manual for the electrical diagram.
Pin (J8) Signal Function
1 EtherCAT_OUT_TX+ EtherCAT out transmit +
2 EtherCAT_OUT_TX- EtherCAT out transmit -
3 EtherCAT_OUT_RX+ EtherCAT out receive +
4, 5 N/A
6 EtherCAT_OUT_RX- EtherCAT out receive -
7, 8 N/A
Pin Positions Cable Connector
53
Table 12: EtherCAT OUT - Pin Assignments
6.11.2. EtherCAT Wiring
Figure 36 describes the wiring diagram for the EtherCAT connections.
Standard CAT5e Ethernet
Cable
Figure 36: EtherCAT RJ-45 Connections
|EtherCAT Communications Version|www.elmomc.com
Gold Solo Whistle Installation Guide
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.11.3. EtherCAT Status Indicator
Figure 37: EtherCAT Status LED
54
The EtherCAT status indicator is a single red/green dual bi-colored LED that combines the green
RUN indicator and the red ERROR indicator of the EtherCAT state machine. For further details, see
the EtherCAT Application Manual.
Note: There is no Gold Solo Whistle ECAT Status indicator equivalent in the CAN version, refer to
the figure below.
Figure 38: Gold Solo Whistle Status Indicator - CAN
|EtherCAT Communications Version|www.elmomc.com
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.12. CAN Communications Version
Fieldbus communications are industrial network protocols for real-time distributed control that
allows connection of servo drives. The Gold Solo Whistle supports the following CAN fieldbus type
industrial network protocol:
Fieldbus Type Product Number
CAN G-SOLWHI XX/YYYSXX
See Section 12.4 in the MAN-G-Panel Mounted Drives Hardware manual for the electrical diagram.
Pin (J22, J23) Signal Function
1 PE Protective Earth
2 COMRET (CAN_RET) CAN Return
3 CAN_L CAN_L bus line (dominant low)
4 CAN_H CAN_H bus line (dominant high)
55
Pin Positions Cable Connector
4-Pin Tyco Plug
Table 13: CAN Connectors Pin Assignments
|CAN Communications Version|www.elmomc.com
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.12.1. CAN Wiring
56
Caution
When installing the CAN
communications, ensure that each
servo drive is allocated a unique ID.
Otherwise, the CAN network may
hang.
Figure 39: Gold Solo Whistle Connection Diagram – CAN
|CAN Communications Version|www.elmomc.com
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MAN-G-SOLWHIIG-EC (Ver. 1.500)
6.13. Powering Up
After the Gold Solo Whistle is connected to its device, it is ready to be powered up.
Caution:
Before applying power, ensure that the DC supply is within the specified range
and that the proper plus-minus connections are in order.
6.14. Initializing the System
After the Gold Solo Whistle has been connected and mounted, the system must be set up and
initialized. This is accomplished using the EASII, Elmo’s Windows-based software application. Install
the application and then perform setup and initialization according to the directions in the EASII
User Manual.
57
|Powering Up|www.elmomc.com
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Whistle - 60
Series Power Dissipation
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
0
0
.
75
1
.
5
2
.
25
3
3
.
75
4
.
5
5
.
25
6
6
.
75
7
.
5
8
.
25
9
9
.
75
Peak Current (A)
Power Dissipation (Watts
50V
40V
30V
20V
External
Heatsink
Gold Solo
Standard 40 °C Ambient Temp.
MAN-G-SOLWHIIG-EC (Ver. 1.500)
58
6.15. Heat Dissipation
The best way to dissipate heat from the Gold Solo Whistle is to mount it so that its heat sink faces
up. For best results leave approximately 10 mm of space between the Gold Solo Whistle’s heat sink
and any other assembly.
6.15.1. Thermal Data
• Heat dissipation capability (θ): Approximately 10 °C/W
• Thermal time constant: Approximately 240 seconds (thermal time constant means that the
Solo Whistle will reach 2/3 of its final temperature after 4 minutes)
• Shut-off temperature: 86 °C to 88 °C (measured on the heat sink)
6.15.2. Heat Dissipation Data
Heat dissipation is shown in graphically below:
Heatsink
Required
not
Required
||Heat Dissipation|www.elmomc.com
Gold Solo Whistle Installation Guide
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Whistle 100
Series Power Dissipation
0.0
1.0
2.0
3.0
4.0
5.0
6.0
0
0.511.522.533.544.5
5
Peak Current (A)
Power Dissipation (W)
85VDC
70VDC
50VDC
Standard 40 °C Ambient Temp.
External
Heatsink
Required
Heatsink
not
Required
Gold Solo
MAN-G-SOLWHIIG-EC (Ver. 1.500)
59
6.15.3. 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:
6. Allow maximum heat sink temperature to be 80 °C or less.
7. Determine the ambient operating temperature of the Solo Whistle.
8. Calculate the allowable temperature increase as follows:
For an ambient temperature of 40 °C , ΔT= 80°C – 40 °C = 40 °C
9. 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.
10. If the dissipated power is below 4 W the Solo Whistle 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.
|Heat Dissipation|www.elmomc.com
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Table of Contents
Chapter 7: Dimensions
MAN-G-SOLWHIIG-EC (Ver. 1.500)
This chapter provides detailed technical dimensions regarding the Gold Solo Whistle.
60
||Heat Dissipation|www.elmomc.com
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61
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