ElmoMC SimplIQ Digital Servo Drives-Bell Installation Guide

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Bell

Digital Servo Drive

Installation Guide

July 2014 (Ver. 1.302)

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Elmo Motion Control and the Elmo Motion Control logo are

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 Bell servo drive in its installation.

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

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

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

registered trademarks of Elmo Motion Control Ltd.

Document no. MAN-BELIG (Ver. 1.302)

Elmo Motion Control Ltd.

Catalog Number

The model that is currently available is the BEL-5/100.

Chapter 1: Safety Information

Bell Installation Guide Safety Information

In order to achieve the optimum, safe operation of the Bell stepper 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 Bell and accompanying equipment.

Please read this chapter carefully before the installation process.

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

Only qualified technical personnel may install, adjust, maintain and repair the stepper drive. Such personnel have the knowledge and authorization to perform tasks such as transporting, assembling, installing, commissioning and operating motors.

The Bell stepper 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 build-up of static electricity.

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:

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

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

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Bell Installation Guide Safety Information

1.1. Warnings

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

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

• Disconnect the Bell from all voltage sources before it is opened for servicing.

• The Bell stepper 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). It is recommended to measure the electrical contact points with a meter before touching the equipment.

1.2. Cautions

• The Bell servo drive contains hot surfaces and electrically-charged components during

operation.

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

parameters outlined in this guide.

• When connecting to Bell to an approved isolated 24 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 Bell, 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 Bell 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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Bell Installation Guide Safety Information

1.3. Directives and Standards

The Bell 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

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 Bell stepper drive has been developed, produced, tested and documented in accordance with the relevant standards. Elmo Motion Control and Digital Feedback Technologies are not responsible for any deviation from the configuration and installation described in this documentation. Furthermore, they are not responsible for the performance of new measurements or ensuring that regulatory requirements are met.

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Bell Installation Guide Safety Information

1.4. CE Mark Conformance

The Bell stepper drive is intended for incorporation in a machine or end product. The actual end product must at a minimum 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 EN60204-1 and EN292-2.

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 Bell 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 — including a warranty of merchantability and fitness for a particular purpose — extend beyond this warranty.

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Chapter 2: Introduction

Bell Installation Guide

This installation guide describes the Bell stepper drive and the steps for its wiring, installation and power-up. Following these guidelines ensures maximum functionality of the drive and the system to which it is connected.

2.1. Drive Description

Elmo Motion Control’s Bell is an intelligent digital stepper drive designed to add stepper technology to the SimplIQ product family. The Bell can deliver up to 500 W of continuous power or 1,000 W of peak power in a compact package.

The Bell is the outcome of many years of designing and manufacturing motion control products. Developed to meet OEM application requirements, the stepper drive offers a desirable solution providing networking and intelligent programming capabilities while using lower cost stepper motors. Additionally, designed as a PCB mounted device, the drive can be implemented efficiently and at low cost.

The Bell incorporates Elmo’s highly efficient and compact power density design together with the rich feature set of the SimplIQ DSP core motion control technology. The combination of the Bell’s programming flexibility, wide variety of feedbacks to close the velocity or position loop (if required) and CAN networking capabilities, makes it an ideal, cost effective solution.

The Bell drive is easily set up and tuned using Elmo’s Composer software tools, and the tuning tools of Digital Feedback Technologies. These Windows-based applications enable users to quickly and simply configure the stepper drive for optimal use with their motor.

2.2. Product Features

2.2.1. Motion Control Modes

• Current/Torque - up to 20 kHz sampling rate

• Velocity - up to 10 kHz sampling rate

• Position - up to 10 kHz sampling rate

2.2.2. Advanced Positioning Motion Control Modes

• PTP, PT, PVT, ECAM, Follower, Dual Loop

• Fast event capturing inputs

• Fast output compare (OC)

• Motion Commands: Analog, PWM, SW, Pulse & Direction

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Controller

Main

12-95 VDC

Power supply

Optional

12-95 VDC

Auxiliary supply

I/Os

Communication

RS 232 and CANopen

Power Stage

Current

Feedback

Motor

Auxilia r y

Encoder

Incremental

Encoder

Analog

Encoder

PWM

Prote ction

Bell Installation Guide Introduction

2.2.3. Feedback Options

• Incremental Encoder - up to 40 Mega-Counts per second

• Digital Halls - up to 2 kHz

• Incremental Encoder with Digital Halls for commutation - up to 40 Mega-Counts

• Interpolated Analog Sine/Cosine Encoder - up to 400 kHz

 Internal Interpolation - up to x4096  Automatic correction of amplitude mismatch, signal offset

• Analog Halls

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

• The Bell 5 V power supply provides supply voltage (5 V, 200 mA max) for one

Encoder/Resolver/Hall Sensor

2.3. System Architecture

Figure 1: Bell System Block Diagram

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Bell Installation Guide Introduction

2.4. How to Use this Guide

In order to install and operate your Bell stepper drive, you will use this manual in conjunction with a set of Elmo and Digital Feedback Technologies 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 Bell.

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

Upon completing the instructions in this guide, your Bell stepper drive should be successfully mounted and installed. From this stage, you need to consult higher-level documentation in order to set up and fine-tune the system for optimal operation. The following figure describes the accompanying documentation that you will require.

Figure 2: Elmo Digital Stepper Drive Documentation

As depicted in the previous figure, this installation guide is an integral part of the Bell documentation set, comprising:

• The SimplIQ for Steppers Command Reference and the SimplIQ for Steppers Application

Note, which describe in detail each software command used to manipulate the Bell motion

controller.

• The SimplIQ Programming and Language Manual, which includes explanations of all the

software tools that are part of Elmo’s Composer software environment.

• The Bell Stepper Drive Installation Guide, which describes, in detail, the differences that

have been introduced by the Bell to SimplIQ to cover 2-phase motors and steppers.

• The SimplIQ for Steppers Getting Started Guide, which describes how to set up and tune

the stepper drive.

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Chapter 3: Installation

Bell Installation Guide Installation

3.1. Site Requirements

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

Environmental Condition Value

Ambient operating temperature

Maximum relative humidity 90% non-condensing

Operating area atmosphere No flammable gases or vapors permitted in

Models for extended environmental conditions are available.

Caution: The Bell dissipates its heat by convection. The maximum operating ambient temperature of 0°C to 40°C (32°F to 104°F) must not be exceeded.

0 °C to 40 °C (32 °F to 104 °F)

area

3.2. Unpacking the Drive Components

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

• The Bell stepper drive

• The Composer software and software manual

The Bell is shipped in a cardboard box with Styrofoam protection.

To unpack the Bell:

1. Carefully remove the stepper drive from the box.

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

3. To ensure that the Bell you have unpacked is the appropriate type for your requirements,

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

locate the part number sticker on the side of the Bell. It looks like this:

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

The model that is currently available is the BEL-5/100.

Verify that the Bell drive is the type that you ordered, and ensure that the voltage meets your specific requirements.

3.3. Pinouts

3.3.1. Connector Types

No.

Type Port Function Connector Location

Pins

2x11

J1 I/O, COMM,

Auxiliary Feedback

15 J2 Main Feedback, Analog

Input, LED

2 M1* Motor power output 1

2 M2* Motor power output 2

2 mm pitch

2 M3* Motor power output 3

2 M4* Motor power output 4

0.51 mm sq

2 PE Protective earth

2 PR Power input return

2 VP+ Positive power input

1 VL Auxiliary power input

* M1 and M2- motor winding A for stepper or DC motors

* M3 and M4- motor winding B for steppers

* M1, M2 and M3 – Brushless DC motor

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3.3.2. Connector J1

Pin Signal Function

J1/1 RS232_RX RS232 receive

J1/2 RS232_TX RS232 Transmit

J1/3 RS232_COMRET Communication return

J1/4 SUPRET Supply return

J1/5 AUX PORT CHA AUX PORT CHA (bidirectional)

J1/6 SUPRET Supply return

J1/7 OUT1 Programmable Digital output 1

J1/8 OUT2 Programmable Digital output 2

J1/9 IN1 Programmable Digital input 1

J1/10 IN2 Programmable Digital input 2

J1/11 IN3 Programmable Digital input 3

J1/12 IN4 Programmable Digital input 4

J1/13 IN5 Programmable Digital input 5

J1/14 IN6 Programmable Digital input 6

J1/15 INRET Programmable Digital input return

J1/16 OUTRET2 Programmable Digital output 2 return

J1/17 OUTRET1 Programmable Digital output 1 return

J1/18 AUX PORT CHB AUX PORT CHB (bidirectional)

J1/19 AUX PORT INDEX AUX PORT INDEX (bidirectional)

J1/20 CAN_COMRET Communication return

J1/21 CAN_L CAN_L busline (dominant low)

J1/22 CAN_H CAN_H busline (dominant high)

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3.3.3. Connector J2

Pin Signal Function

J2/1 +5V Encoder/Hall +5 V supply voltage.

Maximum output current: 200 mA

J2/2 SUPRET Supply return

J2/3 ANALIN1+ Analog input 1+

J2/4 ANALIN1- Analog input 1-

J2/5 CHA Channel A input

J2/6 CHA- Channel A input complement

J2/7 CHB Channel B input

J2/8 CHB- Channel B input complement

J2/9 INDEX+ Index input

J2/10 INDEX- Index input complement

J2/11 HA Hall sensor A input

J2/12 HB Hall sensor B input

J2/13 HC Hall sensor C input

J2/14 LED_2_OUT Bi-color indication output 2 (Cathode)

J2/15 LED_1_OUT Bi-color indication output 1 (Anode)

3.4. Mounting the Bell

The Bell was designed for mounting on a printed circuit board (PCB). It is connected by 2 mm pitch

0.51 mm square pins. When designing the Bell into a device, be sure to leave about 1 cm (0.4") outward from the heatsink to enable free air convection around the Bell. We recommend that the Bell be soldered directly to the board. Alternatively, the Bell can be attached to socket connectors mounted on the PCB. If the PCB is enclosed in a metal chassis, we recommend that the Bell be screw-mounted to it as well, to help with heat dissipation. The Bell has screw-mount holes on each corner of the heatsink for this purpose.

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3.5. Integrating the Bell on a PCB

The Bell is designed to be mounted on a PCB, either by soldering its pins directly to the PCB or by using suitable socket connectors. In both cases the following rules apply:

3.5.1. Traces

1. The size of the traces on the PCB (thickness and width) are determined by the current

carrying capacity required by the application.

 The rated continuous current limit (Ic) of the Bell is the current used for sizing the motor

traces (M1, M2, M3, M4 and PE) and power traces (VP+, PR and PE).

 For control, feedbacks and I/O conductors the actual current is very small but “generous”

thickness and width of the conductors will contribute to a better performance and lower levels of interference.

2. The traces should be as short as possible to minimize EMI and to minimize the heat

generated by the conductors.

3. The spacing between the high voltage conductors (VP+, PR, M1, M2, M3, M4,VL) must be at

least:

 Surface layer: 1.5 mm  Internal layer: 0.10 mm

Complying with the rules above will help satisfy UL safety standards, MIL-STD-275 and the IPC-D275 standard for non-coated conductors, operating at voltages lower than 100 VDC.

3.5.2. Grounds and Returns

The “returns” of the Bell are structured internally in a star configuration. The returns in each functional block are listed:

Functional Block Return Pin

Power PR (Power Return)

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

RS232 Communications RS232_COMRET (J1/3)

CAN Communications CAN_COMRET (J1/20)

Control section Internal, not accessible

Main Feedback SUPRET (J2/2)

Aux. Feedback SUPRET (J1/4)

Analog input ANLRET (J2/2)

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

1. When wiring the traces of the above functions on the Integration Board the returns of each

function must be wired separately to its designated terminal on the Bell. DO NOT USE A COMMON GROUND PLANE. Shorting the commons on the Integration Board may cause performance degradation (ground loops, etc.).

2. Inputs: The 6 inputs are optically isolated from the other parts of the Bell. All 6 inputs share a

single common “Return” (INRET - J1/15). To retain isolation, the Input Return pin, as well as other conductors on the input circuit, must be laid out separately.

3. Outputs: The 2 outputs are optically isolated from the other parts of the Bell. Each output has

a separate floating return (OUTRET1 - J1/17 for output 1 and OUTRET2 J1/16 for output 2). To retain isolation, the Output Return pins, as well as other conductors on the output circuit, must be laid out separately.

4. Return Traces: The return traces should be as large as possible, but without shorting each

other, and with minimal cross-over.

5. Main Power Supply and Motor Traces: The power traces must be kept as far away as possible

from the feedback, control and communication traces.

6. PE Terminal: The PE terminal is connected directly to the heat-sink of the Bell. The heat-sink

serves as an EMI common plane. The PE terminal should be connected to the system’s protective earth. Any other metallic parts (such as the chassis) of the assembly should be connected to the protective earth as well.

7. Under normal operating conditions, the PE trace carries no current. The only time these

traces carry current is under abnormal conditions (such as when the device has become a potential shock or fire hazard while conducting external EMI interferences directly to ground). When connected properly the PE trace prevents these hazards from affecting the drive.

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

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3.6. The Bell Connection Diagram

Figure 3: Bell Connection Diagram

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Bell Installation Guide Installation

3.7. Main Power and Motor Power

Pin Function Cable Pin Positions

VP+ Pos. Power input Power

PR Power return Power

PE Protective earth Power

AC Motor

PE Protective earth Motor

Chassis

Stepper

Motor

Chassis

DC Motor

Motor Chassis

M1 Motor phase Phase 1 Phase 1+ +

M2 Motor phase Phase 2 Phase 1- -

M3 Motor phase Phase 3 Phase 2+ NC

M4 Motor phase NC Phase 2- NC

Note: When connecting several Bells to several motors, all should be wired in an identical

manner. This will enable the same SimplIQ program to run on all drives.

Table 1: Connector for Main Power and Motor

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3.7.1. Connecting Motor Power

Connect the M1, M2, M3, M4 and PE pins on the Bell in the manner described in Section 3.5 (Integrating the Bell on a PCB). The phase connection is arbitrary as the Composer will establish the proper commutation automatically during setup. However, if you plan to copy the setup to other drives, then the phase order on all copy drives must be the same.

Note: The Bell is equipped with four motor wires.

 For DC motors, connect only M1 and M2.  For 3-phase motors, connect M1, M2 and M3.  For steppers and 2-phase motors, connect M1, M2 to one coil and M3, M4 to the other

coil.

Leave unused motor wires disconnected.

Figure 4: AC Motor Power Connection Diagram

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Bell Installation Guide Installation

3.7.2. Connecting Main Power

Connect the VP+, PR and PE pins on the Bell in the manner described in Section 3.5 (Integrating the Bell on a PCB).

The source of the 12 ~ 95 VDC Main Power Supply must be isolated.

Figure 5: Main Power Supply Connection Diagram (no Auxiliary Supply)

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Power from the Bell to the motor must come from the

Bell Installation Guide Installation

3.8. Auxiliary Supply (for Drive Logic)

Note: Notes for 12 ~ 95 VDC auxiliary supply connections:

 The source of the 12 ~ 95 VDC Auxiliary Supply must be isolated.

Connect the VL and PR pins on the Bell in the manner described in Section 3.5 (Integrating the Bell on a PCB).

Pin Function Pin Positions

VL Auxiliary Supply Input

PR Supply Input Return

Main Supply and NOT from the Auxiliary Supply.

Table 2: Auxiliary Supply Pins

3.8.1. Single Supply

A single isolated DC power supply can provide power for both the main power and the Auxiliary (Drive Logic) Supply. The drawing below shows how a single supply is connected.

Figure 6: Single Supply for both the Main Power Supply and the Auxiliary Supply

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3.8.2. Separate Auxiliary Supply

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

Figure 7: Separate Auxiliary Supply Connection Diagram

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3.8.3. Shared 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 6). If backup functionality is required (for storing control parameters in case of power-outs) an additional backup supply can be connected by implementing 'diode coupling' (see the Aux. Backup Supply in Figure 8: Shared Supply Connection Diagram

Note: When using Elmo’s Evaluation Board (Catalog number: WHI-EVLBRD-1), the diode coupling

is “built in”. When you create your own PCB, you need to implement diode coupling.

Figure 8: Shared Supply Connection Diagram

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Bell Installation Guide Installation

3.9. Main Feedback

The Main Feedback port is used to transfer feedback data from the motor to the drive.

The Bell can accept any of the following devices as a main feedback mechanism:

• Incremental encoder only.

• Incremental encoder with digital hall sensors.

• Digital hall sensors only.

• Incremental Analog (Sine/Cosine) encoder (option).

Incremental Encoder Interpolated Analog Encoder

Pin Signal Function Signal Function

J2/13 HC Hall sensor C input NC -

J2/11 HA Hall sensor A input NC -

J2/2 SUPRET Supply return SUPRET Supply return

J2/1 +5V Encoder/Hall +5V supply +5V Encoder/Hall +5V supply

J2/6 CHA- Channel A complement A- Sine A complement

J2/5 CHA Channel A A+ Sine A

J2/10 INDEX- Index complement R- Index complement

J2/9 INDEX Index R+ Index

J2/12 HB Hall sensor B input NC -

J2/8 CHB- Channel B complement B- Cosine B complement

J2/7 CHB Channel B B+ Cosine B

J2/3 ANALIN+ is used for Analog Input

J2/4 ANALIN- is used for Analog Input

J2/14 LED_2_OUT (AOKLED cathode) is used for LED indication

J2/15 LED_1_OUT (AOKLED anode) is used for LED indication

Table 3: Main Feedback Pin Assignments

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Figure 9: Main Feedback - Incremental Encoder Connection Diagram

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Figure 10: Main Feedback- Interpolated Analog Encoder Connection Diagram

3.10. Auxiliary Feedback

For auxiliary feedback, select one of the following options:

 Single-ended auxiliary encoder input, for the input of position data of the master encoder

in follower or ECAM mode.

 Pulse-and-direction input, for single-ended input of pulse-and-direction position

commands.

When using one of the auxiliary feedback options, the relevant functionality is software selected for that option. Refer to the SimplIQ for Steppers Command Reference Manual for detailed setup information.

3.10.1. Main and Auxiliary Feedback Combinations

Main Feedback is always used in motion control devices whereas Auxiliary Feedback is usually used, though not always. The Auxiliary Feedback connector on the Bell has three bi-directional pins (CHA, CHB and INDEX). When used in combination with Main Feedback, the Auxiliary Feedback can be set by software, as follows:

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

Bell Installation Guide Installation

Main Feedback

Incremental Encoder Input

Interpolated Analog

(Sin/Cos) Encoder Input

Auxiliary Feedback

YA[4] = 4 (Aux. Feedback: output)

YA[4] = 2 (Aux. Feedback: input)

YA[4] = 0 (Aux. Feedback: input)

Typical Applications

Any application where the main encoder is used, not only for the drive, but also for other purposes such as position controllers and/or other drives.

Analog Encoder applications where position data is required in the Encoder’s quadrature format.

Any application where two feedbacks are used by the drive.

The Auxiliary Feedback port serves as an input for the auxiliary incremental encoder.

For applications such as Follower, ECAM, or Dual Loop.

Any application where two feedbacks are used by the drive.

The Auxiliary Feedback port serves as an input for Pulse & Direction Commands.

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3.10.2. Auxiliary Feedback: Single-Ended Encoder Input Option

(YA[4]=2)

Pin Signal Function Pin Position

J1/4 SUPRET Supply return

J1/19 INDEX Auxiliary index input

J1/18 CHB Auxiliary channel B input

J1/5 CHA Auxiliary channel A input

Note: The Bell’s Auxiliary Feedback is single-ended. When

mounted on an integration board, circuitry can be added to make it differential.

Table 4: Single-Ended Auxiliary Encoder Pin Assignment

Figure 11: Single-ended Auxiliary Encoder Input - Acceptable Connection Diagram

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Figure 12: Single-ended Auxiliary Encoder Input - Recommended Connection Diagram

Figure 13: Differential Auxiliary Encoder Input – Highly Recommended Connection Diagram

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3.10.3. Auxiliary Feedback: Pulse-and-Direction Input Option

(YA[4]=0)

Pin Signal Function Pin Position

J1/4 SUPRET Supply return

J1/18 DIR/CHB Direction input (push/pull 5 V or open

collector)

J1/5 PULS/CHA Pulse input (push/pull 5 V or open

collector)

Note: The Bell’s Auxiliary Feedback is single-ended. When

mounted on an integration board circuitry can be added to make it differential.

Table 5: Pulse-and-Direction Pin Assignments

Figure 14: Pulse-and-Direction Auxiliary Encoder Input – Direct Connection Diagram

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Figure 15: Pulse-and-Direction Auxiliary Encoder Input – Buffered Connection Diagram

Figure 16: Pulse-and-Direction Auxiliary Encoder Input – Differential Connection Diagram

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3.11. I/Os

The Bell has 6 Digital Inputs, 2 Digital Outputs and 1 Analog Input.

I/O J1 J2 Total

Digital Input 6 - 6

Digital Output 2 - 2

Analog Input - 1 1

3.11.1. Digital Input

Each of the pins below can function as an independent input.

Pin Signal Function Pin Position

J1/9 IN1 Programmable input 1

(general purpose, RLS, FLS, INH)

J1/10 IN2 Programmable input 2

(general purpose, RLS, FLS, INH)

J1/11 IN3 Programmable input 3

(general purpose, RLS, FLS, INH)

J1/12 IN4 Programmable input 4

(general purpose, RLS, FLS, INH)

J1/13 IN5 High Speed Programmable input 5

(event capture, Main Home, general purpose, RLS, FLS, INH)

J1/14 IN6 High Speed Programmable input 6

(event capture, Auxiliary Home, general purpose, RLS, FLS, INH)

J1/15 INRET Programmable input return

Table 6: Digital Input Pin Assignments

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Figure 17: Digital Input Connection Diagram

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3.11.2. Digital Output

Pin Signal Function Pin Position

J1/7 OUT1 High-Speed Programmable digital

output 1

J1/17 OUTRET1 Programmable digital output return 1

J1/8 OUT2 Programmable digital output 2

J1/16 OUTRET2 Programmable digital output return 2

Table 7: Digital Output Pin Assignments

Figure 18: Digital Output Connection Diagram

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3.11.3. Analog Input

Pin Signal Function Pin Position

J2/3 ANLIN1+ Analog input 1+

J2/4 ANLIN1- Analog input 1-

J2/2 ANLRET Analog ground

Table 8: Analog Input Pin Assignments

Figure 19: Analog Input with Single-ended Source

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3.12. Communications

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

• RS-232, full duplex

• CAN

RS-232 communication requires a standard, commercial 3-core null-modem cable connected from the Bell to a serial interface on the PC. The interface is selected and set up in the Composer software.

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

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

3.12.1. RS-232 Communication

Note: Notes for connecting the RS-232 communication cable:

 Connect the shield to the ground of the host (PC). Usually, this connection is soldered

internally inside the connector at the PC end. You can use the drain wire to facilitate connection.

 The RS-232 communication port is non-isolated.  Ensure that the shield of the cable is connected to the shield of the connector used for RS-

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

Pin Signal Function Pin Location

J1/1 RS232_Rx RS-232 receive

J1/2 RS232_Tx RS-232 transmit

J1/3 RS232_COMRET Communication return

Table 9: RS-232 Pin Assignments

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Figure 20: RS-232 Connection Diagram

3.12.2. CAN Communication

Note: To connect the CAN communication cable:

 Connect the shield to the ground of the host (PC). Usually, this connection is soldered

internally inside the connector at the PC end. You can use the drain wire to facilitate connection.

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

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

 Ensure that you have a 120-Ohms resistor termination at each of the two ends of the

network cable.

 The Bell’s CAN ports are non-isolated.

Pin Signal Function Pin Position

J1/20 CAN_GND CAN ground

J1/21 CAN_L CAN_L busline (dominant low)

J1/22 CAN_H CAN_H busline (dominant high)

Table 10: CAN - Pin Assignments

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Figure 21: CAN Network Diagram

Caution:

When installing CAN communication, ensure that each stepper drive is allocated a unique ID. Otherwise the CAN network may hang.

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Whistle

100 Series Power Dissipation

0.0

1.0

2.0

3.0

4.0

5.0

6.0

0.511.522.533.544.5

Peak Current (A)

Power Dissipation (W)

85VDC 70VDC 50VDC

Standard 40 °C Ambient Temp.

Heatsink

Bell

Bell Installation Guide Installation

3.13. Powering Up

After the Bell is connected to its devices, it is ready to be powered up.

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

3.14. Initializing the System

After the Bell has been connected and mounted, the system must be set up and initialized. This is accomplished using the Composer, Elmo’s Windows-based software application, as well as the Tuner program developed by Digital Feedback Technologies. Install the application and then perform setup and initialization according to the directions in the Composer Software Manual.

3.15. Heat Dissipation

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

3.15.1. Bell Thermal Data

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

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

Bell will reach two-thirds of its final temperature after 4 minutes.)

• Shut-off temperature: 86 °C – 88 °C (measured on the heatsink).

3.15.2. Heat Dissipation Data

Heat dissipation is shown graphically below:

Required

not Required

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3.15.3. How to Use the Charts

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

To determine if your application needs a heatsink:

1. Allow the maximum heatsink temperature to be 80 °C or less.

2. Determine the ambient operating temperature of the Bell.

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 Bell will not need additional cooling.

Note: The chart above shows that no heatsink is needed when the heatsink temperature is 80°C,

the ambient temperature is 40 °C and the heat dissipated is 4 W.

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3.16. Evaluation Board and Cable Kit

A circuit board is available for evaluating the Bell. It comes with standard terminal blocks for power connections and D-sub plugs/sockets for signal connections. The Evaluation Board is provided with a cable kit.

Figure 22: The Bell Evaluation Board (available upon request)

• The Bell Evaluation Board (available upon request) - EVA-WHI/GUI/BEL

• Evaluation Board User Manual - MAN-EVLBRD-WHI-BEL-GUI.pdf (available on our web site)

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Chapter 4: Bell Technical Specifications

Bell Installation Guide Bell Technical Specifications

4.1. Features

4.1.1. Motion Control Modes

• Current/Torque – up to 20 kHz sampling rate

• Velocity – up to 10 kHz sampling rate

• Position – up to 10 kHz sampling rate

4.1.2. Advanced Positioning Motion Control Modes

• PTP, PT, PVT, ECAM, Follower, Dual Loop

• Fast event capturing inputs

• Fast output compare (OC)

• Motion Commands: Analog, PWM, SW, Pulse & Direction

4.1.3. Feedback Options

• Incremental Encoder – up to 40 Mega-Counts per second

• Digital Halls – up to 2 kHz

• Incremental Encoder with Digital Halls for commutation – up to 40 Mega-Counts

• Interpolated Analog Sine/Cosine Encoder-up to 400 kHz

 Internal Interpolation – up to x2048  Automatic correction of amplitude mismatch, signal offset

• Analog Halls

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

• The Bell 5 V PS provides supply voltage (5 V, 200 mA max) for one Encoder/Resolver/Hall

Sensor

4.1.4. Accessories

• Heat sinks (TBD)

• Evaluation Board – see Section 3.16

• Cable Kit

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Weight

g (oz)

Dimensions

mm (in)

Mounting method

Digital In / Digital Out / Analog In

Bell Installation Guide Bell Technical Specifications

4.2. Power Ratings

Feature Units 5/100

Minimum supply voltage (VP+) VDC 11

Nominal supply voltage (VP+) VDC 85

Maximum supply voltage (VP+) VDC 95

Efficiency at rated power % > 99

Output voltage % 90% VP

Note: This is the maximum amplitude value

Ts=50 μs)

Continuous phase current limit (Ic) A 5

Peak current limit (RMS) A 10

PWM switching frequency

kHz 20

Switching method Advanced Bipolar or Unipolar PWM

45 g (1.59 oz)

55 x 15 x 58.5 mm (2.165" x 0.591" x 2.303")

Soldered pins

6 / 2 / 1

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4.3. Environmental Conditions

Feature Details

Operating ambient temperature

0 °C to 40 °C (32 °F to 104 °F)

according to IEC60068-2-2

Storage temperature

Maximum non-condensing humidity

-20 °C to +85 °C ( -4 °F to +185 °F)

95%

according to IEC60068-2-78

Maximum Operating Altitude

Mechanical Shock

2,000 m (6562 feet)

15g / 11ms Half Sine

according to IEC60068-2-27

Vibration according to IEC60068-2-6

5 Hz ≤ f ≤ 10 Hz: ±10mm

10 Hz ≤ f ≤ 57 Hz: 4G

57 Hz ≤ f ≤ 500 Hz:5G

4.3.1. Auxiliary Supply

Feature Details

Auxiliary power supply Isolated DC source only

Auxiliary supply input voltage 12 VDC ~ 95 VDC

Auxiliary supply input power < 2.5 VA (this includes the 5 V/200 mA load for the

main encoder only)

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4.4. Control Specifications

4.4.1. Current Loop

Feature Details

Controller type Vector, digital

Compensation for bus voltage variations

Motor types

Current control

“On-the-fly” automatic gain scheduling

• Stepper , 2 phase

• Brushless servo, 2 phase

• AC brushless (sinusoidal)

• DC brushless (trapezoidal)

• DC brush

• Linear motors

• “Voice” coils

• Fully digital

• Winding shape full compensation with vector

control

• Programmable PI control filter based on a pair of

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

• Full DC voltage variation compensation

• Cogging compensation

Current loop bandwidth > 3 kHz

Current sampling time

Programmable >40 µsec

Current sampling rate Up to 30 kHz

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4.4.2. Velocity Loop

Feature Details

Controller type PI + high order filters

Velocity control

• Fully digital

• Programmable PI and FFW control filters

• “On-the-fly” gain scheduling

• Automatic, manual and advanced manual tuning

Velocity and position feedback options

• Incremental Encoder

• Digital Halls

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

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

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

Velocity loop bandwidth > 350 Hz

Velocity sampling time

≥80 µsec (x2 current loop sample time)

Velocity sampling rate up to 10 kHz

Velocity command options

• Analog

• Internally calculated by either jogging or step

Note: All software-calculated profiles support on-the-fly

changes.

4.4.3. Position Loop

Feature Details

Controller type “1-2-4” PIP

Position command options

Position loop bandwidth > 120 Hz

Position sampling time

Position sampling rate up to 10 kHz

• Software

• Pulse and Direction

≥ 80 (x 2 current loop sample time)

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4.5. Feedbacks

4.5.1. Feedback Supply Voltage

The Bell has two feedback ports (Main and Auxiliary). The drives supply voltage only to the main feedback device. The user must provide a separate power supply for auxiliary feedback devices if needed.

Feature Details

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

4.5.2. Main Feedback Options

4.5.2.1. Incremental Encoder Input

Feature Details

Encoder format

• A, B and Index

• Differential

• Quadrature

Interface RS-422

Input resistance

Differential: 120 Ω

Maximum incremental encoder frequency Maximum absolute: 10 MHz pulses

Minimum quadrature input period (PIN) 100 nsec

Minimum quadrature input high/low period (PHL) 25 nsec

Minimum quadrature phase period (PPH) 25 nsec

Maximum encoder input voltage range

Common mode: ±7 V

Differential mode: ±7 V

Figure 23: Main Feedback - Encoder Phase Diagram

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4.5.2.2. Digital Halls

Feature Details

Halls inputs

• H

, HB, HC.

• 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

> 2.5 V

< 1 V

< 5 V

In_Hall

< 15 V

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

3 mA

Source current: 1.5 mA (designed to support open collector Halls as well)

Maximum frequency f

MAX

: 3 kHz

4.5.2.3. Interpolated Analog Encoder (Sine/Cosine)

Feature Details

Analog encoder format Sine and Cosine signals

Analog input signal level

• Offset voltage: 2.2 V – 2.8 V

Differential, 1 V peak to peak

Input resistance

Maximum analog signal frequency f

Differential 120 Ω

: 400 kHz

MAX

Interpolation multipliers Programmable: x4 to x2048

Maximum “counts” frequency 100 mega-counts/sec “internally”

Automatic error correction

Signal amplitudes mismatch Signal phase shift Signal offsets

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4.5.3. Auxiliary Feedback Port (input mode YA[4]= 2, 0)

Feature Details

Encoder input, pulse and direction input

• A, B, Index

• Single ended

Output current capability VIn Low: 0 V < VIL < 0.8 V

High: 2 V < VIH < 5 V

Maximum absolute voltage: 0 < V

< 5.5 V

Input current: ±1 μA

Available as options

• Single-ended encoder inputs

• Pulse and direction inputs

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

noise filtering at remote receiver of encoder signals

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

encoder cycle) and synchronized to A & B

Figure 24: Auxiliary Feedback - Encoder Phase Diagram

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4.6. I/Os

The Bell has:

• 6 Digital Inputs

• 2 Digital Outputs

• 1 Analog Input

4.6.1. Digital Input Interfaces

Feature Details Connector

Location

Type of input

Input current for all inputs

High-level input voltage

Low-level input voltage

Minimum pulse width

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

• Optically isolated

• All six inputs share one signal return line

Iin = 2.4 mA @ 5 V

2.5 V < Vin < 10 V, 5 V typical

0 V < Vin < 1 V

> 360 μsec

If input is set to one of the built-in functions — Home, Inhibit, Hard Stop, Soft Stop, Hard and Soft Stop, Forward Limit, Reverse Limit or Begin — execution is immediate upon detection: 0<T<360 μsec

If input is set to General input, execution depends

on the program. Typical execution time: ≅ 0.5 msec.

High-speed inputs – 5 & 6 minimum pulse width, in highspeed mode

T < 5 µsec

Notes:

• Home mode is high-speed mode and can be

used for fast capture and precise homing.

• High speed input has a digital filter set to the

same value as the digital filter (EF) of the main encoder.

• Highest speed is achieved when turning on the

optocouplers.

Digital Input

Schematic

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(max)Io

VOLVcc

−

Bell Installation Guide Bell Technical Specifications

4.6.2. Digital Output Interface

Feature Details Connector Location

Type of output

Maximum supply output

Max. output current Iout (max) (Vout = Low)

VOL at maximum output voltage (low level)

RL External resistor RL must be selected to

Executable time If output is set to one of the built-in

• Optically isolated

• Open collector and open emitter

30 V

Iout (max) ≤ 10 mA

Vout (on) ≤ 0.3 V

limit output current to no more than 10 mA.

functions — Home flag, Brake or AOK — execution is immediate upon detection: 0 < T < 360 μsec

Digital Output

Schematic

If output is set to General output and is executed from a program, the typical time is approximately 0.5 msec.

4.6.3. Analog Input

Feature Details

Maximum operating differential voltage ± 10 V

Maximum absolute differential input voltage ± 16 V

Differential input resistance 3.74 kΩ

Analog input command resolution 14-bit

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4.7. Communications

Specification Details

RS-232

Signals:

• RxD , TxD , Gnd

• Full duplex, serial communication for setup and control.

• Baud Rate of 9,600 ~ 115,200 bit/sec.

CAN

CANbus Signals:

• CAN_H, CAN_L, CAN_GND

• Maximum Baud Rate of 1 Mbit/sec.

Version:

• DS 301 V4.01

Layer Setting Service and Protocol Support:

• DSP 305

Device Profile (drive and motion control):

• DSP 402

4.8. Pulse Width Modulation (PWM)

Feature Details

PWM resolution 12-bit

PWM switching frequency on the load Factory default 50 kHz on the motor

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4.9. Standards Compliance

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.)

• UL 60950

• IPC-D-275

• IPC-SM-782

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

• IPC-CM-770

• UL 508C

• UL 840

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

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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ElmoMC SimplIQ Digital Servo Drives-Bell Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Chapter 1: Safety Information

1.1. Warnings

1.2. Cautions

1.3. Directives and Standards

1.4. CE Mark Conformance

1.5. Warranty Information

Chapter 2: Introduction

2.1. Drive Description

2.2. Product Features

2.2.1. Motion Control Modes

2.2.2. Advanced Positioning Motion Control Modes

2.2.3. Feedback Options

2.3. System Architecture

2.4. How to Use this Guide

Chapter 3: Installation

3.1. Site Requirements

3.2. Unpacking the Drive Components

3.3. Pinouts

3.3.1. Connector Types

3.3.2. Connector J1

3.3.3. Connector J2

3.4. Mounting the Bell

3.5. Integrating the Bell on a PCB

3.5.1. Traces

3.5.2. Grounds and Returns

3.6. The Bell Connection Diagram

3.7. Main Power and Motor Power

3.7.1. Connecting Motor Power

3.7.2. Connecting Main Power

3.8. Auxiliary Supply (for Drive Logic)

3.8.1. Single Supply

3.8.2. Separate Auxiliary Supply

3.8.3. Shared Supply

3.9. Main Feedback

3.10. Auxiliary Feedback

3.10.1. Main and Auxiliary Feedback Combinations

3.11. I/Os

3.11.1. Digital Input

3.11.2. Digital Output

3.11.3. Analog Input

3.12. Communications

3.12.1. RS-232 Communication

3.12.2. CAN Communication

3.13. Powering Up

3.14. Initializing the System

3.15. Heat Dissipation

3.15.1. Bell Thermal Data

3.15.2. Heat Dissipation Data

3.15.3. How to Use the Charts

3.16. Evaluation Board and Cable Kit

Chapter 4: Bell Technical Specifications

4.1. Features

4.1.1. Motion Control Modes

4.1.2. Advanced Positioning Motion Control Modes

4.1.3. Feedback Options

4.1.4. Accessories

4.2. Power Ratings

4.3. Environmental Conditions

4.3.1. Auxiliary Supply

4.4. Control Specifications

4.4.1. Current Loop

4.4.2. Velocity Loop

4.4.3. Position Loop

4.5. Feedbacks

4.5.1. Feedback Supply Voltage

4.5.2. Main Feedback Options

4.5.2.1. Incremental Encoder Input

4.5.2.2. Digital Halls

4.5.2.3. Interpolated Analog Encoder (Sine/Cosine)

4.5.3. Auxiliary Feedback Port (input mode YA[4]= 2, 0)

4.6. I/Os

4.6.1. Digital Input Interfaces

4.6.2. Digital Output Interface

4.6.3. Analog Input

4.7. Communications

4.8. Pulse Width Modulation (PWM)