ElmoMC SimplIQ Digital Servo Drives-Bell Installation Guide

Bell

Digital Servo Drive

Installation Guide

July 2014 (Ver. 1.302)

www.elmomc.com

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)

Copyright  2014

Elmo Motion Control Ltd.

All rights reserved.

Catalog Number

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

Related Products

• Evaluation Board Catalog Number - EVA-WHI/GUI/BEL (available upon request)

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

site)

Revision History

Version Date Details

Ver. 1.0 Jan 2008 Initial release

Ver. 1.1 June 2009 General update

Ver. 1.2 Dec 2010 MTCR 12-001-10: Figure 3-1 and Section 4.2 removed

from version 1.1.

Ver. 1.3 July 2012 Template update

Ver. 1.301 Feb 2013 Added a caution and recommendation on the type of

cleaning solution to use for the Elmo unit.

Ver. 1.302 July 2014 General format updates

Elmo Worldwide

Head Office

Elmo Motion Control Ltd.

60 Amal St., P.O. Box 3078, Petach Tikva 49516
Israel

Tel: [phone] • Fax: [phone] • [e-mail]

North America

Elmo Motion Control Inc.

42 Technology Way, Nashua, NH 03060
USA

Tel: [phone] • Fax: [phone] • [e-mail]

Europe

Elmo Motion Control GmbH

Hermann-Schwer-Strasse 3, 78048 VS-Villingen
Germany

Tel: [phone] • Fax: [phone] • [e-mail]

China

Elmo Motion Control Technology (Shanghai) Co. Ltd.

Room 1414, Huawen Plaza, No. 999 Zhongshan West Road, Shanghai (200051)
China

Tel: [phone] • Fax: [phone] • [e-mail]

Asia Pacific

Elmo Motion Control APAC Ltd.

B-601 Pangyo Innovalley, 621 Sampyeong-dong, Bundang-gu, Seongnam-si, Gyeonggi-do,
South Korea (463-400)

Tel: [phone] • Fax: [phone] • [e-mail]

MAN-BELI G Ver. 1.302

Table of Contents

Bell Installation Guide Safety Information

Chapter 1: Safety Information .......................................................................................... 7

1.1. Warnings ........................................................................................................................ 8

1.2. Cautions .......................................................................................................................... 8

1.3. Directives and Standards ................................................................................................ 9

1.4. CE Mark Conformance .................................................................................................. 10

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

Chapter 2: Introduction .................................................................................................. 11

2.1. Drive Description .......................................................................................................... 11

2.2. Product Features .......................................................................................................... 11

2.2.1. Motion Control Modes .................................................................................. 11

2.2.2. Advanced Positioning Motion Control Modes .............................................. 11

2.2.3. Feedback Options .......................................................................................... 12

2.3. System Architecture ..................................................................................................... 12

2.4. How to Use this Guide .................................................................................................. 13

5

Chapter 3: Installation .................................................................................................... 14

3.1. Site Requirements ........................................................................................................ 14

3.2. Unpacking the Drive Components ............................................................................... 14

3.3. Pinouts .......................................................................................................................... 15

3.3.1. Connector Types ............................................................................................ 15

3.3.2. Connector J1 .................................................................................................. 16

3.3.3. Connector J2 .................................................................................................. 17

3.4. Mounting the Bell ......................................................................................................... 17

3.5. Integrating the Bell on a PCB ........................................................................................ 18

3.5.1. Traces............................................................................................................. 18

3.5.2. Grounds and Returns ..................................................................................... 18

3.6. The Bell Connection Diagram ....................................................................................... 20

3.7. Main Power and Motor Power ..................................................................................... 21

3.7.1. Connecting Motor Power .............................................................................. 22

3.7.2. Connecting Main Power ................................................................................ 23

3.8. Auxiliary Supply (for Drive Logic).................................................................................. 24

3.8.1. Single Supply .................................................................................................. 24

3.8.2. Separate Auxiliary Supply .............................................................................. 25

3.8.3. Shared Supply ................................................................................................ 26

3.9. Main Feedback ............................................................................................................. 27

3.10. Auxiliary Feedback ........................................................................................................ 29

3.10.1. Main and Auxiliary Feedback Combinations ................................................. 29

3.10.2. Auxiliary Feedback: Single-Ended Encoder Input Option (YA[4]=2) .............. 31

3.10.3. Auxiliary Feedback: Pulse-and-Direction Input Option (YA[4]=0) ................. 33

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Bell Installation Guide Safety Information

3.11. I/Os ............................................................................................................................... 35

3.11.1. Digital Input ................................................................................................... 35

3.11.2. Digital Output ................................................................................................ 37

3.11.3. Analog Input .................................................................................................. 38

3.12. Communications ........................................................................................................... 39

3.12.1. RS-232 Communication ................................................................................. 39

3.12.2. CAN Communication ..................................................................................... 40

3.13. Powering Up ................................................................................................................. 42

3.14. Initializing the System .................................................................................................. 42

3.15. Heat Dissipation ........................................................................................................... 42

3.15.1. Bell Thermal Data .......................................................................................... 42

3.15.2. Heat Dissipation Data .................................................................................... 42

3.15.3. How to Use the Charts ................................................................................... 43

3.16. Evaluation Board and Cable Kit .................................................................................... 44

Chapter 4: Bell Technical Specifications .......................................................................... 45

4.1. Features ........................................................................................................................ 45

4.1.1. Motion Control Modes .................................................................................. 45

4.1.2. Advanced Positioning Motion Control Modes .............................................. 45

4.1.3. Feedback Options .......................................................................................... 45

4.1.4. Accessories .................................................................................................... 45

4.2. Power Ratings ............................................................................................................... 46

4.3. Environmental Conditions ............................................................................................ 47

4.3.1. Auxiliary Supply ............................................................................................. 47

4.4. Control Specifications ................................................................................................... 48

4.4.1. Current Loop .................................................................................................. 48

4.4.2. Velocity Loop ................................................................................................. 49

4.4.3. Position Loop ................................................................................................. 49

4.5. Feedbacks ..................................................................................................................... 50

4.5.1. Feedback Supply Voltage ............................................................................... 50

4.5.2. Main Feedback Options ................................................................................. 50

4.5.2.1. Incremental Encoder Input ........................................................... 50

4.5.2.2. Digital Halls ................................................................................... 51

4.5.2.3. Interpolated Analog Encoder (Sine/Cosine) ................................. 51

4.5.3. Auxiliary Feedback Port (input mode YA[4]= 2, 0) ........................................ 52

4.6. I/Os ............................................................................................................................... 53

4.6.1. Digital Input Interfaces .................................................................................. 53

4.6.2. Digital Output Interface ................................................................................. 54

4.6.3. Analog Input .................................................................................................. 54

4.7. Communications ........................................................................................................... 55

4.8. Pulse Width Modulation (PWM) .................................................................................. 55

4.9. Standards Compliance .................................................................................................. 56

6

MAN-BELI G Ver. 1.302

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.

7

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.

MAN-BELI G Ver. 1.302

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.

8

• 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

9

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.

MAN-BELI G Ver. 1.302

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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Table of Contents

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.

11

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

or

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

12

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.

13

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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Table of Contents

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

14

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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Bell Installation Guide Installation

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

15

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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Bell Installation Guide Installation

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

16

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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Bell Installation Guide Installation

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

17

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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Bell Installation Guide Installation

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:

18

 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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