4.12 Compliance with Standards ..................................................................................... 71
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1 Safety Information
Warning:
Caution:
Cello Installation Guide
In order to achieve the optimum, safe operation of the Cello servo drive, it is imperative that
you implement the safety procedures included in this installation guide. This information is
provided to protect you and to keep your work area safe when operating the Cello 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 Cello servo drive contains electrostatic-sensitive components that can be damaged if
handled incorrectly. To prevent any electrostatic damage, avoid contact with highly insulating
materials, such as plastic film and synthetic fabrics. Place the product on a conductive surface
and ground yourself in order to discharge any possible static electricity build-up.
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:
This information is needed to avoid a safety hazard, which might cause
bodily injury.
This information is necessary for preventing damage to the product or to
other equipment.
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Cello Installation GuideSafety Information
1.1 Warnings
To avoid electric arcing and hazards to personnel and electrical contacts, never
connect/disconnect the servo drive while the power source is on.
Power cables can carry a high voltage, even when the motor is not in motion.
Disconnect the Cello from all voltage sources before it is opened for servicing.
After shutting off the power and removing the power source from your
equipment, wait at least 1 minute before touching or disconnecting parts of
the equipment that are normally loaded with electrical charges (such as
capacitors or contacts). Measuring the electrical contact points with a meter,
before touching the equipment, is recommended.
1.2 Cautions
The Cello 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.
The Cello can operate only through an isolated power source, using an isolated
transformer and a rectifier circuit. Power to this device must be supplied by DC
voltage, within the boundaries specified for the Cello. High voltages may
damage the drive.
The DC power supply voltage range is defined in the table in Section 4.3.
Safety margins must be considered in order to avoid activating the under- or over-voltage
protection against line variations and/or voltage drop under load. The transformer should
be able to deliver the required power to the drive (including peak power) without
significant voltage drops (10% maximum). While driving high-inertia loads, the power
supply circuit must be equipped with a shunt regulator; otherwise, the drive will be
disabled whenever the capacitors are charged above the maximum voltage.
Before switching on the Cello, 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 Cello 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:
The Cello 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 508CPower Conversion Equipment
In compliance with UL 840Insulation 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 Cello servo drive has been developed, produced, tested and documented in accordance
with the relevant standards. Elmo Motion Control is not responsible for any deviation from the
configuration and installation described in this documentation. Furthermore, Elmo is not
responsible for the performance of new measurements or ensuring that regulatory
requirements are met.
1.4 CE Marking Conformance
The Cello servo drive is intended for incorporation in a machine or end product. The actual end
product must comply with all safety aspects of the relevant requirements of the European
Safety of Machinery Directive 98/37/EC as amended, and with those of the most recent
versions of standards EN 60204-1 and EN 292-2 at the least.
According to Annex III of Article 13 of Council Directive 93/68/EEC, amending Council Directive
73/23/EEC concerning electrical equipment designed for use within certain voltage limits, the
Cello meets the provisions outlined in Council Directive 73/23/EEC. The party responsible for
ensuring that the equipment meets the limits required by EMC regulations is the manufacturer
of the end product.
1.5 Warranty Information
The products covered in this manual are warranted to be free of defects in material and
workmanship and conform to the specifications stated either within this document or in the
product catalog description. All Elmo drives are warranted for a period of 12 months from the
time of installation, or 18 months from time of shipment, whichever comes first. No other
warranties, expressed or implied — and including a warranty of merchantability and fitness for
a particular purpose — extend beyond this warranty.
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MAN-CELIG (Ve r. 1.602)
2 Introduction
Cello Installation Guide
This installation guide describes the Cello servo drive and the steps for its wiring, installation
and powering up. Following these guidelines ensures maximum functionality of the drive and
the system to which it is connected.
2.1 Drive Description
The Cello is a powerful servo drive that operates in digital current, velocity, position and
advanced position modes, in conjunction with a permanent-magnet synchronous brushless
motor or DC brush motor. The Cello features flexible sinusoidal and trapezoidal commutation,
with vector control. The Cello can operate as a stand-alone device or as part of a multi-axis
network in a distributed configuration.
The Cello drive is set up and tuned using Elmo’s Composer software. This Windows-based
application enables users to quickly and simply configure the servo drive for optimal use with
their motor.
10
Power to the Cello is provided by a 10 to 195 VDC source. A “smart” control-supply algorithm
enables the Cello to operate with the power supply only, with no need for an auxiliary 24 Volt supply. If backup functionality is required for storing control parameters in case of power-outs,
an external 24 VDC power supply can be connected, providing maximum flexibility and optional
backup functionality when needed.
Two variations of the Cello are available: the Standard version and the Advanced version, which
features advanced positioning capabilities. Both versions operate with RS-232 and/or CAN
communication.
2.2 Product Features
2.2.1 Current Control
Fully digital
Sinusoidal commutation with vector control or trapezoidal commutation with
encoder and/or digital Hall sensors
12-bit current loop resolution
Automatic gain scheduling, to compensate for variations in the DC bus power
supply
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Cello Installation GuideIntroduction
2.2.2 Velocity Control
Fully digital
Programmable PI and FFW (feed forward) control filters
Sample rate two times current loop sample time
“On-the-fly” gain scheduling
Automatic, manual and advanced manual tuning and determination of optimal
gain and phase margins
2.2.3 Position Control
Programmable PIP control filter
Programmable notch and low-pass filters
Position follower mode for monitoring the motion of the slave axis relative to a
master axis, via an auxiliary encoder input
Pulse-and-direction inputs
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Sample time: four times that of current loop
Fast event capturing inputs
2.2.4 Advanced Position Control (Advanced model only)
Position-based and time-based ECAM mode that supports a non-linear follower
mode, in which the motor tracks the master motion using an ECAM table
stored in flash memory
PT and PVT motion modes
Dual (position/velocity) loop
Fast output compare (OC)
2.2.5 Communication Options
Depending on the application, Cello users can select from two communication options:
RS-232 serial communication
CAN for fast communication in a multi-axis distributed environment
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MAN-CELIG (Ve r. 1.602)
Cello Installation GuideIntroduction
2.2.6 Feedback Options
Incremental Encoder – up to 20 Mega-Counts (5 Mega-Pulse) per second
Digital Halls – up to 2 kHz
Incremental Encoder with Digital Halls for commutation – up to 20 Mega-
Counts per second for encoder
Absolute Encoder
Interpolated Analog (Sine/Cosine) Encoder – up to 250 kHz (analog signal)
Internal Interpolation – programmable up to x4096
Automatic Correction of:
• amplitude mismatch
• phase mismatch
• signals offset
Encoder outputs, buffered, differential.
12
Resolver
Programmable 10 to 15 bit resolution
Up to 512 Revolutions Per Second (RPS)
Encoder outputs, buffered, differential
Tachometer and Potentiometer
Two inputs for Tachometer Feedback:
Up to ±50 VDC
Up to ±20 VDC
Potentiometer Feedback:
0 to 5 V voltage range
Resistance: 100 Ω to 1000 Ω
Elmo drives provide supply voltage for all the feedback options
2.2.7 Fault Protection
The Cello includes built-in protection against possible fault conditions, including:
Software error handling
Status reporting for a large number of possible fault conditions
Protection against conditions such as excessive temperature, under/over
voltage, loss of commutation signal, short circuits between the motor power
outputs and between each output and power input/return
Recovery from loss of commutation signals and from communication errors
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MAN-CELIG (Ve r. 1.602)
Auxiliary
Power
Supply
PWM
Controller
Power Stage
Protection
Current
Feedback
Incremental
Encoder
24 VDC
I/Os
Incremental Encoder
Buffered Output
or
Emulated Output
Resolver
Analog
Encoder
Auxiliary
Encoder
or
or
Potentiometer
Tachometer
or
or
Communication
RS 232 and CANopen
Cello Installation Guide Introduction
2.3 System Architecture
13
Figure 1: Cello System Block Diagram
2.4 How to Use this Guide
In order to install and operate your Elmo Cello servo drive, you will use this manual in
conjunction with a set of Elmo documentation. Installation is your first step; after carefully
reading the safety instructions in the first chapter, the following chapters provide you with
installation instructions as follows:
Chapter 3, Installation, provides step-by-step instructions for unpacking,
mounting, connecting and powering up the Cello.
Chapter 4, Technical Specifications, lists all the drive ratings and specifications.
Upon completing the instructions in this guide, your Cello servo drive should be successfully
mounted and installed. From this stage, you need to consult higher-level Elmo documentation
in order to set up and fine-tune the system for optimal operation. The following figure
describes the accompanying documentation that you will require.
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MAN-CELIG (Ve r. 1.602)
SimplIQ Command Reference Manual
Cello Installation Guide
SimplIQ Software Manual
Programming
Setup
Installation
Composer User Manual
CANopen Implementation Guide
Cello Installation Guide Introduction
14
Figure 2: Elmo Documentation Hierarchy
As depicted in the previous figure, this installation guide is an integral part of the Cello
documentation set, comprising:
The Composer Software Manual, which includes explanations of all the
software tools that are part of Elmo’s Composer software environment.
The SimplIQ Command Reference Manual, which describes, in detail, each
software command used to manipulate the Cello motion controller.
The SimplIQ Software Manual, which describes the comprehensive software
used with the Cello.
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MAN-CELIG (Ve r. 1.602)
3 Installation
Cello Installation Guide
The Cello must be installed in a suitable environment and properly connected to its voltage
supplies and the motor.
3.1 Before You Begin
3.1.1 Site Requirements
You can guarantee the safe operation of the Cello by ensuring that it is installed in an
appropriate environment.
Feature Value
15
Ambient operating temperature
Maximum operating altitude 2,000 m (6562 feet)
Maximum non-condensing humidity 90%
Operating area atmosphere No flammable gases or vapors permitted in area
Models for extended environmental conditions are available.
Caution:
The Cello 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)
3.1.2 Hardware Requirements
The components that you will need to install your Cello are:
Component Connector Described in Section Drawing
Main Power Cable VP+ PR 3.4.2.2
Motor Cable M1 M2 M3 3.4.2.1
Backup Supply Cable
(if needed)
24V 3.4.3
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MAN-CELIG (Ve r. 1.602)
Cello Installation GuideInstallation
Component Connector Described in Section Drawing
Main Feedback Cable FEEDBACK A 3.4.5
16
Auxiliary Feedback
Cable
(if needed)
Digital I/O Cable
(if needed)
Digital Inputs and
Analog Inputs Cable
(if needed)
RS232
Communication
Cable
FEEDBACK B 3.4.7 0
GENERAL I/O
3.4.8.1
J1
GENERAL I/O
3.4.8.2
J2
RS232 3.4.9.1
CAN Communication
cable(s) (if needed)
PC for drive setup
and tuning
Motor data sheet or
manual
CAN (in)
CAN (out)
3.4.9.2
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MAN-CELIG (Ve r. 1.602)
Cello Installation GuideInstallation
3.2 Unpacking the Drive Components
Before you begin working with the Cello system, verify that you have all of its components, as
follows:
The Cello servo drive
The Composer software and software manual
The Cello is shipped in a cardboard box with Styrofoam protection.
To unpack the Cello:
Carefully remove the servo drive from the box and the Styrofoam.
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.
To ensure that the Cello you have unpacked is the appropriate type for your requirements,
locate the part number sticker on the side of the Cello. It looks like this:
17
The P/N number at the top gives the type designation as follows:
Verify that the Cello type is the one that you ordered, and ensure that the voltage meets your
specific requirements.
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Cello Installation GuideInstallation
3.3 Mounting the Cello
The Cello has been designed for two standard mounting options:
Wall Mount along the back (can also be mounted horizontally on a metal
surface)
Book Shelf along the side
M4 round head screws, one through each opening in the heat sink, are used to mount the Cello
(see the diagram below).
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Figure 3: Mounting the Cello
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Cello Installation GuideInstallation
3.4 Connecting the Cables
The Cello has ten connectors.
3.4.1 Wiring the Cello
Once the Cello 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 Cello.
Caution:
Follow these instructions to ensure safe and proper wiring:
Use twisted pair shielded cables for control, feedback and communication
connections. For best results, the cable should have an aluminum foil shield
covered by copper braid, and should contain a drain wire.
The drain wire is a non-insulated wire that is in contact with parts of the cable, usually
the shield. It is used to terminate the shield and as a grounding connection.
The impedance of the wire must be as low as possible. The size of the wire
must be thicker than actually required by the carrying current. A 24, 26 or 28
AWG wire for control and feedback cables is satisfactory although 24 AWG is
recommended.
19
Use shielded wires for motor connections as well. If the wires are long, ensure
that the capacitance between the wires is not too high: C < 30 nF is satisfactory
for most applications.
Keep all wires and cables as short as possible.
Keep the motor wires as far away as possible from the feedback, control and
communication cables.
Ensure that in normal operating conditions, the shielded wires and drain carry
no current. The only time these conductors carry current is under abnormal
conditions, when electrical equipment has become a potential shock or fire
hazard while conducting external EMI interferences directly to ground, in order
to prevent them from affecting the drive. Failing to meet this requirement can
result in drive/controller/host failure.
After completing the wiring, carefully inspect all wires to ensure tightness,
good solder joints and general safety.
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Optional
Ground
Power & Motor
CAN
Feedback B
RS-232
J2: I/O
J1: I/O
Feedback A
Cello Installation Guide Installation
The following connectors are used for wiring the Cello.
Type Function Port Connector Location
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5-Pin Phoenix
st
(1
two pins)
Power VP+, PR
(provided)
5-Pin Phoenix
Motor M1, M2, M3
(last 3 pins)
(provided)
3 ground
Ground PE, PE, PE
Backup Supply
screws
2-Pin Phoenix
(provided)
Optional
Backup Supply
24 VDC
Table 1: Connectors on the “Bottom” of the Cello
Type Function Port Connector Location
15-Pin D-Sub Feedback A Feedback A
15-Pin D-Sub
General I/O J1
(high-density)
15-Pin D-Sub
General I/O J2
(high-density)
Table 2: Connectors on the “Front” of the Cello
Type Function Port Connector Location
8-Pin RJ-45 CAN CAN
8-Pin RJ-45 CAN CAN
15-Pin D-Sub
Feedback B Feedback B
(high-density)
8-Pin RJ-45 RS-232 RS-232
Table 3: Connectors on the “Top” of the Cello
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Cello Installation Guide Installation
21
Figure 4: Cello Detailed Connection Diagram
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MAN-CELIG (Ve r. 1.602)
Cello Installation GuideInstallation
3.4.2 Connecting the Power Cables
The main power connector, which is located on the bottom of the Cello, includes the following
pins:
Pin Function Cable Pin Positions
VP+ Pos. Power input Power
PR Power return Power
PE Protective earth Power
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AC
Motor
DC Motor
Cable
Cable
PE Protective earth Motor Motor
M1 Motor phase Motor N/C
M2 Motor phase Motor Motor
M3 Motor phase Motor Motor
Note: When connecting several motors, all must be wired in an identical manner.
Table 4: Connector for Main Power and Motor Cables
3.4.2.1 Connecting the Motor Cable
Connect the motor power cable to the M1, M2, and M3 terminals of the main power connector
and the fourth wire to the PE (Protective Earth) on the heat sink (see diagram above). The
phase connection order is arbitrary because the Composer will establish the proper
commutation automatically during setup.
Notes for connecting the motor cables:
For best immunity, it is highly recommended to use a shielded (not twisted) cable for
the motor connection. A 4-wire shielded cable should be used. The gauge is
determined by the actual current consumption of the motor.
Connect the shield of the cable to the closest ground connection at the motor end.
Connect the shield of the cable to the PE terminal on the Cello.
Be sure that the motor chassis is properly grounded.
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