ElmoMC SimplIQ Digital Servo Drives-Trombone Installation Guide

Trombone

Digital Servo Drive

Installation Guide

July 2014 (Ver. 1.403)

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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 Trombone 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.

• Elmo Motion Control and the Elmo Motion Control logo are trademarks of Elmo Motion

Control Ltd.

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

Document no. MAN-TROIG (Ver. 1.403)

Copyright  2014

Elmo Motion Control Ltd.

All rights reserved.

Catalog Number

Revision History

Version Details

1.0 Initial release

1.1 Significant changes to the Appendix (Chapter 4)

1.2 Upgraded Trombone version to include new absolute

encoder settings and STO.

1.3 Sections 4.3 and 4.3.1: Auxiliary Supply Voltage range: 18

V to 30 V

1.4 September 2012 Change the overvoltage in 800 V mode, Pin layout, UL

recognition, and further optional versions added

“Metronome” was replaced by the “Composer” software.

1.401 February 2013 Added a caution and recommendation on the type of

cleaning solution to use for the Elmo unit.

1.402 June 2014 Document update

1.403 July 2014 Basic format changes

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-TROIG (Ve r. 1.403)

Table of Contents

Trombone Installation Guide

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

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

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

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

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

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

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

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

2.2. Product Features .......................................................................................................... 12

2.2.1. Current Control .............................................................................................. 12

2.2.2. Velocity Control ............................................................................................. 12

2.2.3. Position Control ............................................................................................. 12

2.2.4. Advanced Position Control ............................................................................ 13

2.2.5. Communication Options ................................................................................ 13

2.2.6. Feedback Options .......................................................................................... 13

2.2.7. Fault Protection ............................................................................................. 14

2.3. System Architecture ..................................................................................................... 14

2.4. How to Use this Guide .................................................................................................. 15

5

Chapter 3: Installation ................................................................................................... 16

3.1. Site Requirements ........................................................................................................ 16

3.2. Unpacking the Drive Components ................................................................................ 16

3.3. Pinouts .......................................................................................................................... 18

3.3.1. Connector Types ............................................................................................ 18

3.3.2. Connector J1 .................................................................................................. 19

3.3.3. Connector J2 .................................................................................................. 20

3.4. Mounting the Trombone .............................................................................................. 21

3.5. Integrating the Trombone on a PCB ............................................................................. 22

3.5.1. Traces ............................................................................................................. 22

3.5.2. Grounds and Returns ..................................................................................... 23

3.6. Connection Diagrams ................................................................................................... 24

3.7. Main Power and Motor Power ..................................................................................... 27

3.7.1. Connecting Motor Power .............................................................................. 27

3.7.2. Connecting the DC Power .............................................................................. 28

3.7.2.1. Direct-to-Mains Power Source (Non-Isolated Rectifier) ............... 28

3.7.2.2. Battery Power Supply ................................................................... 32

3.8. Connecting the Control and Backup Supply ................................................................. 32

3.9. Main Feedback ............................................................................................................. 33

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

44

3.10.1. Main and Auxiliary Feedback Combinations ................................................. 45

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Trombone Installation Guide Table of Contents

3.10.2. Auxiliary Feedback: Emulated Encoder Output Option (YA[4]=4) ................. 47

3.10.3. Auxiliary Feedback: Single-Ended Encoder Input Option (YA[4]=2) .............. 49

3.10.4. Auxiliary Feedback: Pulse-and-Direction Input Option (YA[4]=0) ................. 51

3.11. User I/Os ....................................................................................................................... 54

3.11.1. Digital Input ................................................................................................... 54

3.11.2. Digital Output ................................................................................................ 57

3.11.3. Analog Input .................................................................................................. 59

3.12. Communications ........................................................................................................... 60

3.12.1. RS-232 Communication ................................................................................. 60

3.12.2. CAN Communication ..................................................................................... 61

3.13. Powering Up ................................................................................................................. 63

3.13.1. Initializing the System .................................................................................... 63

3.14. Heat Dissipation............................................................................................................ 63

3.14.1. Trombone Thermal Data ............................................................................... 63

3.14.2. Heat Dissipation Data .................................................................................... 64

3.14.3. How to Use the Charts ................................................................................... 65

6

Chapter 4: Technical Specifications ................................................................................ 66

4.1. Features ........................................................................................................................ 66

4.1.1. Motion Control Modes .................................................................................. 66

4.1.2. Advanced Positioning Control Modes ........................................................... 66

4.1.3. Advanced Filters and Gain Scheduling........................................................... 66

4.1.4. Fully Programmable ....................................................................................... 66

4.1.5. Feedback Options .......................................................................................... 67

4.1.6. Input/Output ................................................................................................. 67

4.1.7. Built-In Protection ......................................................................................... 68

4.1.8. Status Indication ............................................................................................ 68

4.1.9. Automatic Procedures ................................................................................... 68

4.2. Dimensions ................................................................................................................... 69

4.3. Power Ratings ............................................................................................................... 70

4.3.1. Auxiliary Supply ............................................................................................. 71

4.4. Environmental Conditions ............................................................................................ 71

4.5. Control Specifications ................................................................................................... 72

4.5.1. Current Loop .................................................................................................. 72

4.5.2. Velocity Loop ................................................................................................. 73

4.5.3. Position Loop ................................................................................................. 73

4.6. Feedbacks ..................................................................................................................... 74

4.6.1. Feedback Supply Voltage ............................................................................... 74

4.6.2. Main Feedback Options ................................................................................. 74

4.6.2.1.

Incremental Encoder Input ........................................................... 74

4.6.2.2. Digital Halls ................................................................................... 75

4.6.2.3. Interpolated Analog (Sine/Cosine) Encoder ................................. 75

4.6.2.4. Absolute Serial Encoder ................................................................ 76

4.6.2.5. Resolver ........................................................................................ 76

4.6.2.6. Tachometer ................................................................................... 77

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Trombone Installation Guide Table of Contents

4.6.2.7. Potentiometer .............................................................................. 77

4.6.3. Auxiliary Feedback Port (output mode YA[4]= 4) .......................................... 78

4.6.4. Auxiliary Feedback Port (input mode YA[4]= 2, 0)......................................... 79

4.7. I/Os ............................................................................................................................... 80

4.7.1. Digital Input Interfaces .................................................................................. 80

4.7.2. Digital Output Interface ................................................................................. 81

4.7.3. Analog Input .................................................................................................. 81

4.8. Communications ........................................................................................................... 82

4.9. Pulse-Width Modulation (PWM) .................................................................................. 82

4.10. Compliance with Standards .......................................................................................... 83

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MAN-TROIG (Ve r. 1.403)

Chapter 1: Safety Information

Trombone Installation Guide

In order to operate the Trombone servo drive safely, 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 Trombone and accompanying equipment.

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

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

8

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

The following safety symbols are used in this manual:

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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MAN-TROIG (Ve r. 1.403)

Trombone 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 Trombone from all voltage sources before it is opened for servicing.

• The Trombone servo drive contains grounding conduits for electric current protection. Any

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

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

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

1.2. Cautions

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

during operation.

9

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

parameters outlined in this guide.

• When connecting to Trombone 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 Trombone, 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 Trombone 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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MAN-TROIG (Ve r. 1.403)

Trombone Installation Guide Safety Information

1.3. Directives and Standards

The Trombone conforms to the following industry safety standards:

Safety Standard Item

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

Recognized UL 508C Power Conversion Equipment

In compliance with UL 840 Insulation Coordination Including Clearances and

Creepage Distances for Electrical Equipment

10

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

Safety of Information Technology Equipment
Including Electrical Business Equipment

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

The Trombone 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 Trombone servo drive is intended for incorporation in a machine or end product. The
actual 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
Trombone 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-TROIG (Ve r. 1.403)

Chapter 2: Product Description

Trombone Installation Guide

This installation guide describes the Trombone servo drive and the steps for its wiring,
installation and power-up. Following these guidelines ensures optimal performance of the drive
and the system to which it is connected.

2.1. Drive Description

The Trombone series of digital servo drives are highly resilient and designed to deliver the
highest density of power and intelligence. The Trombone delivers up to 10 kW of continuous
power or 16 kW of peak power in a compact package.

The digital drives are based on Elmo’s advanced SimplIQ motion control technology. They
operate from a DC power source in current, velocity, position and advanced position modes, in
conjunction with a permanent-magnet synchronous brushless motor, DC brush motor, linear
motor or voice coil. They are designed for use with any type of sinusoidal and trapezoidal
commutation, with vector control. The Trombone can operate as a stand-alone device or as
part of a multi-axis system in a distributed configuration on a real-time network.

11

The drives are easily set up and tuned using Elmo’s Composer software tools. This Windows­based application enables users to configure the servo drive quickly and simply for optimal use
with their motor. The Trombone, as part of the SimplIQ product line, is fully programmable
with Elmo’s Composer motion control language.

Power to the drives is provided by a DC power source (not included with the Trombone).

Since the power stage is fully isolated from the control stage, the DC rectifier can be fed
directly from the mains, without the need for a bulky and expensive transformer.

If backup functionality is required to store control parameters in the event of a mains power
outage, then an S-model Trombone should be used, with an external 24 VDC isolated supply
connected to it.

Note: The backup functionality can operate from an isolated voltage source within the range

of 18 to 30 VDC.

Whenever backup functionality is not required, Trombone models that do not have the Control
Supply S suffix in the catalog number (only for 400 V models -see page 17) can be used, i.e.,
they do not have a 24 V control supply. In these models, a smart control-supply algorithm
enables the Trombone to operate with only the main power supply VP+ and VN-, with no need
for a 24 VDC auxiliary power supply for the logic.

The Trombone is a PCB-mounted device, which enables efficient and cost-effective
implementation. However, stand-alone integrated products (the DC Trombone and Solo
Trombone) are also available, using pluggable connections.

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MAN-TROIG (Ve r. 1.403)

Trombone Installation Guide Product Description

The Trombone is available in two versions:

• The Standard Trombone is a basic servo drive, which operates in current, velocity, and

position modes including Follower and PT & PVT. It operates simultaneously via RS-232 and
CAN DS 301, DS 305, DS 402 communications and features a third-generation programming
environment. (The catalog number begins TRO but is not followed by an A.)

• The Advanced Trombone includes all the motion capabilities and communication options

included in the Standard model, as well as advanced positioning capabilities: ECAM, Dual
Loop and increased program size. (The catalog number begins TRO-A.).

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

• 12-bit current loop resolution

• Automatic gain scheduling, to compensate for variations in the DC bus power supply

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

• Sample time: four times that of the current loop

• Fast event capturing inputs

• PT and PVT motion modes

• Fast output compare (OC)

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MAN-TROIG (Ve r. 1.403)

Trombone Installation Guide Product Description

2.2.4. Advanced Position Control

This relates to the 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

• Dual (position/velocity) loop

2.2.5. Communication Options

Depending on the application, Trombone users can select from two communication options:

• RS-232 serial communication

• CAN for fast communication in a multi-axis distributed environment

2.2.6. Feedback Options

• Incremental Encoder – up to 20 Megacounts (5 Megapulses) per second

• Digital Halls – up to 2 kHz

13

• Incremental Encoder with Digital Halls for commutation – up to 20 Megacounts per second

for encoder

• Interpolated Analog (Sine/Cosine) Encoder – up to 250 kHz (analog signal)

 Internal Interpolation - up to x4096
 Automatic correction of amplitude mismatch, phase mismatch, signals offset
 Auxiliary emulated, unbuffered, single-ended, encoder output

• Resolver

 Programmable 10 to 15 bit resolution
 Up to 512 revolutions per second (RPS)
 Auxiliary emulated, unbuffered, single-ended, encoder output

• Tachometer, Potentiometer

• Absolute Encoder

 Heidenhain 2.1
 Heidenhain 2.2
 Panasonic

• Elmo drives provide supply voltage for all the feedback options

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MAN-TROIG (Ve r. 1.403)

Motor

PWM

Controller

Communication

RS 232 and CANopen

Isolated Power Stage

Protection

I/Os

Resolver

Tachometer

Analog

Encoder

or

Main

DC Power

Supply

Potentiometer

or

or

or

Auxilliary

Encoder

24V Logic

Supply

(Optional)

Isolation

Boundary

Isolation

Boundary

Current

Feedback

Incremental

Encoder

Absolute

or

Trombone Installation Guide Product Description

2.2.7. Fault Protection

The Trombone 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

2.3. System Architecture

14

Figure 1: Trombone System Block Diagram

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MAN-TROIG (Ve r. 1.403)

Trombone Installation Guide Product Description

2.4. How to Use this Guide

In order to install and operate the Trombone 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 Trombone.

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

When you have completed the instructions in this guide, the Trombone 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 SimplIQ Software Manual, which describes the comprehensive software used with the

Trombone

• The SimplIQ Command Reference Manual, which describes, in detail, each software

command used to manipulate the Trombone motion controller

15

• The Composer Software Manual, which includes explanations of all the software tools that

are part of Elmo’s Composer software environment

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MAN-TROIG (Ve r. 1.403)

Chapter 3: Installation

Trombone Installation Guide Installation

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

3.1. Site Requirements

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

Feature Value

16

Ambient operating temperature

Maximum non-condensing humidity 90%

Operating area atmosphere No flammable gases or vapors permitted in

Models for extended environmental conditions are available.

Caution:

The Trombone dissipates its heat by convection. The maximum ambient
operating temperature of 40 °C (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 Trombone, verify that you have all of its components, as
follows:

• The Trombone servo drive

• The Composer software and software manual

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

To unpack the Trombone

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

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

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

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MAN-TROIG (Ve r. 1.403)

Trombone Installation Guide Installation

3. To ensure that the Trombone you have unpacked is the appropriate type for your

requirements, locate the part number sticker on the side of the Trombone.

It looks like this:

4. Verify that the Trombone type is the one that you ordered, and ensure that the voltage

meets your specific requirements.

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

17

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MAN-TROIG (Ve r. 1.403)

Trombone Installation Guide Installation

3.3. Pinouts

The Trombone has 9 connectors.

3.3.1. Connector Types

Pins Type Port Function Connector Location

2 mm pitch

2x18

0.51 mm2

17 J2 Main Feedback, Analog

1x2 J3.1 24 VDC Auxiliary power input

J1 I/O, COMM, Auxiliary

Feedback

Input, LED

positive (Only in Trombone
models with the S suffix)

J3.2 24 VDC Auxiliary power input

return (Only in Trombone
models with the S suffix)

18

2.54 mm pitch

2

0.64 mm2

VP+ Positive DC power input

2 VN- Negative DC power input

2 PE Protective earth

2 M1 Motor power output 1

2 M2 Motor power output 2

2 M3 Motor power output 3

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Trombone Installation Guide Installation

3.3.2. Connector J1

Connector J1: Communications, Auxiliary Feedback, I/O functions)

Pin (J1) Signal Function

1 RS232_RX RS-232 receive

2 RS232_TX RS-232 transmit

3 RS232_COMRET RS-232 communication return

4 AUX PORT CHA Auxiliary port CHA (bidirectional)

5 AUX PORT CHB Auxiliary port CHB (bidirectional)

6 COMRET Common return

7 OUT1 Programmable digital output 1

8 OUT2 Programmable digital output 2

9 OUT3 Programmable digital output 3

19

10 OUT4 Programmable digital output 4

11 IN1 Programmable digital input 1

12 IN2 Programmable digital input 2

13 IN3 Programmable digital input 3

14 IN4 Programmable digital input 4

15 IN5 Programmable digital input 5

16 IN6 Programmable digital input 6

17 SAFETY1 Safety input 1

18 SAFETY2 Safety input 2

19 SAFETY2RET Safety input 1 return (optionally connected to J1/20)

20 SAFETY1RET Safety input 2 return (optionally connected to J1/19)

21 INRET6 Programmable digital input 6 return

22 INRET5 Programmable digital input 5 return

23 INRET4 Programmable digital input 4 return

24 INRET3 Programmable digital input 3 return

25 INRET2 Programmable digital input 2 return

26 INRET1 Programmable digital input 1 return

27 OUTRET4 Programmable digital output 4 return

28 OUTRET3 Programmable digital output 3 return

29 OUTRET2 Programmable digital output 2 return

30 OUTRET1 Programmable digital output 1 return

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Trombone Installation Guide Installation

Pin (J1) Signal Function

31 +5 V Encoder +5 V supply voltage

Maximum output current: 200 mA

32 SUPRET Supply return

33 AUX PORT INDEX Auxiliary port index (bidirectional)

34 CAN_COMRET CAN communication return

35 CAN_L CAN_L bus line (dominant low)

36 CAN_H CAN_H bus line (dominant high)

3.3.3. Connector J2

Connector J2: Main Feedback and Analog Input functions

Pin (J2) Signal Function

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

Maximum output current: 200 mA

20

2 COMRET Supply and common return

3 ANALIN1+ Analog input 1+

4 ANALIN1- Analog input 1-

5 CHA Channel A+

6 CHA- Channel A-

7 CHB Channel B+

8 CHB- Channel B-

9 INDEX+/DATA+ Index + or Data+

10 INDEX-/DATA- Index – or Data-

11 CLOCK+ Clocking+

12 CLOCK- Clocking-

13 HA Hall sensor A input

14 HB Hall sensor B input

15 HC Hall sensor C input

16 LED_2_OUT Bi-color indication output 2 (Cathode). Implement this

pin-out usage by connecting it to a led (as necessary).

17 LED_1_OUT Bi-color indication output 1 (Anode). Implement this

pin-out usage by connecting it to a led (as necessary).

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MAN-TROIG (Ve r. 1.403)

Trombone Installation Guide Installation

3.4. Mounting the Trombone

The Trombone (Figure 2) is designed for mounting on a printed circuit board (PCB). It is
connected by 2 mm pitch 0.51 mm square pins and 2.54 mm pitch 0.64 mm square pins. When
integrating the Trombone into a PCB, be sure to leave about 1 cm (0.4") outward from the heat
sink to enable free convection of the air around the Trombone. We recommend that the
Trombone be soldered directly to the board. If the PCB is enclosed in a metal chassis, we
recommend that the Trombone be screw-mounted to it as well to help with heat dissipation.
The Trombone has screw-mount holes on each corner of the heat sink for this purpose.

21

All dimensions are in mm.

Figure 2: Trombone Dimensions

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MAN-TROIG (Ve r. 1.403)

Trombone Installation Guide Installation

3.5. Integrating the Trombone on a PCB

The Trombone is designed to be mounted on a PCB, by soldering its pins directly to the PCB.
The following procedures apply.

3.5.1. Traces

To implement Traces

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

carrying capacity required by the application.

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

the motor traces (M1, M2, M3 and PE) and power traces (VP+, VN- 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 better
performance and lower interference.

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

generated by the conductors.

22

3. The spacing between the high voltage conductors (VP+, VN-, M1, M2, M3) must be at least:

400 V Drives 800 V Drives

Surface layer Non-coated 2.4 mm 4.2 mm

Coated 1.0 mm 2.4 mm

Internal layer 0.5 mm 1.0 mm

4. The spacing between the high voltage conductors (VP+, VN-, M1, M2, M3) and the logic

part of the drive must be at least:

400 V Drives 800 V Drives

Surface layer Non-coated 4.8 mm 8.4 mm

Coated 2.0 mm 3.8 mm

Internal layer 0.5 mm 1.0 mm

5. The spacing between any voltage conductors and the PE part of the drive, must be at least:

400 V Drives 800 V Drives

Surface layer Non-coated 2.4 mm 4.2 mm

Coated 1.0 mm 2.4 mm

Internal layer 0.5 mm 1.0 mm

Complying with the rules above will help satisfy UL safety standards, MIL-STD-275 and the
IPC-D-275 standard for non-coated conductors, operating at voltages lower than 800 VDC.

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3.5.2. Grounds and Returns

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

Functional Block Return Pin

RS232 Communications RS232_COMRET (J1/3)

CAN Communications CAN_COMRET (J1/34)

Control section COMRET (J1/6)

Aux. Feedback SUPRET (J1/32)

Main Feedback/ Analog input SUPRET (J2/2)

The returns above are all shorted within the control section of the Trombone, 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 Trombone. DO
NOT USE A COMMON GROUND PLANE. Shorting the common returns on the Integration
Board may cause performance degradation (ground loops, etc.).

23

2. Inputs: The 6 digital inputs are optically isolated from the other parts of the Trombone.

Each input has its own return line, INRET#. To retain isolation, the Input Return pins and all
other conductors on the input circuit, must be laid out separately.

3. Outputs: The 4 digital outputs are optically isolated from the other parts of the Trombone.

Each output has its own return line, OUTRET# that is also optically isolated. To retain
isolation, all the output circuit conductors 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 crossover.

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 (Protective Earth) terminal is connected directly to the Trombone‘s

heat-sink. 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. Connection Diagrams

The following three connection diagrams (Figure 3, Figure 4) show the three different ways of
connecting the power supply:

• 400 V and 800 V S models (the catalog number has an S suffix) that feature backup

functionality and require an auxiliary 24 V backup supply. The drive will not be operative
without the external 24 VDC supply.

• 400 V model without backup functionality. The drive’s internal DC/DC converter is fed from

the VP+ and VN- of the internal drive’s bus line.

24

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25

Figure 3: Trombone Connection Diagram – with Backup Functionality

(S Model Drive)

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26

Figure 4: Trombone Connection Diagram – 400 V without Backup Functionality

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3.7. Main Power and Motor Power

The Trombone receives power from main supply and delivers power to the motor. The table
below describes the pinout connections to the main power and motor power cables.

Pin Function Cable Pin Positions

27

AC Motor DC Motor

M3 Motor phase Motor Motor

M2 Motor phase Motor Motor

M1 Motor phase Motor N/C

PE Protective Earth Power and Motor

VN- DC Negative Power input Power

VP+ DC Positive Power input Power

3.7.1. Connecting Motor Power

Connect the M1, M2, M3 and PE pins (Figure 5) on the Trombone in the manner described in
section 3.5 (Integrating the Trombone on a PCB). The phase connection is arbitrary, as the
Composer will establish the proper commutation automatically during setup. When tuning a
number of drives, you can copy the setup file to the other drives and thus avoid tuning each
drive separately. In this case, the motor-phase order must be the same as on the first drive.

Figure 5: Motor Power Connection Diagram

Notes:

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

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

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

• Connect the cable shield to the closest PE terminal of the Trombone.

• Ensure that the motor chassis is properly grounded.

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3.7.2. Connecting the DC Power

The DC power for the Trombone is delivered from a separated rectifying unit (supplied by the
user). The following sections contain topology recommendations for implementing three-phase
and a single-phase supply chains. Elmo offers the end-user, the option to purchase its
Tambourine rectifier, which offers a range of versatile options.

The power stage of the Trombone is fully isolated from the other sections of the Trombone,
such as the control-stage and the heat sink. This isolation allows the user to connect the
common of the control section to the PE, a connection that significantly contributes to proper
functionality, safety and EMI immunity, leading to better performance of the Trombone.

In addition, this isolation simplifies the requirements of the DC power supply that is used to
power the DC bus of the Trombone, by allowing it to operate with a non-isolated DC power
source (a direct-to-mains connection) which eliminates the need for a bulky and expensive
isolation transformer.

However, as well as operating from a non-isolated/direct-to-mains DC power supply, the
Trombone can also operate from an isolated power supply or batteries.

28

When rectifying an AC voltage source, the AC voltage level must be limited to 270 VAC so as
not to exceed the maximum 390 VDC in the case of a 400 VDC drive, or 528 VAC so as not to
exceed the maximum 747 VDC in the case of an 800 VDC drive.

If the Trombone is connected to Elmo’s Tambourine power supply, then the end-user can
exploit the Tambourine’s options, such as EMI-filtering and shunt-regulator.

3.7.2.1. Direct-to-Mains Power Source (Non-Isolated Rectifier)

This section relates to the configuration of the power supply and drive, which are connected
directly to the mains (Figure 6, Figure 7, Figure 8 and Figure 9).

Recommended connection of a non-isolated DC power supply

1. For best immunity, it is highly recommended to use twisted cables for the DC power supply

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

2. Connect both ends of the cable shield to the closest PE connections.

3. Tie one end to the power supply’s PE terminal, and tie the other end to the PE pins of the

module/PE terminal of the integration board, or attach it to one of the four mounting
screws of the drive’s heat sink.

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3.7.2.1.a Three-Phase Direct-to-Mains Connection Topology

Figure 6: Non-Isolated Three-Phase Connection Topology

29

Caution:
Do not connect VN- to PE. In a direct-to-mains connection, the VN- must not be
connected to the PE, as this will cause irreparable damage to the system.

Take care to note that in a direct-to-mains connection the Neutral point is not
the most negative voltage level. It is the mid-point level of the rectified DC bus.

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3.7.2.1.b Single-Phase Direct-to-Mains Connection Topology

Figure 7: Non-Isolated Single-Phase Connection Topology

30

The Power Supply is connected directly to the Mains AC line.

Caution:
Do not connect VN- to PE. In a direct-to-mains connection the VN- must not be
connected to the PE, as this will cause irreparable damage to the system.

Take care and note that in a direct-to-mains connection the Neutral point is not
the most negative voltage level. It is the mid-point level of the rectified DC bus.

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3.7.2.1.c Multiple Connections Topology

When applied in a multi-axis arrangement, it is likely that a single power supply can feed
several drives in parallel.

This topology is efficient and cost saving, reducing the number of power supplies and the
amount of wiring. More importantly, it utilizes an energy-sharing environment among all the
drives that share the same DC bus network.

31

Figure 8: Non-Isolated Three-Phase Multiple-Connection Topology

The power supply is connected directly to the Mains AC line and it feeds more than one drive.

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3.7.2.2. Battery Power Supply

Figure 9: Battery Connection Topology

Caution:

When using batteries, it is recommended to connect the negative pole to the
PE.
When doing so, the charger of the battery must be isolated from the mains by
an isolation transformer.

32

3.8. Connecting the Control and Backup Supply

In Trombone models without the S suffix in the catalog number, a smart control-supply
algorithm enables the Trombone to operate with the main power supply only, with no need for
an auxiliary supply voltage to supply the drive’s logic section.

Note: In Trombone models without the S suffix, there is no backup ability at all.

If a backup functionality is required to store control parameters in the event of a mains power
outages, then an S-model Trombone should be used, with an external 24 VDC isolated power
supply connected to it.

Note that S-model Trombone always requires an external 24 VDC power supply, regardless of
whether or not backup functionality is required.

Connect the auxiliary 24 VDC power supply as described below (Figure 10).

Notes for 24 VDC backup supply connections:

• Use a 24 AWG twisted pair shielded cable. The shield should have copper braid.

• The source of the 24 VDC backup supply must be isolated with an isolation transformer.

• For safety and EMI reasons, connect the return of the 24 VDC backup supply to the closest

ground (PE).
Connect the cable shield to the closest ground (PE) near the power source.
Before applying power, first verify that the polarity of the connection is correct.

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Figure 10: Auxiliary 24 VDC Backup Supply Connection Diagram

Pin (J3) Function Pin Positions

1 +24V Auxiliary Supply Input Positive

2 24VRET Auxiliary Supply Input Return

33

Table 1: Auxiliary 24 VDC Backup Supply Pins and Polarity

3.9. Main Feedback

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

The Trombone can accept any one the following devices as a main feedback mechanism:

• Incremental encoder only

• Incremental encoder with digital Hall sensors

• Digital Hall sensors only

• Interpolated Analog (Sine/Cosine) encoder (optional)

• Resolver (optional)

• Tachometer (optional)

• Potentiometer (optional)

• Absolute Encoder (optional)

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Table 2 and Table 3 describe the various options available for the main feedback pin
assignments for Encoders, Resolver, and the Tachometer & Potentiometer.

34

Incremental Encoder Interpolated Analog

Encoder

Absolute Encoder

TRO-XX/YYY_ TRO-XX/YYYI TRO-XX/YYYQ

Pin

Signal Function Signal Function Signal Function

(J2)

1 +5V Encoder/Hall

+5V supply

+5V Encoder/ Hall

+5V supply

+5V Encoder/ Hall

+5V supply

2 SUPRET Supply return SUPRET Supply return SUPRET Supply return

3 ANALIN+ is used for Analog Input

4 ANALIN- is used for Analog Input

5 CHA Channel A+ A+ Sine A+ A+ Sine A+

6 CHA- Channel A- A- Sine A- A- Sine A-

7 CHB Channel B+ B+ Cosine B+ B+ Cosine B+

8 CHB- Channel B - B- Cosine B - B- Cosine B -

9 INDEX Index+ R+ Reference+ DATA+ Data+

10 INDEX- Index - R- Reference - DATA- Data-

11 NC

12 NC

13 HA Hall sensor A

input

14 HB Hall sensor B

input

15 HC Hall sensor C

input

NC

NC

HA Hall sensor A

HB Hall sensor B

HC Hall sensor C

input

input

input

Clock+ Clock+

Clock- Clock-

HA Hall sensor A

input

HB Hall sensor B

input

HC Hall sensor C

input

16 LED_2_OUT (AOKLED cathode) is used for implementing LED indication

17 LED_1_OUT (AOKLED anode) is used for implementing LED indication

Table 2: Main Feedback Pin Assignments in Encoders

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Resolver Tachometer & Potentiometer

TRO-XX/YYYR TRO-XX/YYYT

Pin Signal Function Signal Function

35

1 +5V

2 SUPRET

+5V Encoder/ Hall +5V supply

SUPRET Supply return

3 ANALIN+ is used for Analog Input

4 ANALIN- is used for Analog Input

5 S1 Sine A+ Tac 1+ Tacho Input 1 Pos. (20V max)

6 S3 Sine A - Tac 1- Tacho Input 1 Neg. (20 V max)

7 S2 Cosine B+ Tac 2+ Tacho Input 2 Pos. (50V max)

8 S4 Cosine B - Tac 2- Tacho Input 2 Neg. (50 V max)

9 R1 Vref f=1/TS, 50mA

POT Potentiometer Input (5V Max)

Max.

10 R2 Vref- f= 1/TS, 50 mA

NC -

Max.

11 NC

11 NC

NC

NC

13 HA

14 HB

13 HC

HA Hall sensor A input

HB Hall sensor B input

HC Hall sensor C input

16 LED_2_OUT (AOKLED cathode) is used for LED indication

17 LED_1_OUT (AOKLED anode) is used for LED indication

Table 3: Main Feedback Pin Assignments in the Resolver, Tachometer & Potentiometer

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The following connection diagrams detailed in Figure 11 through Figure 20 describe the main
feedback connections, shown in the tables above.

36

Figure 11: Main Feedback – Incremental Encoder with Digital Hall Sensors Connection

Diagram

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37

Figure 12: Main Feedback – Interpolated Analog (Sine/Cosine) Encoder Connection Diagram

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38

Figure 13: Main Feedback – Interpolated Analog (Sine/Cosine) Encoder with Digital Hall

Sensors Connection Diagram

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39

Figure 14: Main Feedback – Heidenhain Absolute Encoder with Digital Hall Sensors

Connection Diagram

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40

Figure 15: Main Feedback – Resolver Connection Diagram

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41

Figure 16: Main Feedback – Resolver and Digital Hall Sensors Connection Diagram

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42

Figure 17: Main Feedback – Tachometer Feedback with Digital Hall Sensors (Connection

Diagram for Brushless Motors)

Figure 18: Main Feedback – Tachometer Feedback Connection Diagram for Brush Motors

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43

Figure 19: Main Feedback – Potentiometer Feedback with Digital Hall Sensors (Connection

Diagram for Brushless Motors)

Figure 20: Main Feedback – Potentiometer Feedback Connection Diagram

for Brush Motors and Voice Coils

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3.10. Auxiliary Feedback

For auxiliary feedback, select one of the following options:

a. Single-ended emulated encoder outputs, used to provide emulated encoder signals to

another controller or drive. The Emulated Encoder Output option is only available when
using a resolver, interpolated analog encoder, tachometer, potentiometer or absolute
encoder as the main feedback device.

This option can be used in the following scenarios:

 The Trombone is used as a current Servo-Drive to provide position data to the position

controller.

 The Trombone is used in velocity mode to provide position data to the position

controller.

 The Trombone is used as a master in follower or ECAM mode.

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

in follower or ECAM mode.

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

commands.

44

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

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3.10.1. Main and Auxiliary Feedback Combinations

The Main Feedback is always used in motion control devices, whereas Auxiliary Feedback is
often, but not always used. The Auxiliary Feedback connector on the Trombone has three bi­directional pins (CHA, CHB and INDEX). When used in combination with Main Feedback, the
Auxiliary Feedback can be set, by software, as follows:

Main Feedback Auxiliary Feedback

45

Software
Setting

Incremental
Encoder Input

Interpolated
Analog
(Sine/Cosine)
Encoder Input

YA[4] = 4

(Aux. Feedback: output)

Main Feedback:
Incremental Encoder

Aux. Feedback:
There is no Aux. Feedback
output option, when an
Incremental Encoder is the
main feedback device.

1. Main Feedback:
Analog Encoder

YA[4] = 2

(Aux. Feedback: input)

Main Feedback Input:
Incremental Encoder

or Analog Encoder

or Resolver

or Absolute encoder

or Tachometer

or Potentiometer

Aux. Feedback:
Single-ended Incremental
Encoder Input

YA[4] = 0

(Aux. Feedback: input)

Main Feedback Input:
Incremental Encoder

or Analog Encoder

or Resolver

or Absolute encoder

or Tachometer

or Potentiometer

Aux. Feedback:
Single-ended Pulse and
Direction Commands

Resolver Input

Aux. Feedback:
Analog Encoder position data,
emulated in single-ended,
un-buffered incremental
Encoder format

2. Main Feedback: Resolver

Aux. Feedback:
Resolver position data
emulated in single-ended un­buffered Incremental Encoder
format

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Main Feedback Auxiliary Feedback

46

Software
Setting

Absolute Encoder
Input

Potentiometer or
Tachometer Input

YA[4] = 4

(Aux. Feedback: output)

3. Main Feedback:
Absolute Encoder

Aux. Feedback:
Absolute position data
emulated in single-ended un­buffered Incremental Encoder
format

4. Main Feedback:
Potentiometer or Tachometer

Aux. Feedback:
Tachometer or Potentiometer
position data, emulated in
single-ended un-buffered
Incremental Encoder format

YA[4] = 2

(Aux. Feedback: input)

Main Feedback Input:
Incremental Encoder

or Analog Encoder

or Resolver

or Absolute Encoder

or Tachometer

or Potentiometer

Aux. Feedback:
Single-ended Incremental
Encoder Input

YA[4] = 0

(Aux. Feedback: input)

Main Feedback Input:
Incremental Encoder

or Analog Encoder

or Resolver

or Absolute Encoder

or Tachometer

or Potentiometer

Aux. Feedback:
Single-ended Pulse and
Direction Commands

Typical Applications

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

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

3. Tachometer or
potentiometer applications
where position data is
required in the Encoder’s
quadrature format.

4. Absolute Encoder
applications where
position data is required by
means of a digital word

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: Emulated Encoder Output Option

47

(YA[4]=4

)

Pin (J1) Signal Function Pin Positions

32 COMRET Common return

33 INDEXO Auxiliary index output

5 CHBO Auxiliary Channel B output

4 CHAO Auxiliary Channel A output

Note: The Emulated Encoder Output Option (Figure 21,

Figure 22 (recommended)) is only available when using a
resolver, absolute encoder, analog encoder, tachometer
or potentiometer as the main feedback device.
The Trombone‘s Auxiliary Feedback is single-ended.
When mounted on an integration board, circuitry can be
added to make it differential (Figure 23 (highly
recommended)).

Table 4: Emulated Single-Ended Encoder Output Pin Assignments

Figure 21: Emulated Encoder Direct Output – Acceptable Connection Diagram

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48

Figure 22: Emulated Encoder Buffered Output – Recommended Connection Diagram

Figure 23: Emulated Encoder Differential Output – Highly Recommended Connection Diagram

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3.10.3. Auxiliary Feedback: Single-Ended Encoder Input Option

49

(YA[4]=2

)

Pin (J1) Signal Function Pin Positions

31 +5 V Encoder supply voltage

6 SUPRET Supply return

33 INDEX Auxiliary index input

5 CHB Auxiliary channel B input

4 CHA Auxiliary channel A input

The Trombone‘s Auxiliary Feedback is

single-ended (Figure 24, Figure 25 (recommended)).
When mounted on an integration board, circuitry can
be added to make it differential (Figure 26 (highly
recommended)).

Table 5: Single-Ended Auxiliary Encoder Pin Assignment

Figure 24: Single-Ended Auxiliary Encoder Input - Acceptable Connection Diagram

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Figure 25: Single-Ended Auxiliary Encoder Input - Recommended Connection Diagram

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51

Figure 26: Differential Auxiliary Encoder Input – Highly Recommended Connection Diagram

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

(YA[4]=0

Pin (J1) Signal Function Pin Positions

32 COMRET Common return

5 DIR/CHB Direction input (push/pull 5 V

4 PULS/CHA Pulse input (push/pull 5 V or

Note: The Trombone‘s Auxiliary Feedback is

single-ended (Figure 27, Figure 28 (recommended)).
When mounted on an integration board, circuitry can
be added to make it differential (Figure 29 (highly
recommended)).

)

or open collector)

open collector)

Table 6: Pulse-and-Direction Pin Assignments

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52

Figure 27: Pulse-and-Direction Auxiliary Encoder Input – Direct Connection Diagram,

Acceptable

Figure 28: Pulse-and-Direction Auxiliary Encoder Input – Buffered Connection Diagram,

Recommended

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Figure 29: Pulse-and-Direction Auxiliary Encoder Input – Differential Connection Diagram,

Highly Recommended

53

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3.11. User I/Os

The Trombone has 6 Digital Inputs, 4 Digital Outputs, and 1 Analog Input

I/O J1 J2

Digital Input 6 -

Digital Output 4 -

Analog Input - 1

Table 7: Various I/O Distributions

3.11.1. Digital Input

Each of the pins below can function as an independent input (Figure 31, Figure 32).

Pin (J1) Signal Function Pin Positions

11 IN1 Programmable input 1

(general purpose, RLS, FLS, INH)

54

12 IN2 Programmable input 2

(general purpose, RLS, FLS, INH)

13 IN3 Programmable input 3

(general purpose, RLS, FLS, INH)

14 IN4 Programmable input 4

(general purpose, RLS, FLS, INH)

15 IN5 Hi-Speed Programmable input 5

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

16 IN6 Hi-Speed Programmable input 6

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

21 INRET6 Programmable input 6 return

22 INRET5 Programmable input 5 return

23 INRET4 Programmable input 4 return

24 INRET3 Programmable input 3 return

25 INRET2 Programmable input 2 return

26 INRET1 Programmable input 1 return

Table 8: Digital Input Pin Assignments

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Figure 30: Digital Input Connection Diagram – 5V Level

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Figure 31: Digital Input Connection Diagram -PLC

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3.11.2. Digital Output

Pin (J1) Signal Function Pin Positions

7 OUT1 High-Speed Programmable

digital output 1

8 OUT2 Programmable digital

output 2

9 OUT3 Programmable digital

output 3

10 OUT4 Programmable digital

output 4

30 OUTRET1 Programmable digital

output 1 return

29 OUTRET2 Programmable digital

output 2 return

57

28 OUTRET3 Programmable digital

output 3 return

27 OUTRET4 Programmable digital

output 4 return

Table 9: Digital Output Pin Assignment

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Figure 32: Digital Output Connection Diagram

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3.11.3. Analog Input

Pin (J2) Signal Function

3 ANLIN1+ Analog input 1+

4 ANLIN1- Analog input 1-

2 ANLRET Analog ground

Table 10: Analog Input Pin Assignments

59

Figure 33: 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 Trombone can
communicate using the following options:

a. RS-232, full duplex

b. CAN

RS-232 communication requires a standard, commercial 3-core null-modem cable connected
from the Trombone 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

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.

60

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 (J1) Signal Function

1 RS232_Rx RS-232 receive

2 RS232_Tx RS-232 transmit

3 RS232_COMRET Communication return

Table 11: RS-232 Pin Assignments

Figure 34: RS-232 Connection Diagram

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3.12.2. CAN Communication

Connecting 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.
Make sure to have a 120-Ω resistor termination at each of the two ends of the network cable.
The Trombone’s CAN port is non-isolated.

Pin (J1) Signal Function

34 CAN_RET CAN ground

35 CAN_L CAN_L bus line (dominant low)

36 CAN_H CAN_H bus line (dominant high)

Table 12: CAN – Pin Assignments

Note: The CAN_RET terminal must always be used and connected, to provide electrical

immunity.

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Figure 35: CAN Network Diagram

Caution:

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

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3.13. Powering Up

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

Caution:
Before applying power, ensure that:

1. The DC supply is within the specified range.

2. The proper plus-minus connections are in order.

3. The VN- is not connected to the PE nor to the Neutral, when working with a

non-isolated power supply.

3.13.1. Initializing the System

After the Trombone 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. Install the application and then perform setup and initialization according to the
directions in the Composer Software Manual.

63

3.14. Heat Dissipation

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

3.14.1. Trombone Thermal Data

• Heat dissipation capability (θ): Approximately 5.5 °C/W

• Thermal time constant: Approximately 600 seconds (thermal time constant means that the

Trombone will reach 2/3 of its final temperature after 10 minutes)

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

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3.14.2. Heat Dissipation Data

Heat Dissipation is shown graphically below:

64

Figure 36: Dissipation versus Current Graph for 560 and 680 VDC

Figure 37: Dissipation versus Current Graph for 330 VDC

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3.14.3. How to Use the Charts

The power dissipation in the chart includes the losses of the rectifying bridge.
Regarding Figure 37 and Figure 38, the following should be noted:

560 3X400

680 3X480

330 3X230

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

To determine if your application needs a heat sink:

1. Allow maximum heat sink temperature to be 80 °C or less (shunt down is 6 °C to 8 °C

higher).

2. Determine the ambient operating temperature of the Trombone as ≤ 40 °C.

3. Calculate the allowable temperature increase according to the following example: For

an ambient temperature of 40 °C, ΔT = 80 to 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.

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Chapter 4: Technical Specifications

Trombone Installation Guide

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

4.1. Features

The Trombone's features determine how it controls motion, as well as how it processes host
commands, feedback and other input.

4.1.1. Motion Control Modes

• Current/Torque - up to 14 kHz sampling rate

• Velocity - up to 7 kHz sampling rate

• Position - up to 3.5 kHz sampling rate

66

4.1.2. Advanced Positioning Control Modes

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

• Fast event capturing inputs

• Fast output compare (OC)

• Motion Commands: analog, pulse-width modulation (PWM), digital (software) and pulse

and direction

4.1.3. Advanced Filters and Gain Scheduling

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

• Velocity and position with “1-2-4” PIP controllers

• Automatic commutation alignment

• Automatic motor phase sequencing

4.1.4. Fully Programmable

• Third generation programming structure with motion commands – “Composer”

• Event capturing interrupts

• Event triggered programming

• 32 KB memory in Advanced models (‘A’ prefix)

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4.1.5. Feedback Options

• Incremental Encoder – up to 20 Megacounts (5 Megapulses) per second

• Digital Halls – up to 2 kHz

• Absolute Encoder

• Incremental Encoder with Digital Halls for commutation – up to 20 Megacounts per second

for encoder

• Interpolated Analog (Sine/Cosine) Encoder – up to 250 kHz (analog signal)

 Internal interpolation – up to x4096
 Automatic correction of amplitude mismatch, phase mismatch, signal offset
 Emulated outputs of the analog encoder: single-ended and unbuffered

• Analog Hall sensor

• Resolver

 Programmable 10 to 15 bit resolution
 Up to 512 revolutions per seconds (RPS)
 Emulated outputs of the resolver: single-ended and unbuffered

67

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

• Tachometer & Potentiometer

• The Trombone can provide power (5 V, 2 x 200 mA max) for Encoders, Resolver or Halls.

4.1.6. Input/Output

• One Analog Input – up to 14-bit resolution

• Six separate programmable Digital Inputs, optically isolated (two of which are fast event

capture inputs)

 Inhibit/enable motion
 Software and analog reference stop
 Motion limit switches
 Begin on input
 Abort motion
 Homing
 General purpose

• Four separate programmable Digital Outputs, optically isolated (open collector), one with

fast output compare (OC):

 Brake control
 Servo-Drive fault indication
 General purpose
 Servo enable indication

• Pulse and direction inputs (single-ended)

• PWM current command output for torque and velocity

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4.1.7. Built-In Protection

• Software error handling

• Abort (hard stops and soft stops)

• Status reporting

• Protection against:

 Shorts between motor power outputs
 Shorts between motor power outputs and power input/return
 Failure of internal power supplies
 Over-heating
 Continuous temperature measurement. Temperature can be read on-the-fly, and a

warning can be initiated x degrees before temperature disable is activated.

 Over-/under-voltage
 Loss of feedback
 Following error
 Current limits

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4.1.8. Status Indication

• By software/composer interface during continuous communication

• Output for a bi-color LED - to be implemented via user external LED.

4.1.9. Automatic Procedures

• Commutation alignment

• Phase sequencing

• Current loop offset adjustment

• Current loop gain tuning

• Current gain scheduling

• Velocity loop offset adjustment

• Velocity gain tuning

• Velocity gain scheduling

• Position gain tuning

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4.2. Dimensions

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4.3. Power Ratings

Feature Units 12/400 16/400 R17/400 R22/400 8/800 12/800 R11/800 R16/800

Minimum supply
voltage

Nominal supply
voltage

Maximum supply
voltage

Maximum continuous
power output

Efficiency at rated
power (at nominal
conditions)

Auxiliary supply
voltage option

Auxiliary power
supply

Continuous current
limit (Ic) Amplitude
sinusoidal/DC
trapezoidal
commutation

VDC S suffix in P/N*: 50

No S suffix in P/N: 100

VDC 325 560 for 400 VAC

VDC 400 780

W Up to 10 kW of continuous qualitative power

% > 98

VDC 18 V to 30 V

Only for Control Supply S suffix Model

VA ≤5 VA without external loading

≤8 VA with full external loading

A 12 16 17 22 8 12 11 16

S suffix in P/N*: 95+

680 for 480 VAC

Sinusoidal continuous
RMS current limit (Ic)

Peak current limit A 2 x Ic No peak 2 x Ic No peak

Weight g (oz) 250 g (8.8 oz)

Dimensions mm

Digital in/Digital out/
Analog in

Mounting method PCB Mounted

A 8.5 11.3 12 15.5 5.7 8.5 7.8 11.3

111 x 76 x 30 (4.33" x 2.95" x 1.18")

(in)

6/4/1

*See page 17 for details on the part number. The S suffix appears in models where there is a
24 V control supply. If there is no S suffix, the control power supply operates from the main
power.

Note on current ratings: The current ratings of the Trombone are given in units of DC

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

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4.3.1. Auxiliary Supply

This table applies only to the models with an S suffix. See page 17 for further details on the part
number.

Feature Details

Auxiliary power supply Isolated DC source only

Auxiliary supply input voltage 18 to 30 VDC

Auxiliary supply input power < 8 VA (This includes the 5 V/2 x 200 mA load for the

main and auxiliary encoders)

Note: An S-type drive will not operate unless it has the Aux. supply (Mandatory).

4.4. Environmental Conditions

Feature Details

71

Operating ambient temperature
according to IEC60068-2-2

Storage temperature

Maximum non-condensing humidity
according to IEC60068-2-78

Maximum Operating Altitude

Mechanical Shock
according to IEC60068-2-27

Vibration
according to IEC60068-2-6

Feature

0 °C to 40 °C (32 °F to 104 °F)

-20 °C to +85 °C ( -4 °F to +185 °F)

95%

2,000 m (6562 feet)

15g / 11ms Half Sine

5 Hz ≤ f ≤ 10 Hz: ±10mm

10 Hz ≤ f ≤ 57 Hz: 4G

57 Hz ≤ f ≤ 500 Hz:5G

Details

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4.5. Control Specifications

4.5.1. Current Loop

Feature Details

Controller type Vector, digital

Compensation for bus voltage variations On-the-fly automatic gain scheduling

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Motor types

• AC brushless (sinusoidal)

• DC brushless (trapezoidal)

• DC brush

• Linear motors

• “Voice” coils

Current control

• Fully digital

• Sinusoidal with vector control

• Programmable PI control filter based on a

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

Current loop bandwidth < 2.5 kHz

Current loop sampling time

Programmable 100 to 200 µsec

Current loop sampling rate Default 10 kHz

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4.5.2. Velocity Loop

Feature Details

Controller type PI

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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

• Absolute Encoder

• Interpolated Analog (Sine/Cosine) Encoder (optional)

• Resolver (optional)

• Tachometer and Potentiometer (optional)

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

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

Velocity loop bandwidth < 350 Hz

Velocity loop sampling time

140 to 200 µsec (twice the current loop sample time)

Velocity loop sampling rate Up to 8 kHz; default 5.5 kHz

Velocity command options

• Analog

• Internally calculated by either jogging or step

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

changes.

4.5.3. Position Loop

Feature Details

Controller type “1-2-4” PIP

Position command options

Position loop bandwidth < 80 Hz

Position loop sampling time

Position loop sampling rate Up to 4 kHz; default 2.75 kHz

• Software

• Pulse and Direction

• Analog Potentiometer

280 to 400 µsec (four times the current loop sample time)

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4.6. Feedbacks

The Trombone can receive and process feedback input from diverse types of devices.

4.6.1. Feedback Supply Voltage

The Trombone has two feedback ports (Main and Auxiliary). It supplies voltage to the Main
feedback device, and to the Auxiliary feedback device if needed.

Feature Details

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

Auxiliary encoder supply voltage 5 V ±5% @ 200 mA maximum

4.6.2. Main Feedback Options

4.6.2.1. Incremental Encoder Input

Feature Details

74

Encoder format

• A, B and Index

• Differential

• Quadrature

Interface RS-422

Input resistance

Differential: 120 Ω

Maximum incremental encoder frequency Maximum absolute: 5 MHz pulses

Minimum quadrature input period (PIN) 112 nsec

Minimum quadrature input high/low period (PHL) 56 nsec

Minimum quadrature phase period (PPH) 28 nsec

Maximum encoder input voltage range

Common mode: ±7 V

Differential mode: ±7 V

Figure 38: Main Feedback - Encoder Phase Diagram

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4.6.2.2. Digital Halls

Feature Details

Halls inputs HA, HB, HC.

Single-ended inputs

Built in hysteresis of 1 V for noise immunity

75

Input voltage Nominal operating range: 0 V < V

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

InHig h

InLow

In_Hall

> 2.5 V

< 1 V

< 5 V

In_Hall

< 15 V

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

Maximum frequency f

MAX

: 2 kHz

4.6.2.3. Interpolated Analog (Sine/Cosine) Encoder

Feature Details

Analog encoder format Sine and Cosine signals

Analog input signal level

Input resistance

Maximum analog signal frequency f

Interpolation multipliers Programmable: x4 to x4096

• Offset voltage: 2.2 V to 2.8 V

• Differential, 1 V peak to peak

Differential 120 Ω

: 250 kHz

MAX

Maximum “counts” frequency 80 Megacounts/sec “internally”

Automatic error correction Signal amplitudes mismatch

Signal phase shift

Signal offsets

Encoder outputs See Auxiliary Encoder Outputs specifications ( 4.6.3)

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4.6.2.4. Absolute Serial Encoder

Feature Details

76

Encoder format

• NRZ (Panasonic)

• EnDAT 2.21 (with analogue Sin/Cos)

• Stegmann in DC-TRO/SOL-TRO

Interface

• RS-485

• Clock – Differential output line

• Data – Differential bidirectional line

Input Resistance

Differential 120 Ω

Transmission Rate Up to 2.5 MHz

4.6.2.5. Resolver

Feature Details

Resolver format

Input resistance

Resolution Programmable: 10 to 15 bits

• Sine/Cosine

• Differential

Differential 2.49 kΩ

Maximum electrical frequency (RPS) 512 revolutions/sec

Resolver transfer ratio 0.5

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

Reference voltage Supplied by the Trombone

Reference current up to ±50 mA

Encoder outputs See Auxiliary Encoder Output specifications ( 4.6.3)

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4.6.2.6. Tachometer*

Feature Details

Tachometer format Differential

Maximum operating differential voltage for TAC1+, TAC1- ±20 V

Maximum absolute differential input voltage for TAC1+, TAC1- ±25 V

Maximum operating differential voltage for TAC2+, TAC2- ±50 V

Maximum absolute differential input voltage for TAC2+, TAC2- ±60 V

Input resistance for TAC1+, TAC1- 46 kΩ

Input resistance for TAC2+, TAC2- 100 kΩ

Resolution 14 bit

* Only one Tachometer port can be used at a time (either TAC1+/TAC1- or TAC2+/TAC2-).
TAC1+/TAC1- is used in applications with a Tachometer of less than 20 V.
TAC2+/TAC2- is used in applications with a Tachometer of 20 V to 50 V.

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4.6.2.7. Potentiometer

Feature Details

Potentiometer Format Single-ended

Operating Voltage Range 0 to 5 V supplied by the Trombone

Potentiometer Resistance 100 Ω to 1 kΩ above this range, linearity is

detrimentally affected

Input Resistance 100 kΩ

Resolution 14 bit

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4.6.3. Auxiliary Feedback Port (output mode YA[4]= 4)

Feature Details

78

Emulated output

• A, B, Index

• Single ended

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

> 3.0 V

OH

= 2 mA

OL

< 0.4 V

OL

Available as options

High level output voltage: V

Minimum output current: I

Low level output voltage: V

• Emulated encoder outputs of following:

• Analog encoder

• Resolver

• Absolute encoder

• Tachometer

• Potentiometer

Maximum frequency f

: 5 MHz pulses/output

MAX

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

noise filtering at remote receiver of emulated
encoder signals

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

an encoder cycle) and synchronized to A&B

Figure 39: Auxiliary Feedback - Encoder Phase Diagram

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

Feature Details

79

Encoder input,
pulse and direction input

• A, B, Index

• Single ended

Input voltage VIn Low: 0 V < VIL < 0.8 V

V

High: 2 V < VIH < 5 V

In

Maximum absolute voltage: 0 < V

< 5.5 V

In

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 emulated
encoder signals

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

an encoder cycle) and synchronized to A&B

Figure 40: Auxiliary Feedback - Encoder Phase Diagram

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4.7. I/Os

The Trombone has:

• 6 Digital Inputs

• 4 Digital Outputs

• 1 Analog Input

4.7.1. Digital Input Interfaces

The digital inputs are 5 V level compatible by default, but can be configured to PLC level, on the
integration board.

Feature Details

80

Type of input

• Optically isolated

• Each input has its own return

Input current for all inputs Iin = 4.7 mA @ Vin = 5 V

High-level input voltage 3.0 V < Vin < 10 V, 5 V typical

Low-level input voltage 0 V < Vin < 1 V

Minimum pulse width > 4 x TS, where TS is sampling time

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

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 < 4 x TS

If input is set to General input, execution depends on

program. Typical execution time: ≅ 0.5 msec.

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

Capture Time (T) < 5 µsec

Notes:

speed mode

• 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.

• The highest speed is achieved when turning on

optocouplers.

Figure 41: Digital Input Schematic

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4.7.2. Digital Output Interface

Feature Details

81

Type of output

• Optically isolated

• Open collector and open emitter

• Each output has its own return

Maximum supply output (VCC) 30 V

Max. output current
I

(max) (V

out

= Low)

out

VOL at maximum output voltage (low

(max) ≤ 8 mA

I

out

V

(on) ≤ 0.4 V

out

level)

RL The external resistor RL must be selected to limit

the output current to no more than 8 mA.

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

Home flag, Brake or AOK — execution is immediate
upon detection:
0 < T < 4 x TS

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

0.5 msec.

Figure 42: Digital Output Schematic

4.7.3. 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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4.8. Communications

Specification Details

82

RS-232

Signals:

• RxD, TxD, Gnd

• Full duplex, serial communication for setup and control

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

CAN CAN bus 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:

• DS 305

Device Profile (drive and motion control):

• DS 402

4.9. Pulse-Width Modulation (PWM)

Feature Details

PWM resolution 12-bit

PWM switching frequency on the load 2/Ts (factory default 22 kHz on the motor)

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4.10. Compliance with Standards

Specification Details

Quality Assurance

ISO 9001:2008 Quality Management

Design

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

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

MIL-HDBK- 217F Reliability prediction of electronic equipment

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

83

• 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

84

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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