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 Solo Whistle servo
drive in its installation.
• The text and graphics included in this manual are for the purpose of illustration and
reference only. The specifications on which they are based are subject to change without
notice.
• 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-SOLWHIIG (Ver. 1.503)
Copyright 2014
Elmo Motion Control Ltd.
All rights reserved.
Catalog Number
Note: The catalog number suffix is a number from 01 to 08, as shown above. The odd
numbers are models with connectors, and the even numbers are models with wires. For
currents of 10 A or less, both models are available; for currents of 15 A or more, only a wires
model is available.
Formatted according to the new template
Revision History
Version Date Details
1.0 June 2008 Initial Release
1.1 November
2008
1.2 February
2009
1.3 March
2009
1.4 March
2010
1.5 Sept.
2012
1.501 Jan. 2013 Updated the auxiliary power supply value.
Changed: Front matter, P/N explanations, sticker & schematics in
Section 4.2, Figure 14, Figure 15, Figure 16, Section 3.7 and
Section 3.8. Added information for auxiliary input features in
Chapters 2 and 3 and in Section 4.7.4.
MTCR 00-100-33: Weight of product changed to 68.4 grams in
Section 4.3
MTCR 01-009-39: Section 3.7.1: Advanced not mandatory
therefore in Mode 1 catalog number, “A” was removed.
MTCR 01-009-41: Clarifications regarding models with connectors
and wires on the Notice page (above) and on Pages 17, 18. 4-Pin
option added to table on Page 18.
MTCR 04-009-48: Section 3.5: Pin J1/2 renamed to PR.
“Metronome” was replaced by the “Composer” software.
Updated the 200 V power ratings table.
Section 4.3: Physical Specifications, was added.
Added a caution and recommendation on the type of cleaning
solution to use for the Elmo unit.
1.502 Dec. 2013 General document update
1.503 July 2014 General updates
Elmo Worldwide
Head Office
Elmo Motion Control Ltd.
60 Amal St., P.O. Box 3078, Petach Tikva 49516
Israel
4.11. Compliance with Standards .......................................................................................... 68
7
MAN-SOLWH IIG (V er. 1.503)
Chapter 1: Safety Information
Warning:
Caution:
Solo Whistle Installation Guide
In order to achieve the optimum, safe operation of the Solo Whistle 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 Solo Whistle as
well as the 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 Solo Whistle 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:
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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MAN-SOLWH IIG (V er. 1.503)
Solo Whistle Installation GuideSafety Information
1.1. Warnings
• Power cables can carry a high voltage, even when the motor is not in motion. Disconnect
the Solo Whistle from all voltage sources before it is opened for servicing.
• The Solo Whistle 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). Measuring the electrical
contact points with a meter, before touching the equipment, is recommended.
1.2. Cautions
• The Solo Whistle servo drive contains hot surfaces and electrically-charged components
during operation.
• The maximum DC power supply connected to the instrument must comply with the
parameters outlined in this guide.
9
• When connecting the Solo Whistle to an approved 11 to 95 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 Solo Whistle, 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 Solo Whistle 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 Solo Whistle drives conform 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
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 Solo Whistle 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 Solo Whistle 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
Solo Whistle drive 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-SOLWH IIG (V er. 1.503)
Chapter 2: Introduction
Solo Whistle Installation Guide
The Solo Whistle is an integrated solution designed to simply and efficiently connect Elmo’s
Whistle servo drive directly to the application. The solution consists of the Whistle together
with a convenient connection interface which either eliminates or reduces development time
and resources when designing an application’s PCB board.
This installation guide describes the Solo Whistle servo drive and the steps for its wiring,
installation and power-up. Following these guidelines ensures maximum functionality of the
drive and the systems to which it is connected.
2.1. Drive Description
The Solo Whistle series of digital servo drives is designed to deliver “the highest density of
power and intelligence”. The Solo Whistle is a lightweight and highly compact solution which
can be used whenever reduced size and weight are essential to the application. The Solo
Whistle delivers up to 1600 W of continuous power or 3200 W of peak power in a
77.19 cc/4.55 in³ (58.25 x 28.5 x 46.5 mm or 2.3" x 1.1" x 1.8") package.
11
The Solo Whistle drive is designed for OEMs. It operates 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. It is designed for use
with any type of sinusoidal and trapezoidal commutation, with vector control. The Solo Whistle
can operate as a stand-alone device or as part of a multi-axis system in a distributed
configuration on a real-time network.
The drive is easily set up and tuned using Elmo’s Composer software tools. This Windows-based
application enables users to quickly and simply configure the servo drive for optimal use with
their motor. The Solo Whistle, as part of the
Elmo’s Composer motion control language.
Power to the drive is provided by a 12 to 195 VDC isolated DC power source (not included with
the Solo Whistle). A “smart” control-supply algorithm enables the Solo Whistle to operate with
only one power supply in up to 100 V models with no need for an auxiliary power supply for the
logic. For 200 V models, auxiliary power supply in the range of 12 to 95 V is always required.
If backup functionality is required for storing control parameters in case of power-loss, an
external 12 to 95 VDC isolated supply should be connected (via the +VL terminal on the Solo
Whistle) providing maximum flexibility and backup functionality when needed.
Note: This backup functionality can operate from any voltage source within the 12 to 95 VDC
range. This is much more flexible than to be restricted by only using a standard 24 VDC power
supply.
SimplIQ product line, is fully programmable with
If backup power is not needed in up to 100 V models, two terminals (VP and VL) are shorted so
that the main power supply will also power the control/logic supply. In this way there is no
need for a separate control/logic supply.
200 V models require two separate power supplies.
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MAN-SOLWH IIG (V er. 1.503)
Solo Whistle Installation GuideIntroduction
The Solo Whistle drive is available in two models:
• The standard model is a basic servo drive which operates in current, velocity and position
modes including PT & PVT. It operates simultaneously via RS-232 and CANopen DS 301, DS
305, DS 402 communications and features a third-generation programming environment.
• The advanced model includes all the motion capabilities and communication options
included in the standard model, as well as advanced positioning capabilities – ECAM,
Follower and Dual Loop-and increased program size.
The two models operate with both RS-232 and CANopen 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
• 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
• 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-SOLWH IIG (V er. 1.503)
Solo Whistle Installation GuideIntroduction
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
Solo Whistle users can use two communication options:
• RS-232 serial communication
• CANopen for fast communication in a multi-axis distributed environment
2.2.6. Feedback Options
• Incremental Encoder – up to 20 Mega-Counts (5 Mega-Pulse) per second
• Digital Halls – up to 2 kHz
13
• Incremental Encoder with Digital Halls for commutation – up to 20 Mega-Counts 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
Emulated encoder outputs
• Resolver
Programmable 10 to 15 bit resolution
Up to 512 revolutions per second (RPS)
Emulated encoder outputs
• Tachometer, Potentiometer
• Elmo drives provide supply voltage for all the feedback options
2.2.7. Fault Protection
The Solo Whistle drive 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-SOLWH IIG (V er. 1.503)
Solo Whistle Installation GuideIntroduction
2.3. System Architecture
14
Figure 1: Solo Whistle System Block Diagram
2.4. How to Use this Guide
In order to install and operate your Elmo Solo Whistle 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 Solo Whistle.
• Chapter 4, Technical Specifications, lists all the drive ratings and specifications.
Upon completing the instructions in this guide, your Solo Whistle 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-SOLWH IIG (V er. 1.503)
Solo Whistle Installation GuideIntroduction
15
Figure 2: Elmo Digital Servo Drive Documentation Hierarchy
As depicted in the previous figure, this installation guide is an integral part of the Solo Whistle
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 SimplIQCommand Reference Manual, which describes, in detail, each software
command used to manipulate the Solo Whistle motion controller.
• The SimplIQ Software Manual, which describes the comprehensive software used with the
Solo Whistle.
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MAN-SOLWH IIG (V er. 1.503)
Chapter 3: Installation
Solo Whistle Installation Guide
The Solo Whistle 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 Solo Whistle drive by ensuring that it is installed in
an appropriate environment.
Feature Value
16
Ambient operating temperature
Maximum relative humidity 90% non-condensing
Operating area atmosphere No flammable gases or vapors permitted in area
Models for extended environmental conditions are available.
Caution:
The Solo Whistle drive dissipates 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)
3.2. Unpacking the Drive
Before you begin working with the Solo Whistle, verify that you have all of the components, as
follows:
• The Solo Whistle servo drive
• The Composer software and software manual
The Solo Whistle is shipped in a cardboard box with Styrofoam protection.
To unpack the Solo Whistle:
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.
3. To ensure that the Solo Whistle drive you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Solo Whistle.
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MAN-SOLWH IIG (V er. 1.503)
Solo Whistle Installation GuideInstallation
The part number at the top gives the type designation as follows:
17
4. Verify that the Solo Whistle model is the one that you ordered, and ensure that the voltage
meets your specific requirements.
Note: The catalog number suffix is a number from 01 to 08, as shown above. The odd numbers
are models with connectors and the even numbers are models with wires. For currents of 10 A
or less, both models are available; for currents of 15 A or more, only a wires model is available.
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MAN-SOLWH IIG (V er. 1.503)
Solo Whistle Installation GuideInstallation
3.3. Connector Types
The Solo Whistle has eight connectors (in the connectors version).
Pins Type Port Function
9 3.5 mm Pitch J1 Power Connector
12 2 mm Pitch J2 I/O
8 2 mm Pitch J3 Auxiliary Feedback
12 2 mm Pitch J4 Main Feedback
3 2 mm Pitch J5 RS232
3 2 mm Pitch J6 CANIN
3 2 mm Pitch J7 CANOUT
8 3.81 mm Pitch J8 Motor Connection
18
4 16 AWG (M1, M2, M3)
18 AWG (PE)
Connector Locations
Wires Motor Connection
Table 1: Connector Types
Note: Throughout this chapter there are pairs of diagrams of the Solo Whistle. The diagram on
the left is the Solo Whistle with connectors, and the diagram on the right shows the product
with wires.
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MAN-SOLWH IIG (V er. 1.503)
Solo Whistle Installation GuideInstallation
3.4. Motor Power – J8
Pin (J8) Signal Function
1 PTC Positive Temperature Coefficient
2 PTC Positive Temperature Coefficient
3 N/C Not Connected
4 N/C Not Connected
AC Motor DC Motor
5 PE Protective earth Motor Motor
6 M1 Motor phase Motor N/C
7 M2 Motor phase Motor Motor
8 M3 Motor phase Motor Motor
Pin Positions
19
Note: When connecting several drives to several motors, all should be wired in the same motor
phases and feedback sequences. This will enable the same SimplIQ program to run on all drives.
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MAN-SOLWH IIG (V er. 1.503)
Solo Whistle Installation GuideInstallation
3.4.1. Connecting Motor Power
Connect the M1, M2, M3 and PE pins on the Solo Whistle. The phase connection is arbitrary as
the Composer will establish the proper commutation automatically during setup. However, if
you plan to copy the setup to other drives, then the phase order on all copy drives must be the
same.
20
Figure 3: AC Motor Power Connection Diagram
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MAN-SOLWH IIG (V er. 1.503)
Solo Whistle Installation GuideInstallation
3.5. Main Power – J1
Pin (J1) Signal Function
1 VL+ Auxiliary supply input
2 PR Auxiliary supply input return
3 VP+ Pos. power input
4 VP+ Pos. power input
5 PR Power return
6 PR Power return
7 PE Protective earth
8 N/C Not connected
9 N/C Not connected
Pin Positions
21
Note: When connecting several drives to several motors, all should be wired in the same
motor phases and feedback sequences. This will enable the same SimplIQ program to run on all
drives.
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