ElmoMC SimplIQ Digital Servo Drives-Whistle Installation Guide

Whistle and Tweeter

Digital Servo Drives

Installation Guide

July 2014 (Ver. 1.604)

www.elmomc.com

Maximum DC

Operating Voltage

Continuous Current

(Amps)

Version:

Blank =

Standard

A = Advanced

Feedback:

Blank =

Incremental
Encoder
and/or Halls

R = Resolver

WHI-A

XX/YYY

R

T =

Tachometer &
Potentiometer

I =

Interpolated
Analog
Encoder

Maximum DC

Operating Voltage

Continuous Current

(Amps)

Version :

Blank = Standard

A = Advanced

Feedback:

Blank = Incremental

Encoder
and/or Halls

R = Resolver

TWE- A

XX/YYY R

T =

Tachometer &
Potentiometer

I = Interpolated

Analog
Encoder

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 Whistle
and Tweeter servo drives in their 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-WHTWIG (Ver. 1.604)

Copyright  2013

Elmo Motion Control Ltd.

All rights reserved.

Catalog Numbers

Evaluation Board

Catalog Number: EVA-WHI/GUI/BEL (can be ordered separately). For further details, see the
documentation for this evaluation board (MAN-EVLBRD-WHI_BEL_GUI-UG.pdf).

Revision History

Version Date Details

1.0 June 2006 Initial Release(MAN-WHTWIG.PDF)

1.01 July 2006 Correction to PT & PVT in standard models

1.02 Oct. 2006 Correction to Interpolated Analog Encoders

1.1 May 2007 Added WHI-15/60, WHI-10/100 and WHI-15/100

1.2 April 2008 Updated Power Ratings Table in Section 4.34.3

1.3 March 2009 MTCR 01-009-38: Note added to Section 3.8.3; Figure 9

updated

1.4 March 2010 MTCR 01-010-01: Figure 20updated

1.5 July 2010 MTCR 03-010-02: Updated: Sections 3.4 and 4.1.8;

Figure 31

1.6 September 2012 Formatted according to the new template

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

New table for 200 VDC series added.

1.601 January 2013 Updated the auxiliary voltage value

Added a caution and recommendation on the type of
cleaning solution to use for the Elmo unit.

1.602 February 2013 Whistle and Tweeter dimension details added –
Section 4.2

1.603 December 2013 General document updates

1.604 July 2014 General document update

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-WHTWIG (Ver. 1.604)

Table of Contents

Whistle and Tweeter 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: Introduction ................................................................................................. 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 ............................................................................................. 13

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

2.4. How to Use this Guide .................................................................................................. 14

5

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

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

3.2. Unpacking the Drives .................................................................................................... 16

3.3. Connectors.................................................................................................................... 17

3.3.1. Connector Types ............................................................................................ 17

3.3.2. Pinouts ........................................................................................................... 18

3.3.2.1. Connector J1 ................................................................................. 18

3.3.2.2. Connector J2 ................................................................................. 19

3.4. Mounting ...................................................................................................................... 20

3.4.1. Whistle ........................................................................................................... 20

3.4.2. Tweeter .......................................................................................................... 21

3.5. Integrating the Whistle or Tweeter on a PCB ............................................................... 22

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

3.5.2. Grounds and Returns ..................................................................................... 22

3.6. The Whistle/Tweeter Connection Diagram .................................................................. 25

3.7. Main Power and Motor Power ..................................................................................... 26

3.7.1. Connecting Motor Power .............................................................................. 26

3.7.2. Connecting Main Power ................................................................................ 27

3.8. Auxiliary Supply (for Drive Logic) .................................................................................. 27

3.8.1. Single Supply .................................................................................................. 28

3.8.2. Separate Auxiliary Supply .............................................................................. 28

MAN-WHTWIG (Ver. 1.604)

Whistle and Tweeter Installation Guide Table of Contents

3.8.3. Shared Supply for up to 100 V Models .......................................................... 29

3.9. Main Feedback ............................................................................................................. 30

3.10. Auxiliary Feedback ........................................................................................................ 34

3.10.1. Main and Auxiliary Feedback Combinations ................................................. 35

3.10.2. Auxiliary Feedback: Emulated Encoder Output Option (YA[4]=4) ................. 36

3.10.3. Auxiliary Feedback: Single-Ended Encoder Input Option (YA[4]=2) .............. 38

3.10.4. Auxiliary Feedback: Pulse-and-Direction Input Option (YA[4]=0) ................. 40

3.11. I/Os ............................................................................................................................... 42

3.11.1. Digital Input ................................................................................................... 42

3.11.2. Digital Output ................................................................................................ 44

3.11.3. Analog Input .................................................................................................. 45

3.12. Communications ........................................................................................................... 46

3.12.1. RS-232 Communication ................................................................................. 46

3.12.2. CAN Communication ..................................................................................... 47

3.13. Powering Up ................................................................................................................. 49

3.14. Initializing the System ................................................................................................... 49

3.15. Heat Dissipation............................................................................................................ 49

3.15.1. Whistle Thermal Data .................................................................................... 49

3.15.2. Heat Dissipation Data .................................................................................... 50

3.15.3. How to Use the Charts ................................................................................... 51

3.15.4. Tweeter Thermal Data ................................................................................... 51

3.16. Evaluation Board and Cable Kit .................................................................................... 52

6

Chapter 4: Technical Specifications ................................................................................ 53

4.1. Features ........................................................................................................................ 53

4.1.1. Motion Control Modes .................................................................................. 53

4.1.2. Advanced Positioning Control Modes ........................................................... 53

4.1.3. Advanced Filters and Gain Scheduling........................................................... 53

4.1.4. Fully Programmable ....................................................................................... 53

4.1.5. Feedback Options .......................................................................................... 54

4.1.6. Input/Output ................................................................................................. 54

4.1.7. Built-In Protection ......................................................................................... 55

4.1.8. Accessories .................................................................................................... 55

4.1.9. Status Indication ............................................................................................ 55

4.1.10. Automatic Procedures ................................................................................... 55

4.2. Dimensions ................................................................................................................... 56

4.2.1. Whistle ........................................................................................................... 56

4.2.2. Tweeter .......................................................................................................... 56

4.3. Power Ratings ............................................................................................................... 57

4.3.1. Whistle

........................................................................................................... 57

4.3.2. Tweeter .......................................................................................................... 59

4.3.3. Auxiliary Supply ............................................................................................. 59

4.4. Environmental Conditions ............................................................................................ 60

4.4.1. Control Specifications .................................................................................... 60

4.4.2. Current Loop .................................................................................................. 60

MAN-WHTWIG (Ver. 1.604)

Whistle and Tweeter Installation Guide Table of Contents

4.4.3. Velocity Loop ................................................................................................. 61

4.4.4. Position Loop ................................................................................................. 61

4.5. Feedbacks ..................................................................................................................... 62

4.5.1. Feedback Supply Voltage ............................................................................... 62

4.5.2. Main Feedback Options ................................................................................. 62

4.5.2.1. Incremental Encoder Input ........................................................... 62

4.5.2.2. Digital Halls ................................................................................... 63

4.5.2.3. Interpolated Analog (Sine/Cosine) Encoder ................................. 63

4.5.2.4. Resolver ........................................................................................ 64

4.5.2.5. Tachometer ................................................................................... 64

4.5.2.6. Potentiometer .............................................................................. 65

4.5.3. Auxiliary Feedback Port (Output mode YA[4]= 4) ......................................... 65

4.5.4. Auxiliary Feedback Port (Input mode YA[4]= 2, 0) ........................................ 66

4.6. I/Os ............................................................................................................................... 67

4.6.1. Digital Input Interfaces .................................................................................. 67

4.6.2. Digital Output Interface ................................................................................. 68

4.6.3. Analog Input .................................................................................................. 68

4.7. Communications ........................................................................................................... 69

4.8. Pulse-Width Modulation (PWM) .................................................................................. 69

4.9. Compliance with Standards .......................................................................................... 70

7

MAN-WHTWIG (Ver. 1.604)

Chapter 1: Safety Information

Warning:

Caution:

Whistle and Tweeter Installation Guide

In order to achieve the optimum, safe operation of the Whistle and Tweeter servo drives, 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
Whistle and Tweeter 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 Whistle and Tweeter servo drives contain 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-WHTWIG (Ver. 1.604)

Whistle and Tweeter 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.

• Power cables can carry a high voltage, even when the motor is not in motion.
Disconnect the Whistle and Tweeter from all voltage sources before it is opened for
servicing.

• The Whistle and Tweeter servo drives contain 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.

9

1.2. Cautions

• The Whistle and Tweeter servo drives contain hot surfaces and electrically-charged
components during operation.

• The maximum DC power supply connected to the instrument must comply with the
parameters outlined in this guide.

• When connecting the Whistle and Tweeter 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 Whistle and Tweeter, 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 Whistle and Tweeter drives’ 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-WHTWIG (Ver. 1.604)

Whistle and Tweeter Installation Guide Safety Information

1.3. Directives and Standards

The Whistle and Tweeter 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 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 Whistle and Tweeter servo drives have 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 Whistle and Tweeter servo drives are 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
Whistle and Tweeter meet 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-WHTWIG (Ver. 1.604)

Chapter 2: Introduction

Whistle and Tweeter Installation Guide

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

2.1. Drive Description

The Whistle and Tweeter series of digital servo drives are designed to deliver “the highest
density of power and intelligence”. While both are light and highly compact solutions, the
Tweeter can be used whenever reduced size and weight are essential to the application. The
Whistle delivers up to 1600 W of continuous power or 3200 W of peak power in a 2 in³ (55 x
15 x 46.5 mm or 2" x 0.6" x 1.8") 38 cc package. The Tweeter delivers up to 200 W of
continuous power or 400 W of peak power.

The Whistle and Tweeter are designed for OEMs. They operate from a DC power source in
current, velocity, position and advanced position modes, in conjunction with a permanent­magnet 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 Whistle and Tweeter 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 quickly and simply configure the servo drive for optimal use
with their motor. The Whistle and Tweeter, as part of the
programmable with Elmo Composer motion control language.

Power to the drives is provided by a 12 to 195 VDC isolated DC power source (not included with
the Whistle and Tweeter). A “smart” control-supply algorithm enables the Whistle and
Tweeter 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, the auxiliary power supply in the range
of 12 -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 Whistle
and Tweeter) 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.

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.

SimplIQ product line, are fully

200 V models require two separate power supplies.

The Whistle and Tweeter are PCB mounted devices which enable efficient and cost saving
implementation.

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MAN-WHTWIG (Ver. 1.604)

Whistle and Tweeter Installation Guide Introduction

The Whistle and Tweeter are available in two models:

• The Standard models are basic servo drives which operate in current, velocity and
position modes include PT & PVT. They operate simultaneously via RS-232 and CAN DS
301, DS 305, DS 402 communications and feature a third-generation programming
environment.

• The Advanced models include 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 CAN communication.

2.2. Product Features

2.2.1. Current Control

• Fully digital

• Sinusoidal commutation with vector control or trapezoidal commutation with encoder

and/or digital Hall sensors

12

• 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

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Whistle and Tweeter Installation Guide Introduction

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

• Fast output compare (OC)

2.2.5. Communication Options

Whistle and Tweeter users can use two communication options:

• RS-232 serial communication

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

2.2.6. Feedback Options

13

• Incremental Encoder – up to 20 Mega-Counts (5 Mega-Pulse) per second

• Digital Halls – up to 2 kHz

• Incremental Encoder with Digital Halls for commutation – up to 20 Mega-Counts per

second for encoder

• 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

• Elmo drives provide supply voltage for all the feedback options

2.2.7. Fault Protection

The Whistle and Tweeter include 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-WHTWIG (Ver. 1.604)

Whistle and Tweeter Installation Guide Introduction

2.3. System Architecture

Figure 1: Whistle/Tweeter System Block Diagram

14

2.4. How to Use this Guide

In order to install and operate your Elmo Whistle or Tweeter servo drives, 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 Whistle and Tweeter

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

Upon completing the instructions in this guide, your Whistle and Tweeter servo drives 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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Whistle and Tweeter Installation Guide Introduction

15

Figure 2: Elmo Digital Servo Drive Documentation Hierarchy

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

• The Whistle Evaluation Board User Guide contains information about how to use the
Whistle Evaluation Board and Cable Kit

• The Composer Software Manual, which includes explanations of all the software tools
that are part of Elmo’s Composer software environment

• The SimplIQ Command Reference Manual, which describes, in detail, each software
command used to manipulate the Whistle and Tweeter motion controller

• The SimplIQ Software Manual, which describes the comprehensive software used with
the Whistle and Tweeter

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MAN-WHTWIG (Ver. 1.604)

Chapter 3: Installation

Whistle and Tweeter Installation Guide

The Whistle and Tweeter 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 Whistle and Tweeter by ensuring that they are
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 Whistle and Tweeter dissipate 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 Drives

Before you begin working with the Whistle or Tweeter, verify that you have all of their
components, as follows:

• The Whistle or Tweeter servo drives

• The Composer software and software manual

The Whistle and Tweeter are shipped in a cardboard box with Styrofoam protection.

To unpack the Whistle and Tweeter:

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 Whistle or Tweeter you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Whistle or and Tweeter. It
looks like this:

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MAN-WHTWIG (Ver. 1.604)

Maximum DC

Operating Voltage

Continuous Current

(Amps)

Version:

Blank = Standard

A = Advanced

Feedback:

Blank =

Incremental
Encoder
and/or Halls

R = Resolver

WHI-A

XX/YYY

R

T =

Tachometer &
Potentiometer

I =

Interpolated
Analog
Encoder

Maximum DC

Operating Voltage

Continuous Current

(Amps)

Version :

Blank = Standard

A = Advanced

Feedback:

Blank = Incremental

Encoder
and/or Halls

R = Resolver

TWE- A

XX/YYY

R

T =

Tachometer &
Potentiometer

I = Interpolated

Analog
Encoder

Whistle and Tweeter Installation Guide Installation

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

17

Verify that the Whistle or Tweeter type is the one that you ordered, and ensure that the
voltage meets your specific requirements.

3.3. Connectors

The Whistle and Tweeter have nine connectors.

3.3.1. Connector Types

Port Pins Type Function Connector Location

J1 2x11 2 mm pitch

0.51 mm sq

J2 15 Main Feedback,

M1 2 Motor power output 1

M2 2 Motor power output 2

M3 2 Motor power output 3

I/O, COMM,
Auxiliary Feedback

Analog Input, LED

PE 2 Protective earth

PR 2 Power input return

VP+ 2 Positive power input

VL 1 Auxiliary power input

Table 1: Connector Types

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Whistle and Tweeter Installation Guide Installation

3.3.2. Pinouts

The pinouts in this section describe the function of each pin in the Whistle and Tweeter J1 and
J2 connectors.

3.3.2.1. Connector J1

Pin (J1) Signal Function

1 RS232_RX RS232 receive

2 RS232_TX RS232 Transmit

3 RS232_COMRET Communication return

4 SUPRET Supply return

5 AUX PORT CHA AUX PORT CHA (bidirectional)

6 SUPRET Supply return

7 OUT1 Programmable Digital output 1

18

8 OUT2 Programmable Digital output 2

9 IN1 Programmable Digital input 1

10 IN2 Programmable Digital input 2

11 IN3 Programmable Digital input 3

12 IN4 Programmable Digital input 4

13 IN5 Programmable Digital input 5

14 IN6 Programmable Digital input 6

15 INRET Programmable Digital input return

16 OUTRET2 Programmable Digital output 2 return

17 OUTRET1 Programmable Digital output 1 return

18 AUX PORT CHB AUX PORT CHB (bidirectional)

19 AUX PORT INDEX AUX PORT INDEX (bidirectional)

20 CAN_COMRET Communication return

21 CAN_L CAN_L busline (dominant low)

22 CAN_H CAN_H busline (dominant high)

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Whistle and Tweeter Installation Guide Installation

3.3.2.2. Connector J2

Pin (J2) Signal Function

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

Maximum output current: 200 mA

2 SUPRET Supply return

3 ANALIN1+ Analog input 1+

4 ANALIN1- Analog input 1-

5 CHA Channel A input

6 CHA- Channel A input complement

7 CHB Channel B input

8 CHB- Channel B input complement

9 INDEX+ Index input

19

10 INDEX- Index input complement

11 HA Hall sensor A input

12 HB Hall sensor B input

13 HC Hall sensor C input

14 LED_2_OUT Bi-color indication output 2 (Cathode)

15 LED_1_OUT Bi-color indication output 1 (Anode)

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Whistle and Tweeter Installation Guide Installation

3.4. Mounting

3.4.1. Whistle

The Whistle was designed for mounting on a printed circuit board (PCB) via 2 mm pitch 0.51
mm square pins. When integrating the Whistle into a device, be sure to leave about 1 cm (0.4")
outward from the heat-sink to enable free air convection around the drive. We recommend
that the Whistle be soldered directly to the board. Alternatively, though this is not
recommended, the Whistle can be attached to socket connectors mounted on the PCB. If the
PCB is enclosed in a metal chassis, we recommend that the Whistle be screw-mounted to it as
well to help with heat dissipation. The Whistle has screw-mount holes on each corner of the
heat-sink for this purpose – see below.

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Figure 3: The Whistle Footprint

When the Whistle is not connected to a metal chassis, the application’s thermal profile may
require a solution for heat dissipation due to insufficient air convection. In this case, we
recommend that you connect an external heat-sink. Elmo has an external heat-sink (Catalog
number: WHI-HEATSINK-2) that can be ordered for this purpose – see below.

Figure 4: Whistle External Heat-sink

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Whistle and Tweeter Installation Guide Installation

3.4.2. Tweeter

The Tweeter was designed for mounting on a printed circuit board (PCB) via 2 mm pitch 0.51
mm square pins. When integrating the Tweeter into a device, be sure to leave about 1 cm
(0.4") outward from the lower board to enable free air convection around the Tweeter. We
recommend that the Tweeter be soldered directly to the board. Alternatively, the Tweeter can
be attached to socket connectors mounted on the PCB.

Note: Elmo recommends you leave approximately 1 cm (0.4 in) of space on the side opposite

the terminals to allow for free air convection.

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Whistle and Tweeter Installation Guide Installation

3.5. Integrating the Whistle or Tweeter on a PCB

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

3.5.1. Traces

1. The size of the traces on the PCB (thickness and width) is determined by the current
carrying capacity required by the application.
 The rated continuous current limit (Ic) of the Whistle and Tweeter is the current used

for sizing the motor traces (M1, M2, M3 and PE) and power traces (VP+, PR and PE).

 For control, feedbacks and Inputs/ outputs conductors the actual current is very small

but “generous” thickness and width of the conductors will contribute to a better
performance and lower interferences.

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

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

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

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

3.5.2. Grounds and Returns

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

Functional Block Return Pin

Power PR (Power Return)

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

RS232 Communications RS232_COMRET (J1/3)

CAN Communications CAN_COMRET (J1/20)

Control section Internal, not accessible

Main Feedback SUPRET (J2/2)

Aux. Feedback SUPRET (J1/4)

Analog input ANLRET (J2/2)

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

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