ElmoMC SimplIQ Digital Servo Drives-Whistle Installation Guide

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Whistle and Tweeter

Digital Servo Drives

Installation Guide

July 2014 (Ver. 1.604)

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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

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)

Elmo Motion Control Ltd.

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: +972 (3) 929-2300 • Fax: +972 (3) 929-2322 • info-il@elmomc.com

North America

Elmo Motion Control Inc.

42 Technology Way, Nashua, NH 03060 USA

Tel: +1 (603) 821-9979 • Fax: +1 (603) 821-9943 • info-us@elmomc.com

Europe

Elmo Motion Control GmbH

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

Tel: +49 (0) 7721-944 7120 • Fax: +49 (0) 7721-944 7130 • info-de@elmomc.com

China

Elmo Motion Control Technology (Shanghai) Co. Ltd.

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

Tel: +86-21-32516651 • Fax: +86-21-32516652 • info-asia@elmomc.com

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: +82-31-698-2010 • Fax: +82-31-801-8078 • info-asia@elmomc.com

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

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

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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

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

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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

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.

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.

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

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.

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-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

• 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

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

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

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

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

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:

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

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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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

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.

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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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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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:

 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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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 Whistle or Tweeter. DO NOT USE A COMMON GROUND PLANE. Shorting the commons on the Integration Board may cause performance degradation (ground loops, etc.).

2. Inputs: The 6 inputs are optically isolated from the other parts of the Whistle and Tweeter. All 6 inputs share a single common “Return” (INRET - J1/15). To retain isolation, the Input Return pin, as well as other conductors on the input circuit, must be laid out separately.

3. Outputs: The 2 outputs are optically isolated from the other parts of the Whistle and Tweeter. Each output has a separate floating return (OUTRET1 - J1/17 for output 1 and OUTRET2 J1/16 for output 2). To retain isolation, the Output Return pins, as well as other conductors on the output circuit, must lay out separately.

4. Return Traces: The return traces should be as large as possible, but without shorting each other, and with minimal cross-overs.

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 terminal is connected directly to the Whistle’s heatsink or to the Tweeter's 2 PE strips on its lower board. In the Whistle, the heatsink 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.

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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 or host failure.

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3.6. The Whistle/Tweeter Connection Diagram

Figure 5: Whistle/Tweeter Connection Diagram

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3.7. Main Power and Motor Power

The Whistle and Tweeter receive power from main and delivers power to the motor.

Pin Function Cable Pin Positions

VP+ Pos. Power input Power

PR Power return Power

PE Protective earth Power

Brushless

Motor

Brush DC

Motor

PE Protective earth Motor Motor

M1 Motor phase Motor N/C

M2 Motor phase Motor Motor

M3 Motor phase Motor Motor

Note: When connecting several 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.

Table 2: Connector for Main Power and Motor

3.7.1. Connecting Motor Power

Connect the M1, M2, M3 and PE pins on the Whistle and Tweeter in the manner described in Section 3.5 (Integrating the Whistle or Tweeter on a PCB). 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.

Figure 6: AC Motor Power Connection Diagram

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3.7.2. Connecting Main Power

Connect the VP+, PR and PE pins on the Whistle and Tweeter in the manner described in Section 3.5 (Integrating the Whistle or Tweeter on a PCB).

Note: The source of the 12 to 195 VDC Main Power Supply must be isolated.

Figure 7: Main Power Supply Connection Diagram

3.8. Auxiliary Supply (for Drive Logic)

Notes: The source of the 12 to 95 VDC Auxiliary Supply must be isolated.

Connect the VL and PR pins on the Whistle and Tweeter in the manner described in Section 3.5 (Integrating the Whistle or Tweeter on a PCB).

Pin Function Pin Positions

VL Auxiliary Supply Input

PR Supply Input Return

Table 3: Auxiliary Supply Pins

Caution:

Power from the Whistle and Tweeter to the motor must come from the Main Supply and not from the Auxiliary Supply.

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3.8.1. Single Supply

A single isolated DC power supply can provide power for both the main power and the Auxiliary (Drive Logic) Supply in up to 100 V models. The drawing below shows how a single supply is connected.

Figure 8: Single Supply for both the Main Power Supply and

the Auxiliary Supply in Up to 100 V Models

Note: For 200 V models, it is forbidden to connect VL to VP+. Two separate power supplies are

required

3.8.2. Separate Auxiliary Supply

Power to the Auxiliary Supply can be provided by a separate Auxiliary Supply.

Figure 9: Separate Auxiliary Supply Connection Diagram

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3.8.3. Shared Supply for up to 100 V Models

A "Main" DC Power Supply can be designed to supply power to the drive's Logic as well as to the Main Power (see Figure 8). If backup functionality is required (for storing control parameters in case of power-outs) an additional backup supply can be connected by implementing 'diode coupling' (see the Auxiliary Backup Supply in Figure 10).

Note: When using Elmo’s Evaluation Board (Catalog number: WHI-EVLBRD-1), the diode

coupling is “built in”. When you create your own PCB, you need to implement diode coupling.

Figure 10: Shared Supply Connection Diagram

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Signal

Function

Signal

Function

Signal

Function

Signal

Function

Whistle and Tweeter Installation Guide Installation

3.9. Main Feedback

The Main Feedback port is used to transfer feedback data from the motor to the drive. In order to copy the setup to other drives, the phase order on all copy drives must be the same.

The Whistle and Tweeter 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 (option)

• Resolver (option)

• Tachometer (option)

• Potentiometer (option)

Incremental

Encoder

WHI-XX/YYY_ TWE- XX/YYY _

13 HC

11 HA

2 SUPRET Supply return SUPRET Supply return SUPRET Supply return SUPRET Supply return

1 +5V

6 CHA-

5 CHA Channel A A+ Sine A S1 Sine A Tac 1+

10 INDEX-

9 INDEX Index R+ Reference R1

12 HB

8 CHB-

7 CHB Channel B B+ Cosine B S2 Cosine B Tac 2+

3 ANALIN+ is used for Analog Input

4 ANALIN- is used for Analog Input

14 LED_2_OUT (AOKLED cathode) is used for LED indication

15 LED_1_OUT (AOKLED anode) is used for LED indication

Hall sensor C input

Hall sensor A input

Encoder/Hall +5V supply

Channel A complement

Index complement

Hall sensor B input

Channel B complement

Interpolated Analog Encoder

WHI- XX/YYYI TWE- XX/YYYI

+5V

A-

R-

B-

Hall sensor C input

Hall sensor A input

Encoder/Hall +5V supply

Sine A complement

Reference complement

Hall sensor B input

Cosine B complement

Resolver Tachometer and

Potentiometer

WHI- XX/YYYR TWE- XX/YYYR

NC - HC

NC - HA

+5V

NC - HB

Encoder/Hall +5V supply

Sine A complement

Vref complmnt f= 1/TS, 50 mA Maximum

Vref f=1/TS, 50 mA Max.

Cosine B complement

WHI- XX/YYYT TWE- XX/YYYT

Hall sensor C input

Hall sensor A input

+5V

Tac 1-

NC -

POT

Tac 2-

Encoder/Hall +5V supply

Tacho Input 1 Neg. (20 V max)

Tacho Input 1 Pos. (20 V max)

Potentiometer Input (5 V Max)

Hall sensor B input

Tacho Input 2 Neg. (50 V max)

Tacho Input 2 Pos. (50 V max)

Table 4: Main Feedback Pin Assignments

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Figure 11: Main Feedback- Incremental Encoder Connection Diagram

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

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Figure 13: Main Feedback – Resolver Connection Diagram

Figure 14: Main Feedback – Tachometer Feedback with Digital Hall Sensor

Connection Diagram for Brushless Motors

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Figure 15: Main Feedback – Tachometer Feedback Connection Diagram for Brush Motors

Figure 16: Main Feedback – Potentiometer Feedback with Digital Hall Sensor

Connection Diagram for Brushless Motors

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Potentiometer Feedback Connection Diagram for Brush Motors and Voice Coils

Figure 17: Main Feedback –

3.10. Auxiliary Feedback

For auxiliary feedback, select one of the following options:

• 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 or Interpolated Analog Encoder as the main feedback device.

This option can be used when:

 The Whistle and Tweeter are used as current amplifiers to provide position data to the

position controller.

 The Whistle and Tweeter are used in velocity mode to provide position data to the

position controller.

 The Whistle and Tweeter are used as masters in follower or ECAM mode.

• Single-ended auxiliary encoder input, for the input of position data of the master encoder in follower or ECAM mode.

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

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

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Incremental

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

Main

Feedback:

Incremental

Encoder

Main Feedback:

Incremental

Encoder

Analog Encoder

Resolver

Tachometer

Potentiometer

Input

Aux. Feedback: Singe-ended Incremental Encoder Input

Main Feedback:

Incremental

Encoder

Analog Encoder

Resolver

Tachometer

Potentiometer

Input

Aux. Feedback: Singe-ended Pulse & Direction Commands Input

Interpolated

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

Main

Feedback:

Analog

Encoder

Resolver

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

Main

Feedback:

Resolver

Potentiometer

Aux. Feedback: There is no Aux. Feedback output option when a Potentiometer or Tachometer is the main feedback device

Main Feedback: Potentiometer or Tachometer

Typical







Whistle and Tweeter Installation Guide Installation

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 Whistle and Tweeter has three bi-directional pins (CHA, CHB and INDEX). When used in combination with Main Feedback, the Auxiliary Feedback can be set, by software, as follows:

Main Feedback

Software Setting

Encoder Input

Analog

(Sine/Cosine) Encoder Input

Input

YA[4] = 4

(Aux. Feedback: output)

Auxiliary Feedback

YA[4] = 2

(Aux. Feedback: input)

YA[4] = 0

(Aux. Feedback: input)

Tachometer Input

Applications

encoder is used, not only for the drive, but also for other purposes such as position controllers and/or other drives.

 Analog Encoder applications

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

 Resolver applications where

position data is required in the

 Any application where the main

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.

Encoder’s quadrature format.

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3.10.2. Auxiliary Feedback: Emulated Encoder Output Option

(YA[4]=4)

Pin (J1) Signal Function Pin Positions

4 SUPRET Supply return

19 INDEX+ Index output

18 CHBO Channel B output

5 CHAO Channel A output

Notes:

The Emulated Encoder Output Option is only available when using a Resolver or Interpolated Analog Encoder as the main feedback device.

The Whistle and Tweeter's Auxiliary Feedback is singleended. When mounted on an integration board, circuitry can be added to make it differential (Figure 20 (highly recommended)).

Table 5: Emulated Single-Ended Encoder Output Pin Assignments

Figure 18: Emulated Encoder Direct Output – Acceptable Connection Diagram

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Figure 19: Emulated Encoder Buffered Output – Recommended Connection Diagram

Figure 20: Emulated Encoder Differential Output – Highly Recommended Connection Diagram

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3.10.3. Auxiliary Feedback: Single-Ended Encoder Input Option

(YA[4]=2)

Pin Signal Function Pin Positions

J1/4 SUPRET Supply return

J1/19 INDEX Auxiliary index input

J1/18 CHB Auxiliary channel B input

J1/5 CHA Auxiliary channel A input

Note: The Whistle and Tweeter's Auxiliary Feedback is

single-ended (Figure 21 (acceptable) and Figure 22 (recommended)). When mounted on an integration board, circuitry can be added to make it differential (Figure 23 (highly recommended).

Table 6: Single-Ended Auxiliary Encoder Pin Assignment

Figure 21: Single-Ended Auxiliary Encoder Input - Acceptable Connection Diagram

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Figure 22: Single-Ended Auxiliary Encoder Input - Recommended Connection Diagram

Figure 23: Differential Auxiliary Encoder Input – Highly Recommended Connection Diagram

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

(YA[4]=0)

Pin (J1) Signal Function Pin Positions

4 SUPRET Supply return

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

open collector)

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

collector)

Note: The Whistle and Tweeter's Auxiliary Feedback is

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

Table 7: Pulse-and-Direction Pin Assignments

Figure 24: Pulse-and-Direction Auxiliary Encoder Input – Direct Connection Diagram

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Figure 25: Pulse-and-Direction Auxiliary Encoder Input – Buffered Connection Diagram

Figure 26: Pulse-and-Direction Auxiliary Encoder Input – Differential Connection Diagram

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3.11. I/Os

The Whistle and Tweeter have the following I/Os:

• 6 digital inputs

• 2 digital outputs

• 1 analog input

I/O J1 J2 Total

Digital Input 6 - 6

Digital Output 2 - 2

Analog Input - 1 1

3.11.1. Digital Input

Each of the pins below can function as an independent input.

Pin (J1) Signal Function Pin Positions

9 IN1 Programmable input 1

(general purpose, RLS, FLS, INH)

10 IN2 Programmable input 2

(general purpose, RLS, FLS, INH)

11 IN3 Programmable input 3

(general purpose, RLS, FLS, INH)

12 IN4 Programmable input 4

(general purpose, RLS, FLS, INH)

13 IN5 Hi-Speed Programmable input 5

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

14 IN6 Hi-Speed Programmable input 6

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

15 INRET Programmable input return

Table 8: Digital Input Pin Assignments

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Figure 27: Digital Input Connection Diagram

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3.11.2. Digital Output

Pin (J1) Signal Function Pin Positions

J1/7 OUT1 High-Speed Programmable digital

output 1

J1/17 OUTRET1 Programmable digital output

return 1

J1/8 OUT2 Programmable digital output 2

J1/16 OUTRET2 Programmable digital output

return 2

Table 9: Digital Output Pin Assignment

Figure 28: Digital Output Connection Diagram

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3.11.3. Analog Input

Pin (J2) Signal Function Pin Positions

J2/3 ANLIN1+ Analog input 1+

J2/4 ANLIN1- Analog input 1-

J2/2 ANLRET Analog ground

Table 10: Interpolated Input Pin Assignments

Figure 29: 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 Whistle and Tweeter 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 Whistle or Tweeter 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

Notes for 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.

Ensure that the shield of the cable is connected to the shield of the connector used for RS232 communications. The drain wire can be used to facilitate the connection.

Pin (J1) Signal Function Pin Locations

1 RS232_Rx RS-232 receive

2 RS232_Tx RS-232 transmit

3 RS232_COMRET Communication return

Table 11: RS-232 Pin Assignments

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Figure 30: RS-232 Connection Diagram

3.12.2. CAN Communication

Notes for 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 Whistle and Tweeter's CAN ports are non-isolated.

Pin (J1) Signal Function Pin Positions

20 CAN_GND CAN ground

21 CAN_L CAN_L busline (dominant low)

22 CAN_H CAN_H busline (dominant high)

Table 12: CAN - Pin Assignments

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Figure 31: 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 Whistle or Tweeter is connected to its device, it is ready to be powered up.

Caution: Before applying power, ensure that the DC supply is within the specified range and that the proper plus-minus connections are in order.

3.14. Initializing the System

After the Whistle/Tweeter 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.

3.15. Heat Dissipation

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

3.15.1. Whistle Thermal Data

• Heat dissipation capability (θ): Approximately 10 °C/W

• Thermal time constant: Approximately 240 seconds (thermal time constant means that

the Whistle will reach 2/3 of its final temperature after 4 minutes)

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

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Whistle

Series Power Dissipation

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

Peak Current (A)

Power Dissipation (Watts

50V 40V 30V 20V

Standard 40 °C Ambient Temp.

External

Heatsink

Whistle 100 Series Power Dissipation

0.0

1.0

2.0

3.0

4.0

5.0

6.0

0.511.522.533.544.5

Peak Current (A)

Power Dissipation (W)

85VDC 70VDC 50VDC

Standard 40 °C Ambient Temp.

External

Heatsink

Whistle and Tweeter Installation Guide Installation

3.15.2. Heat Dissipation Data

Heat dissipation is shown graphically below:

Heatsink Required

not

Required

Heatsink

Required

not

Required

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3.15.3. How to Use the Charts

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

To determine if your application needs a heatsink:

1. Allow maximum heatsink temperature to be 80 °C or less.

2. Determine the ambient operating temperature of the Whistle.

3. Calculate the allowable temperature increase as follows:

 for an ambient temperature of 40 °C , ΔT= 80°C – 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.

5. If the dissipated power is below 4 W the Whistle will need no additional cooling.

Notes:

The chart above shows that no heatsink is needed when the heatsink temperature is 80 °C, ambient temperature is 40 °C and heat dissipated is 4 Watts.

When an external heatsink is required, you can use the Elmo external heatsink (Catalog number: WHI-HEATSINK-2) – see Figure 4.

3.15.4. Tweeter Thermal Data

The best way to dissipate heat from the Tweeter is to mount it so that its lower board faces upward. For best results leave approximately 10 mm of space between the Tweeter's lower board and any other assembly.

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3.16. Evaluation Board and Cable Kit

A circuit board is available for evaluating the Whistle and Tweeter. It comes with standard terminal blocks for power connections and D-Sub plugs/sockets for signals connection. The Evaluation Board is provided with a cable kit.

Figure 32: The Evaluation Board (can be ordered separately)

Evaluation Board Evaluation Board User Manual

Catalog Number: EVA-WHI/GUI/BEL

MAN-EVLBRD-WHI_BEL_GUI-UG.pdf (available on our

website)

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Chapter 4: Technical Specifications

Whistle and Tweeter Installation Guide

This chapter provides detailed technical information regarding the Whistle and Tweeter. 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 features of the Whistle and Tweeter determine how they control motion, as well as how they process 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

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 current and velocity, pulse-width modulation (PWM)

current and velocity, digital (SW) 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

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4.1.5. Feedback Options

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

• Digital Halls – up to 2 kHz

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

second for encoder

• 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 encoder outputs, single-ended, unbuffered of the Analog  encoder

• Analog Hall Sensor

• Resolver

 Programmable 10 to 15 bit resolution  Up to 512 revolutions per second (RPS)  Emulated encoder outputs, single-ended, unbuffered of the Resolver

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

• Tachometer & Potentiometer

• Provide power (5 V, 200 mA max) for one Encoder, Resolver or Hall

4.1.6. Input/Output

• One Analog Input – up to 14-bit resolution

• Six 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

• Two programmable Digital Outputs, optically isolated (open collector) one with fast output compare (OC)

 Brake Control  Amplifier 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 output and power input/return  Failure of internal power supplies  Over temperature

• Cont. temperature measurement. Temp can be read on the fly, Warning can be initiated X degrees before temp disable is activated.

 Over/Under voltage  Loss of feedback  Following error  Current limits

4.1.8. Accessories

• External heatsink (Whistle). See Section 3.4.1 for more details. Catalog number: WHI-HEATSINK-2.

• Evaluation Board. See Section 3.16 for a picture and more details. Catalog number: EVA-WHI/GUI/BEL.

• Cable Kit. See Section 3.16 for more details. Catalog number: CBL-EVAUNIKIT01.

4.1.9. Status Indication

• Output for a bi-color LED

4.1.10. 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

4.2.1. Whistle

4.2.2. Tweeter

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4.3. Power Ratings

4.3.1. Whistle

Feature

Minimum supply voltage VDC 6 7.5 12

Nominal supply voltage VDC 42 50 85

Maximum supply voltage VDC 48 59 95

Maximum continuous power output

Efficiency at rated power (at nominal conditions)

Maximum output voltage

Auxiliary power supply VDC 12 – 95 VDC (up to 2.5 VA inc. 5 V/200 mA for encoder)

Amplitude sinusoidal/DC continuous current

Sinusoidal continuous RMS current limit (Ic)

Peak current limit A 2 x Ic

Weight g (oz) 50 g (1.8 ounces)

Units

15/48

20/48

W 600 800 50 120 240 480 720 960 80 200 400 800 1200 1600

% > 99

> 95% of DC bus voltage at f=22 kHz

A 15 20 1 2.5 5 10 15 20 1 2.5 5 10 15 20

A 10.6 14.1 0.7 1.8 3.5 7 10.6 14.1 0.7 1.8 3.5 7 10.6 14.1

5/60

10/60

15/60

20/60

1/100

2.5/100

5/100

10/100

15/100

20/100

Dimensions mm

(in)

Digital in/Digital out/ Analog in

Mounting method PCB mount

6/2/1

55 x 15 x 46.5 (2" x 0.6" x 1.8")

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Elmo now offers a 200 VDC maximum output rating selection of Whistle, according to the following technical data:

Feature Units 3/200 6/200 10/200

Minimum supply voltage VDC 24

Nominal supply voltage VDC 170

Maximum supply voltage VDC 195

Maximum continuous power output W 480 960 1600

Efficiency at rated power (at

% > 99

nominal conditions)

Maximum output voltage > 95% of DC bus voltage at f = 22 kHz

Auxiliary power supply VDC

Amplitude sinusoidal/DC

A 3 6 10

12 – 95 VDC (up to 2.5 VA inc. 5 V/200 mA for

encoder)

continuous current

Sinusoidal continuous RMS current

A 2.12 4.24 7.07

limit (Ic)

Peak current limit A 2 x Ic

Weight g (oz)

Dimensions mm (in)

50 g (1.8 ounces)

55 x 15 x 46.5 (2" x 0.6" x 1.8")

Digital in/Digital out/Analog in 6/2/1

Mounting method PCB mount

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4.3.2. Tweeter

Feature Units 3/60 2.5/100

Minimum supply voltage VDC 7.5 12

Nominal supply voltage VDC 50 85

Maximum supply voltage VDC 59 95

Maximum continuous power output

Efficiency at rated power (at nominal conditions)

Maximum output voltage > 95% of DC bus voltage at f=22 kHz

Auxiliary power supply VDC 12 to 95 VDC (up to 2.5 VA inc. 5 V/200 mA for encoder)

Amplitude sinusoidal/ DC continuous current

Sinusoidal continuous RMS current limit (Ic)

Peak current limit A 2 x Ic

Weight g (oz) 27 g (0.95 oz)

Dimensions mm (in) 51 x 12.5 x 42 (2" x 0.49" x 1.65")

Digital in/Digital out/Analog in 6/2/1

Mounting method PCB mount or soldered pins

W 160 200

% > 99

A 3.3 2.5

A 2.3 1.8

4.3.3. Auxiliary Supply

Feature Details

Auxiliary power supply Isolated DC source only

Auxiliary supply input voltage 12 VDC to 95 VDC

Auxiliary supply input power < 2.5 VA (this includes the 5 V/200 mA load for

the main encoder only)

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4.4. Environmental Conditions

Feature Details

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

4.4.1. Control Specifications

4.4.2. Current Loop

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

Feature Details

Controller type Vector, digital

Compensation for bus voltage

“On-the-fly” automatic gain scheduling

variations

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 70 to 120 µsec

Current sampling rate Up to 16 kHz; default 11 kHz

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4.4.3. Velocity Loop

Feature Details

Controller type PI

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

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 240 µsec (2x 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.

4.4.4. Position Loop

Feature Details

Controller type “1-2-4” PIP

Position command options Software

Pulse and Direction

Analog Potentiometer

Position loop bandwidth < 80 Hz

Position loop sampling time

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

280 to 480 µsec (4x current loop sample time)

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4.5. Feedbacks

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

4.5.1. Feedback Supply Voltage

The Whistle and Tweeter have two feedback ports (Main and Auxiliary). The drives supply voltage only to the main feedback device. The user must provide a separate power supply for auxiliary feedback devices if needed.

Feature Details

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

4.5.2. Main Feedback Options

4.5.2.1. Incremental Encoder Input

Feature Details

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 33: Main Feedback - Encoder Phase Diagram

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4.5.2.2. Digital Halls

Feature Details

Halls inputs HA, HB, HC

Single ended inputs

Built in hysteresis of 1 V for noise immunity

Input voltage Nominal operating range: 0 V < V

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

InHigh

InLow

In_Hall

> 2.5 V

< 1 V

< 5 V

In_Hall

< 15 V

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

3 mA

Source current: 1.5 mA (designed to also support open collector Halls)

Maximum frequency f

: 2 kHz

MAX

4.5.2.3. Interpolated Analog (Sine/Cosine) Encoder

Feature Details

Analog encoder format Sine and Cosine signals

Analog input signal level Offset voltage: 2.2 V – 2.8 V

Differential, 1 V peak to peak

Input resistance

Maximum analog signal frequency f

Differential 120 Ω

: 250 kHz

MAX

Interpolation multipliers Programmable: x4 to x4096

Maximum “counts” frequency 80 mega-counts/sec “internally”

Automatic errors correction Signal amplitudes mismatch

Signal phase shift

Signal offsets

Encoder outputs See Auxiliary Encoder Outputs specifications

( 4.5.3)

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4.5.2.4. Resolver

Feature Details

Resolver format Sine/Cosine

Differential

Input resistance

Differential 2.49 kΩ

Resolution Programmable: 10 to 15 bits

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 Whistle and Tweeter

Reference current Up to ±50 mA

Encoder outputs

See Auxiliary Encoder Output specifications

4.5.2.5. Tachometer*

Feature Details

Tachometer format Differential

Maximum operating differential voltage for TAC1+, TAC1-

±20 V

Maximum absolute differential input

±25 V

voltage for TAC1+, TAC1-

Maximum operating differential voltage

±50 V

for TAC2+, TAC2-

Maximum absolute differential input

±60 V

voltage for TAC2+, TAC2-

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 having a Tachometer of less than 20 V. TAC2+/TAC2- is used in applications with having a Tachometer of between 20 V and 50 V.

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4.5.2.6. Potentiometer

Feature Details

Potentiometer Format Single-ended

Operating Voltage Range 0 to 5 V supplied by the Whistle and Tweeter

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

detrimentally

Input Resistance 100 kΩ

Resolution 14 bit

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

Feature Details

Emulated output A, B, Index

Single ended

Output current capability

Maximum output current: I High level output voltage: V Minimum output current: I Low level output voltage: V

(max) = 2 mA

> 3.0 V

= 2 mA

< 0.4 V

Available as options Emulated encoder outputs of the analog encoder

Emulated encoder outputs of the resolver

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 34: Auxiliary Feedback - Encoder Phase Diagram

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

Feature Details

Encoder input, pulse and direction input

A, B, Index

Single ended

Output current capability VIn Low: 0 V < VIL < 0.8 V

High: 2 V < VIH < 5 V

Maximum absolute voltage: 0 < V

< 5.5 V

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 35: Auxiliary Feedback - Encoder Phase Diagram

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Whistle and Tweeter Installation Guide Technical Specifications

4.6. I/Os

The Whistle and Tweeter have:

• 6 Digital Inputs

• 2 Digital Outputs

• 1 Analog Input

4.6.1. Digital Input Interfaces

Feature Details

Type of input Optically isolated

All six inputs share one signal return line

Input current

Iin = 2.4 mA @ Vin = 5 V

for all inputs

High-level input voltage 2.5 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<4xTS

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 highspeed mode

T < 5 µsec

Notes:

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 same value as digital filter (EF) of main encoder.

Highest speed is achieved when turning on optocouplers.

Figure 36: Digital Input Schematic

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4.6.2. Digital Output Interface

Feature Details

Type of output Optically isolated

Open collector and open emitter

Maximum supply output (VCC) 30 V

Max. output current I

(max) (V

out

= Low)

out

VOL at maximum output voltage

(max) ≤ 10 mA

out

(on) ≤ 0.3 V

out

(low level)

RL The external resistor RL must be selected to limit the

output current to no more than 10 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 37: Digital Output Schematic

4.6.3. 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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CAN

Whistle and Tweeter Installation Guide Technical Specifications

4.7. Communications

Specification Details

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 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

4.8. 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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4.9. 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.)

• 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

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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ElmoMC SimplIQ Digital Servo Drives-Whistle Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Chapter 1: Safety Information

1.1. Warnings

1.2. Cautions

1.3. Directives and Standards

1.4. CE Marking Conformance

1.5. Warranty Information

Chapter 2: Introduction

2.1. Drive Description

2.2. Product Features

2.2.1. Current Control

2.2.2. Velocity Control

2.2.3. Position Control

2.2.4. Advanced Position Control

2.2.5. Communication Options

2.2.6. Feedback Options

2.2.7. Fault Protection

2.3. System Architecture

2.4. How to Use this Guide

Chapter 3: Installation

3.1. Site Requirements

3.2. Unpacking the Drives

3.3. Connectors

3.3.1. Connector Types

3.3.2. Pinouts

3.3.2.1. Connector J1

3.3.2.2. Connector J2

3.4. Mounting

3.4.1. Whistle

3.4.2. Tweeter

3.5. Integrating the Whistle or Tweeter on a PCB

3.5.1. Traces

3.5.2. Grounds and Returns

3.6. The Whistle/Tweeter Connection Diagram

3.7. Main Power and Motor Power

3.7.1. Connecting Motor Power

3.7.2. Connecting Main Power

3.8. Auxiliary Supply (for Drive Logic)

3.8.1. Single Supply

3.8.2. Separate Auxiliary Supply

3.8.3. Shared Supply for up to 100 V Models

3.9. Main Feedback

3.10. Auxiliary Feedback

3.10.1. Main and Auxiliary Feedback Combinations

3.11. I/Os

3.11.1. Digital Input

3.11.2. Digital Output

3.11.3. Analog Input

3.12. Communications

3.12.1. RS-232 Communication

3.12.2. CAN Communication

3.13. Powering Up

3.14. Initializing the System

3.15. Heat Dissipation

3.15.1. Whistle Thermal Data

3.15.2. Heat Dissipation Data

3.15.3. How to Use the Charts

3.15.4. Tweeter Thermal Data

3.16. Evaluation Board and Cable Kit

Chapter 4: Technical Specifications

4.1. Features

4.1.1. Motion Control Modes

4.1.2. Advanced Positioning Control Modes

4.1.3. Advanced Filters and Gain Scheduling

4.1.4. Fully Programmable

4.1.5. Feedback Options

4.1.6. Input/Output

4.1.7. Built-In Protection

4.1.8. Accessories

4.1.9. Status Indication

4.1.10. Automatic Procedures

4.2. Dimensions

4.2.1. Whistle

4.2.2. Tweeter

4.3. Power Ratings

4.3.1. Whistle

4.3.2. Tweeter