Page 1
DC Whistle
Digital Servo Drive
Installation Guide
July 2014 (Ver. 1.101)
www.elmomc.com
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Notice
This guide is delivered subject to the following conditions and restrictions:
• This guide contains proprietary information belonging to Elmo Motion Control Ltd. Such
information is supplied solely for the purpose of assisting users of the DC Whistle servo
drive in its installation.
• The text and graphics included in this manual are for the purpose of illustration and
reference only. The specifications on which they are based are subject to change without
notice.
• Elmo Motion Control and the Elmo Motion Control logo are trademarks of Elmo Motion
Control Ltd.
• Information in this document is subject to change without notice.
Document no. MAN-DCWHIIG (Ver. 1.101)
Copyright 2014
Elmo Motion Control Ltd.
All rights reserved.
Catalog Number
Cable Kit
Catalog number: CBL-DCWHIKIT-01 (can be ordered separately). For further details, see the
documentation for this cable kit in Chapter 5.
Revision History
Version Date Details
Ver. 1.00 Sep 2012 Initial release
Ver. 1.001 Jan 2013 Updated the Power Ratings tables
Updated the auxiliary voltage value
Section 4.4: Physical Specifications, was added.
Added a caution and recommendation on the type of cleaning solution
to use for the Elmo unit.
Ver. 1.002 Feb 2013 Updated the table heading in Section 4.4: Physical Specifications.
Ver. 1.100 June 2014 Updates to document
Ver. 1.101 July 2014 General format updates
Page 3
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
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MAN-DCWHIIG (Ver . 1.101)
Table of Contents
DC Whistle Installation Guide
Chapter 1: Safety Information ...................................................................................... 7
1.1. Warnings .....................................................................................................................8
1.2. Cautions ......................................................................................................................8
1.3. Directives and Standards ............................................................................................9
1.4. CE Marking Conformance ...........................................................................................9
1.5. Warranty Information ................................................................................................9
Chapter 2: Introduction ............................................................................................. 10
2.1. Product Description ................................................................................................. 10
2.2. Product Features ..................................................................................................... 11
2.2.1. Current Control ......................................................................................... 11
2.2.2. Velocity Control ........................................................................................ 11
2.2.3. Position Control ........................................................................................ 11
2.2.4. Advanced Position Control (in Advanced model only).............................. 11
2.2.5. Communication Options ........................................................................... 12
2.2.6. Feedback Options ..................................................................................... 12
2.2.7. Fault Protection ........................................................................................ 12
2.3. System Architecture ................................................................................................ 13
2.4. How to Use this Guide ............................................................................................. 14
4
Chapter 3: Installation ............................................................................................... 15
3.1. Site Requirements ................................................................................................... 15
3.2. Unpacking the Drive Components ........................................................................... 15
3.3. Mounting the DC Whistle ........................................................................................ 16
3.4. Connecting the Cables ............................................................................................. 17
3.4.1. Wiring the DC Whistle .............................................................................. 17
3.5. DC Whistle Connector Types ................................................................................... 19
3.6. Hardware Requirements ......................................................................................... 20
3.7. DC Whistle Connection Diagram ............................................................................. 21
3.8. The Main Power and Motor Power Connectors ...................................................... 22
3.8.1. Connecting Motor Power ......................................................................... 22
3.8.2. Connecting Main Power ........................................................................... 23
3.8.3. Low-Power Auxiliary Supply (optional) .................................................... 24
3.9. Main Feedback ........................................................................................................ 26
3.10. Auxiliary Feedback (bi-directional) .......................................................................... 32
3.10.1. Main and Auxiliary Feedback Combinations ............................................ 33
3.10.2. Auxiliary Feedback – Emulated, Differential Buffered Encoder Output
Option (YA[4]=4) ....................................................................................... 34
3.10.3. Auxiliary Feedback - Differential Encoder Input Option (YA[4]=2) ........... 37
3.10.4. Auxiliary Feedback – Differential Pulse-and-Direction Input Option (YA[4]=0)
.................................................................................................................. 39
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Table of Contents
3.11. I/O ............................................................................................................................ 41
3.11.1. I/O ............................................................................................................. 42
1.1.1.1 Digital Input ............................................................................. 43
1.1.1.2 Digital Output .......................................................................... 44
3.11.2. Analog Input ............................................................................................. 44
3.12. Communications ...................................................................................................... 45
3.12.1. RS-232 Communication ............................................................................ 45
3.12.2. CAN Communication ................................................................................ 47
3.13. Powering Up ............................................................................................................ 49
3.14. Initializing the System .............................................................................................. 49
Chapter 4: Technical Specifications ............................................................................ 50
4.1. Features ................................................................................................................... 50
4.2. Built-In Protection ................................................................................................... 52
4.3. DC Whistle Dimensions ........................................................................................... 52
4.4.
Physical Specifications
............................................................................................. 53
4.5. Power Ratings .......................................................................................................... 53
4.6. Control Specifications .............................................................................................. 55
4.6.1. Current Loop ............................................................................................. 55
4.6.2. Velocity Loop ............................................................................................ 56
4.6.3. Position Loop ............................................................................................ 56
4.7. Feedbacks ................................................................................................................ 57
4.7.1. Incremental Encoder ................................................................................ 57
4.7.2. Feedback Supply Voltage .......................................................................... 57
4.7.3. Digital Halls ............................................................................................... 57
4.7.4. Interpolated Analog (Sine/Cosine) Encoder ............................................. 58
4.7.5. Resolver .................................................................................................... 59
4.7.6. Tachometer............................................................................................... 59
4.7.7. Potentiometer .......................................................................................... 60
4.7.8. Auxiliary Feedback Port (output mode YA[4]= 4) ..................................... 61
4.7.9. Auxiliary Feedback Port (input mode YA[4]= 2, 0).................................... 62
4.8. I/Os .......................................................................................................................... 63
4.8.1. Digital Input Interface – 4/6 Digital Inputs ............................................... 63
4.8.2. Digital Output Interface – 2 Digital Outputs ............................................. 64
4.8.3. Analog Inputs – 1 Analog Input ................................................................ 64
4.9. Mechanical Specifications ....................................................................................... 65
4.10. Environmental Conditions ....................................................................................... 65
4.11. Compliance with Standards ..................................................................................... 66
5
Chapter 5: Cables (Optional) ...................................................................................... 68
5.1. Cable Photos
............................................................................................................ 68
5.2. Cable Kit ................................................................................................................... 69
5.3. Main Feedback Cable (CBL-HDRFB-001) .................................................................. 70
5.4. Auxiliary Feedback (CBL-HDRAUX-001) ................................................................... 71
5.5. I/O (CBL-HDRIO-001) ............................................................................................... 72
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Table of Contents
5.6. Communication Cables ............................................................................................ 73
5.6.1. RS-232 Option (CBL-RJ452321) ................................................................. 73
5.6.2. CAN (CBL-RJ45CAN1) ................................................................................ 74
5.7. Guidelines for Making Your Own Cables ................................................................. 75
5.7.1. Recommended Wire Cross Sections ......................................................... 75
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MAN-DCWHIIG (Ver . 1.101)
Chapter 1: Safety Information
Warning:
Caution:
DC Whistle Installation Guide
In order to achieve the optimum, safe operation of the DC Whistle, 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 DC Whistle and
accompanying equipment.
Please read this chapter carefully before you begin the installation process.
Before you start, ensure that all system components are connected to earth ground. Electrical
safety is provided through a low-resistance earth connection.
Only qualified personnel may install, adjust, maintain and repair the servo drive. A qualified
person has the knowledge and authorization to perform tasks such as transporting, assembling,
installing, commissioning and operating motors.
The DC Whistle contains electrostatic-sensitive components that can be damaged if handled
incorrectly. To prevent any electrostatic damage, avoid contact with highly insulating materials,
such as plastic film and synthetic fabrics. Place the product on a conductive surface and ground
yourself in order to discharge any possible static electricity build-up.
7
To avoid any potential hazards that may cause severe personal injury or damage to the product
during operation, keep all covers and cabinet doors shut.
The following safety symbols are used in this manual:
This information is needed to avoid a safety hazard, which might cause bodily
injury.
This information is necessary for preventing damage to the product or to
other equipment.
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Safety Information
1.1. Warnings
• To avoid electric arcing and hazards to personnel or electrical damage, never
connect/disconnect any plug or cable from 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 DC Whistle from all voltage sources before it is opened for servicing.
• The DC Whistle contains grounding conduits for electric current protection. Any disruption
to these conduits may cause the instrument to become hot (live) and dangerous.
• After shutting off the power and removing the power source from your equipment, wait at
least 1 minute before touching or disconnecting parts of the equipment that are normally
loaded with electrical charges (such as capacitors or contacts). Measuring the electrical
contact points with a meter, before touching the equipment, is recommended.
1.2. Cautions
• The DC Whistle contains hot surfaces and electrically-charged components during
operation.
8
• The maximum AC/DC power supply connected to the instrument must comply with the
parameters outlined in this guide. Furthermore, the power supply must be isolated from
hazardous live voltages using reinforced or double insulation in accordance to approved
safety standards.
• When connecting the DC Whistle to an approved 11 to 95 VDC (8.5 to 67 VAC) auxiliary
power supply, connect it through a line that is isolated from hazardous live voltages using
reinforced or double insulation in accordance with approved safety standards.
• Before switching on the DC Whistle, verify that all safety precautions have been observed
and that the installation procedures in this manual have been followed.
• Do not clean any of the DC Whistle drive's soldering with solvent cleaning fluids of pH
greater than 7 (8 to 14). The solvent corrodes the plastic cover causing cracks and eventual
damage to the drive's PCBs.
Elmo recommends using the cleaning fluid Vigon-EFM which is pH Neutral (7).
For further technical information on this recommended cleaning fluid, select the link:
http://www.zestron.com/fileadmin/zestron.comusa/daten/electronics/Product_TI1s/TI1-VIGON_EFM-US.pdf
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Safety Information
1.3. Directives and Standards
The DC Whistle conforms to the following industry safety standards:
Safety Standard Item
Approved IEC/EN 61800-5-1, Safety Adjustable speed electrical power drive systems
Recognized UL 508C Power Conversion Equipment
In compliance with UL 840 Insulation Coordination Including Clearances and
Creepage Distances for Electrical Equipment
9
In compliance with UL 60950-1
(formerly UL 1950)
Safety of Information Technology Equipment
Including Electrical Business Equipment
In compliance with EN 60204-1 Low Voltage Directive 73/23/EEC
The DC Whistle has been developed, produced, tested and documented in accordance with the
relevant standards. Elmo Motion Control is not responsible for any deviation from the
configuration and installation described in this documentation. Furthermore, Elmo is not
responsible for the performance of new measurements or ensuring that regulatory
requirements are met.
1.4. CE Marking Conformance
The DC Whistle is intended for incorporation in a machine or end product. The actual end
product must comply with all safety aspects of the relevant requirements of the European
Safety of Machinery Directive 98/37/EC as amended, and with those of the most recent
versions of standards EN 60204-1 and EN 292-2 at the least.
According to Annex III of Article 13 of Council Directive 93/68/EEC, amending Council Directive
73/23/EEC concerning electrical equipment designed for use within certain voltage limits, the
DC Whistle meets the provisions outlined in Council Directive 73/23/EEC. The party responsible
for ensuring that the equipment meets the limits required by EMC regulations is the
manufacturer of the end product.
1.5. Warranty Information
The products covered in this manual are warranted to be free of defects in material and
workmanship and conform to the specifications stated either within this document or in the
product catalog description. All Elmo drives are warranted for a period of 12 months from the
time of installation, or 18 months from time of shipment, whichever comes first. No other
warranties, expressed or implied — and including a warranty of merchantability and fitness for
a particular purpose — extend beyond this warranty
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MAN-DCWHIIG (Ver . 1.101)
Chapter 2: Introduction
DC Whistle Installation Guide
This installation guide describes the DC Whistle and the steps for its wiring, installation and
power-up. Following these guidelines ensures maximum functionality of the product and the
system to which it is connected.
2.1. Product Description
The DC Whistle series of servo drives enhances Elmo’s range of digital servo drives, recognized
for having the highest power density and intelligence. The DC Whistle is a highly compact
integrated solution containing a single drive.
The DC Whistle integrates Elmo’s advanced “Elmo First Control” technology, which contributes
to the product’s excellent control performance, wide range of functionalities and high
efficiency and reliability. The solution includes one fully separated digital motion controller
featuring:
• CANopen-based networking operating simultaneously via RS-232 and CANopen DS 301,
DSP 305, DSP 402 communications and featuring a third-generation programming
environment
10
• Current, velocity and position control loops including PT and PVT
• Commutation types
• Position feedbacks
The benefits are high dynamics and increased precision for single axis automated machines
such as robots, feeders, up- and down-loaders, conveyor belts and production lines.
Power to the various DC Whistle models is provided by a 11 to 95 VDC source. A “smart”
control-supply algorithm enables the DC Whistle to operate with only one power supply and
there is no need for an auxiliary power supply for the logic.
If backup functionality is required for storing control parameters in case of power-loss, an
external 11 to 95 VDC supply should be connected (via the VL+ terminal on the DC Whistle)
providing maximum flexibility and backup functionality when needed.
Note: This backup power supply can operate from any voltage source within the range from
11 to 95 VDC. This is much more flexible than a standard 24 VDC power supply requirement.
The DC Whistle series fully complies with all relevant safety and EMC regulations.
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Introduction
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
11
• 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 rate four times current loop sample time
• Fast event capturing inputs
2.2.4. Advanced Position Control (in Advanced model only)
• Position-based and time-based ECAM mode that supports a non-linear follower mode, in
which the motor tracks the master motion using an ECAM table stored in flash memory
• PT and PVT motion modes
• Dual (position/velocity) loop
• Fast output compare (OC)
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Introduction
2.2.5. Communication Options
Depending on the application, DC Whistle users can select from two communication options:
• RS-232 serial communication
• CANopen for fast communication in a multi-axis distributed environment
2.2.6. Feedback Options
• Incremental Encoder – up to 20 Mega-Counts (5 Mega-Pulse) per second
• Digital Halls – up to 2 kHz
• 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
12
• Resolver
Programmable 10 to 15 bit resolution
Up to 512 Revolution 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 DC Whistle includes built-in protection against possible fault conditions, including:
• Software error handling
• Status reporting for a large number of possible fault conditions
• Protection against conditions such as excessive temperature, under/over voltage, loss of
commutation signal, short circuits between the motor power outputs and between each
output and power input return
• Recovery from loss of commutation signals and from communication errors
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MAN-DCWHIIG (Ver . 1.101)
Power Stage
Main
Feedback
Input
Aux. Feedback
Differential Input
Communication
User I/O Interface
Motion
Control
Logic
Incremental
Encoder
Incremental
Encoder
Digital
Inputs
Digital
Outputs
RS232
CANopen
Main DC Power
Supply
Optional DC
Auxiliary Supply
Motor
PWM
Current
Feedback,
Protection
Aux. Feedback
Differential
Output
Other Axis or
Devices
Interpolated
Analog
Encoder
Resolver
Tachometer &
Potentiometer
OR
OR
OR
DC Whistle Installation Guide Introduction
2.3. System Architecture
13
Figure 1: DC Whistle System Block Diagram
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Introduction
2.4. How to Use this Guide
In order to install and operate your Elmo DC Whistle, 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 DC Whistle.
• Chapters 4 and 5 list all the drive ratings and specifications as well as information on the
relevant cables.
Upon completing the instructions in this guide, your DC Whistle 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 Composer Software Manual, which includes explanations of all the software tools that
are part of Elmo’s Composer software environment
14
• The SimplIQ Command Reference Manual, which describes, in detail, each software
command used to manipulate the DC Whistle motion controllers
• The SimplIQ Software Manual, which describes the comprehensive software used with the
DC Whistle
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MAN-DCWHIIG (Ver . 1.101)
Chapter 3: Installation
Caution:
DC Whistle Installation Guide
The DC Whistle must be installed in a suitable environment and properly connected to its
voltage supplies and the motor.
3.1. Site Requirements
You can guarantee the safe operation of the DC Whistle by ensuring that it is installed in an
appropriate environment.
Feature Value
Ambient operating temperature 0 °C to 40 °C (32 °F to 104 °F)
Maximum operating altitude 2,000 m (6562 feet)
Maximum relative humidity 90% non-condensing
Operating area atmosphere No flammable gases or vapors permitted in area
15
Models for extended environmental conditions are available.
The Whistle on the DC Whistle dissipates its heat by convection. The
maximum operating ambient temperature of 0 °C to 40 °C (32 °F to 104 °F)
must not be exceeded. Refer to the Heat Dissipation section of the
Whistle/Tweeter Installation Guide for more information.
3.2. Unpacking the Drive Components
Before you begin working with the DC Whistle, verify that you have all of its components, as
follows:
• The DC Whistle.
• The Composer software and software manual.
The DC Whistle is shipped in a cardboard box with Styrofoam protection.
To unpack the DC Whistle:
Carefully remove the DC Whistle from the box and the Styrofoam.
Check the DC Whistle 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 DC Whistle.
To ensure that the DC Whistle you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the DC Whistle. It looks like
this:
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Installation
The part number at the top gives the type designation as follows:
Verify that the DC Whistle type is the one that you ordered, and ensure that the voltage meets
your specific requirements.
3.3. Mounting the DC Whistle
16
The DC Whistle has been designed for two standard mounting options:
• Wall Mount, along the back (can also be mounted horizontally on a metal surface)
• Book Shelf, along the side
M4 round head screws, one through each opening in the heat sink, are used to mount the DC
Whistle (see the diagram below).
Figure 2: Mounting the DC Whistle
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Installation
3.4. Connecting the Cables
3.4.1. Wiring the DC Whistle
Once the DC Whistle is mounted, you are ready to wire the device. Proper wiring, grounding
and shielding are essential for ensuring safe, immune and optimal servo performance of the DC
Whistle.
Caution:
Perform the following instructions to ensure safe and proper wiring.
1. Use twisted pair shielded cables for control, Feedback and communication connections. For
best results, the cable should have an aluminum foil shield covered by copper braid, and
should contain a drain wire.
The drain wire is a non-insulated wire that is in contact with parts of the cable, usually the
shield. It is used to terminate the shield and as a grounding connection.
The impedance of the wire must be as low as possible. The size of the wire must be thicker
than actually required by the carrying current. A 26 or 28 AWG wire for control and
Feedback cables is satisfactory although 26 AWG is recommended.
17
Use shielded wires for motor connections as well. If the wires are long, ensure that the
capacitance between the wires is not too high: C < 30 nF is satisfactory for most
applications.
Keep all wires and cables as short as possible.
Keep the motor wires as far away as possible from the Feedback, control and communication
cables.
Ensure that in normal operating conditions, the shielded wires and drain carry no current. The
only time these conductors carry current is under abnormal conditions, when electrical
equipment has become a potential shock or fire hazard while conducting external EMI
interferences directly to ground, in order to prevent them from affecting the drive. Failing
to meet this requirement can result in drive/controller/host failure.
After completing the wiring, carefully inspect all wires to ensure tightness, good solder joints
and general safety.
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MAN-DCWHIIG (Ver . 1.101)
Motor Power
Main Power
Aux. Power
CAN IN
CAN OUT
DC Whistle Installation Guide Installation
The following connectors are used for wiring the DC Whistle:
Type Function
Main Power VP+, PR, PE
Motor Power PE, M1, M2, M3
Aux. Power VL+, PR
Connectors Location
Table 1: Connectors on the “Power Connectors side” of the DC Whistle
Type Function
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Main Feedback Feedback
I/O I/O
Auxiliary Feedback Auxiliary Feedback
Connectors Location
Table 2: Connectors on the “Feedback and I/O side” of the DC Whistle
Type Function
CAN CAN IN
CAN CAN OUT
RS-232 RS-232
Connectors Location
Table 3: Connectors on the “Communication side” of the DC Whistle
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MAN-DCWHIIG (Ver . 1.101)
Main Power
I/O
Main Feedback
Motor Power
Aux. Power
RS-232
Auxiliary Feedback
CAN
DC Whistle Installation Guide Installation
3.5. DC Whistle Connector Types
The DC Whistle has 9 connectors.
Type Qty Conn. On Board Connector
Main Power 1 Phoenix 3-pin Header
Motor Power 1 Phoenix 4-pin Header
Auxiliary Power 1 Phoenix 2-pin Header
Main Feedback 1 12-Pin Molex Header
I/O 1 14-Pin Molex Header
Auxiliary Feedback 1 16-Pin Molex Header
CAN Comm. 2 8-Pin RJ-45 Socket
RS-232 Comm. 1 8-Pin RJ-45 Socket
Connector Location
19
Table 4: Connector Types
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Installation
3.6. Hardware Requirements
The components that you will need to install your DC Whistle are:
20
Component Qty
Conn.
Mating
Connector
Function Cable Drawing
Main Power 1 Phoenix 3-pin Plug VP+, PR, PE
Motor Power 1 Phoenix 4-pin Plug PE, M1, M2, M3
Aux. Power 1 Phoenix 2-pin Plug VL+, PR
Main Feedback 1 12-Pin Molex Plug Feedback
I/O 1 14-Pin Molex Plug I/O
Auxiliary Feedback 1 16-Pin Molex Plug Auxiliary
feedback
RS-232 Comm. 1 8-Pin RJ-45 Plug RS-232
CAN Comm. 2 8-Pin RJ-45 Plug CAN IN
CAN OUT
Table 5: Connector Cross Reference
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Installation
3.7. DC Whistle Connection Diagram
21
Figure 3: DC Whistle Connection Diagram
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Installation
3.8. The Main Power and Motor Power Connectors
The DC Whistle receives power from main and auxiliary supplies and delivers power to the
motor.
Pin Function Cable
Main Power
PE Protective earth Power
PR Power return Power
VP+ Pos. Power input Power
Aux. Supply
PR Aux. Supply Input Return Auxiliary
VL+ Aux. Supply Input Auxiliary
22
AC Motor Cable DC Motor Cable
M3 Motor phase Motor Motor
M2 Motor phase Motor Motor
M1 Motor phase Motor N/C
PE Protective earth Motor Motor
Pins Location
Table 6: Connectors for Main Power and Motors
3.8.1. Connecting Motor Power
Connect the motor power cable to the M1, M2, M3 and PE terminals of the relevant axis. The
phase connection order is arbitrary because the Composer will establish the proper
commutation automatically during setup. If several motor/drive combinations are designed to
operate in an identical manner, it is recommended to download the program into all the drives
and connecting them in the same way.
Notes for connecting the motor cables:
1. For the greatest immunity, it is highly recommended to use a shielded (not twisted)
cable for the motor connection. A 4-wire shielded cable should be used. The gauge is
determined by the actual current consumption of the motor.
2. Connect the shield of the cable to the closest ground connection at the motor end.
3. Be sure that the motor chassis is properly grounded.
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Installation
Figure 4: AC Motor Power Connection Diagram
3.8.2. Connecting Main Power
Connect the DC power supply cable to the VP+ and PR terminals of the Main power connector.
Notes for connecting the DC power supply:
1. The source of the 0 to 95 VDC Power Supply must be isolated.
2. For the greatest immunity, it is highly recommended to use twisted and shielded cables
for the DC power supply cable. A 3-wire shielded cable should be used. The gauge is
determined by the actual current consumption of the motor.
3. Connect the cable shield to the closest ground connection near the power supply.
4. Connect the PE to the closest ground connection near the power supply.
5. Connect the PR to the closest ground connection near the power supply.
6. Before applying power, first verify the polarity of the connection.
23
Figure 5: Main Power DC Supply Connection Diagram
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MAN-DCWHIIG (Ver . 1.101)
Caution:
DC Whistle Installation Guide Installation
3.8.3. Low-Power Auxiliary Supply (optional)
Notes for 11 to 95 VDC Auxiliary Supply connections:
1. The source of the 11 to 95 VDC Auxiliary Supply must be isolated from the Main.
2. For safety reasons, connect the return (common) of the Auxiliary Supply source to the
closest ground near the Auxiliary Supply source.
3. Connect the cable shield to the closest ground near the Auxiliary Supply source.
4. Before applying power, first verify the polarity of the connection.
Power to each Whistle and motor must come from the Main Supply and NOT
from the Auxiliary Supply.
24
Figure 6: Auxiliary Supply Connection Diagram
The backup functionality can be used for storing control parameters in case of power-loss,
providing maximum flexibility and backup functionality when needed.
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25
Figure 7: Shared Supply Connection Diagram
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3.9. Main Feedback
The Main Feedback port is used to transfer Feedback data from the motor to the drive.
Figure 8: Main Feedback Port
The Main Feedback port on the DC Whistle has a 12-pin Molex Header plug. The DC Whistle
accepts the following as a Main Feedback mechanism:
• Incremental encoder only
• Incremental encoder with digital hall sensors
• Digital hall sensors only
• Interpolated analog (sine/cosine) encoder (option)
26
• Resolver (option)
• Tachometer and potentiometer (option)
• Analog Halls
Incremental Encoder Interpolated Analog Encoder
DC-WHI-XX/YYY DC-WHI-XX/YYYI
Pin Signal Function Signal Function
1 +5V Encoder/Hall +5V supply +5V Encoder/Hall +5V supply
2 SUPRET Supply return SUPRET Supply return
3 CHA Channel A A+ Sine A
4 CHA- Channel A complement A- Sine A complement
5 CHB Channel B B+ Cosine B
6 CHB- Channel B complement B- Cosine B complement
7 INDEX Index R+ Reference
8 INDEX- Index complement R- Reference complement
9 HA Hall sensor A input HA Hall sensor A input
10 HB Hall sensor B input HB Hall sensor B input
11 HC Hall sensor C input HC Hall sensor C input
12 SUPRET Supply return SUPRET Supply return
Table 7: Main Feedback Cable Pin Assignment for Incremental and Interpolated Analog
Encoder
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Resolver Tachometer and Potentiometer
DC-WHI-XX/YYYR DC-WHI XX/YYYT
Pin Signal Function Signal Function
1 +5V Encoder/Hall +5V supply +5V Encoder/Hall +5V supply
2 SUPRET Supply return SUPRET Supply return
3 S1 Sine A Tac 1+ Tacho Input 1 Pos. (20 V max)
4 S3 Sine A complement Tac 1- Tacho Input 1 Neg. (20 V max)
5 S2 Cosine B Tac 2+ Tacho Input 2 Pos. (50 V max)
6 S4 Cosine B complement Tac 2- Tacho Input 2 Neg. (50 V max)
7 R1 Vref f=1/TS, 50 mA Max. POT Potentiometer Input
27
8 R2 Vref complement
f= 1/TS, 50 mA Max
9 NC - HA Hall sensor A input
10 NC - HB Hall sensor B input
11 NC - HC Hall sensor C input
12 SUPRET Supply return SUPRET Supply return
NC -
Table 8: Main Feedback Cable Pin Assignment for Resolver, Tachometer &Potentiometer
Figure 9: Main Feedback- Incremental Encoder with Digital Halls Sensors Connection Diagram
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28
Figure 10: Main Feedback- Incremental Encoder Only Connection Diagram
Figure 11: Main Feedback – Interpolated Analog (Sine/Cosine) Encoder Connection Diagram
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29
Figure 12: Main Feedback– Resolver Connection Diagram
Figure 13: Main Feedback – Tachometer Feedback
with Digital Hall Sensor - Connection Diagram for Brushless Motors
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Figure 14: Main Feedback – Tachometer Feedback Connection Diagram for Brush Motors
30
Figure 15: Main Feedback – Potentiometer Feedback
with Digital Hall Sensor - Connection Diagram for Brushless Motors
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Figure 16: Main Feedback – Potentiometer Feedback Connection Diagram
31
for Brush Motors and Voice Coils
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3.10. Auxiliary Feedback (bi-directional)
When using one of the Auxiliary Feedback options, the relevant functionality of the Auxiliary
Feedback's ports are software selected for that option. Refer to the SimplIQ Command
Reference Manual for detailed information about Auxiliary Feedback setup.
The Auxiliary Feedback connector has two ports – B1 and B2.
• Port B1 has three pairs of differential buffered inputs
• Port B2 has three pairs of differential buffered outputs
There are two modes of operation for this interface:
• Mode 1 (Composer Command: YA[4]=4) see Section 3.10.2
When the Auxiliary port of the Whistle is set by the software to act as an emulated encoder
output (this is practical only when using a Resolver or Analog Encoder as the Main
Feedback):
B1 input becomes inactive.
B2 presents emulated differential buffered encoder output signals of the Main
Feedback.
32
• Mode 2 (Composer Command: YA[4]=2 or YA[4]=0) see Sections 3.10.3 and 3.10.4
When the Auxiliary port of the Whistle is set by software to act as an input:
B1 becomes an active differential buffered input.
B2 presents differential buffered encoder output signals of B1.
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MAN-DCWHIIG (Ver . 1.101)
B2 – output Analog Encoder position data
emulated in differential, buffered, incremental
Encoder format
B1 – not available
Main Feedback: Analog Encoder
B2 – output Resolver position data emulated in
differential, buffered, incremental Encoder
format
B1 – not available
Main Feedback: Resolver
DC Whistle 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 has two ports (B1 and B2). When
used in combination with Main Feedback, the Auxiliary Feedback can be set, by software, as
follows:
Main Feedback Auxiliary Feedback: Output
33
Software
Setting
Incremental
Encoder Input
Interpolated
Analog
(Sine/Cosine)
Encoder Input
Resolver Input
YA[4] = 4
(Auxiliary Feedback: output)
N/A
Potentiometer
Tachometer
Input
Typical
Applications
N.A
Analog Encoder applications where position data is required, in the Encoder’s
quadrature format, for other purposes such as position controllers and/or
other drives.
Resolver applications where position data is required in the Encoder’s
quadrature format, for other purposes such as position controllers and/or
other drives.
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MAN-DCWHIIG (Ver . 1.101)
Auxiliary Feed back
B1
Buffered
Differential
Incremental
Encoder
Input
B2
Buffered
Encoder
Output of B1
Main Feedback
Incremental
Encoder
or
Analog Encoder
or
Resolver
or
Tachometer
or
Potentiometer
Input
Auxiliary Feed back
B1
Buffered
Differential
Pulse &
Direction
Commands
Input
B2
Buffered
Differential
Pulse &
Direction
Commands
Output of B1
Main Feedback
Incremental
Encoder
or
Analog Encoder
or
Resolver
or
Tachometer
or
Potentiometer
Input
DC Whistle Installation Guide Installation
Main Feedback Auxiliary Feedback: Input
34
Software Setting
Incremental
Encoder Input
Interpolated
Analog
(Sine/Cosine)
Encoder Input
Resolver Input
Potentiometer
Tachometer
Input
YA[4] = 2
(Auxiliary Feedback: input) YA[4] = 0 (Auxiliary Feedback: input)
Typical
Applications
3.10.2. Auxiliary Feedback – Emulated, Differential Buffered Encoder
The Auxiliary Feedback's B2 port can provide emulated encoder signals to other controllers or
drives. This option can be used when:
• A Resolver or Analog Encoder is used as a Main Feedback device.
• The DC Whistle is used as a current amplifier to provide position data to the position
controller.
• The DC Whistle is used in velocity mode, to provide position data to the position controller.
• The DC Whistle is used as a master in Follower or ECAM mode.
Below are the signals on the Auxiliary Feedback ports when the Whistle Auxiliary Feedback port
is set up for emulated output of the Main Feedback device (Resolver or Analog Incremental
Encoder only).
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.
Output Option (YA[4]=4)
Any application where two Feedbacks are
used by the drive.
The Auxiliary Feedback port serves as an input
for Pulse & Direction Commands.
The Auxiliary Feedback on the DC Whistle has a 16-pin Molex Header plug.
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Port Pin Signal Function
PWR 1 +5V Encoder supply voltage
PWR 2 SUPRET Supply Return
B1 3 NA When YA[4]=4 the B1 port is not available
B1 4 NA When YA[4]=4 the B1 port is not available
B1 5 NA When YA[4]=4 the B1 port is not available
B1 6 NA When YA[4]=4 the B1 port is not available
B1 7 NA When YA[4]=4 the B1 port is not available
B1 8 NA When YA[4]=4 the B1 port is not available
B2 9 CHAO Buffered Channel A output
B2 10 CHAO- Buffered Channel A complement output
B2 11 CHBO Buffered channel B output
35
B2 12 CHBO- Buffered channel B complement output
B2 13 INDEXO Buffered Index output
B2 14 INDEXO- Buffered Index complement output
PWR 15 +5V Encoder supply voltage
PWR 16 SUPRET Supply Return
Pin Positions
Table 9: Emulated Encoder Output on the Auxiliary Feedback Port B2 - Pin Assignments
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36
Figure 17: Emulated Encoder Outputs of the Resolver or Analog Encoder -
Connection Diagram
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3.10.3. Auxiliary Feedback - Differential Encoder Input Option
(YA[4]=2)
The Whistle can be used as a slave by receiving the position data (on Port B1) of the master
encoder in Follower or ECAM mode. In this mode Port B2 provides differential buffered
Auxiliary outputs of B1 for the next slave axis in Follower or ECAM mode.
Below are the signals on the Auxiliary Feedback ports when the Whistle Auxiliary Feedback port
is set up to run as a differential Auxiliary input:
Port Pin Signal Function
PWR 1 +5V Encoder supply voltage
PWR 2 COMRET Common return
B1 3 CHA Auxiliary channel A input
B1 4 CHA- Auxiliary channel A complement input
B1 5 CHB Auxiliary channel B input
B1 6 CHB- Auxiliary channel B complement input
37
B1 7 INDEX Auxiliary Index Input
B1 8 INDEX- Auxiliary Index complement Input
B2 9 CHAO Buffered Channel A output
B2 10 CHAO- Buffered Channel A complement output
B2 11 CHBO Buffered channel B output
B2 12 CHBO- Buffered channel B complement output
B2 13 INDEXO Buffered Index output
B2 14 INDEXO- Buffered Index complement output
PWR 15 +5V Encoder supply voltage
PWR 16 COMRET Common return
Pin Positions
Table 10: Differential Auxiliary Encoder Input Option along with Differential Encoder Outputs
on Auxiliary Feedback - Pin Assignments
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38
Figure 18: Differential Auxiliary Input Option - Block Diagram
Figure 19: Differential Auxiliary Input Option on Auxiliary Feedback - Connection Diagram
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DC Whistle Installation Guide Installation
3.10.4. Auxiliary Feedback – Differential Pulse-and-Direction Input
Option (YA[4]=0)
This mode is used for input of differential pulse-and-direction position commands on Port B1.
In this mode Port B2 provides differential buffered pulse-and-direction outputs of B1 for
another axis.
Below are the signals on the Auxiliary Feedback ports when set up to run as a differential pulseand-direction input:
Port Pin Signal Function
PWR 1 +5V Encoder supply voltage
PWR 2 COMRET Common return
B1 3 CHA Auxiliary Pulse input
B1 4 CHA- Auxiliary Pulse complement input
B1 5 CHB Auxiliary Direction input
B1 6 CHB- Auxiliary Direction complement input
39
B1 7 NA Do not connect this pin
B1 8 NA Do not connect this pin
B2 9 CHAO Buffered Pulse output
B2 10 CHAO- Buffered Pulse complement output
B2 11 CHBO Buffered Direction output
B2 12 CHBO- Buffered Direction complement output
B2 13 NA Do not connect this pin
B2 14 NA Do not connect this pin
PWR 15 +5V Encoder supply voltage
PWR 16 COMRET Common return
Pin Positions
Table 11: Pulse-and-Direction Pin Assignment on Auxiliary Feedback
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40
Figure 20: Pulse-and-Direction Input Option on Auxiliary Feedback - Connection Diagram
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3.11. I/O
41
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3.11.1. I/O
The DC Whistle has 6 digital inputs, 2 digital outputs and a single analog input.
The I/O port has a 14-pin Molex Header plug with the following pin-outs.
Pin Signal Function
1 OUT1 Programmable Digital output 1
2 OUTRET1 Programmable Digital output 1 return
3 OUT2 Programmable Digital output 2
4 OUTRET2 Programmable Digital output 2 return
5 IN1 Programmable Digital input 1
6 IN2 Programmable Digital input 2
7 IN3 Programmable Digital input 3
8 IN4 Programmable Digital input 4
9 IN5 Programmable Digital input 5
42
10 IN6 Programmable Digital input 6
11 INRET Programmable Digital input return
12 COMRET Common return
13 ANALOGIN1+ Analog input 1+
14 ANALOGIN1- Analog input 1-
Pin Positions
Table 12: I/O Port and Cable - Pin Assignment
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1.1.1.1 Digital Input
Note: The Default Digital Input level Signal is set to 24 V (PLC).
5 V is also available (TTL).
43
Figure 21: Digital Input Connection Diagram
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1.1.1.2 Digital Output
Figure 22: Digital Output Connection Diagram
44
3.11.2. Analog Input
Figure 23: Analog Input with Single-Ended Source
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MAN-DCWHIIG (Ver . 1.101)
shield
DC Whistle Installation Guide Installation
3.12. Communications
The communication cables use an 8-pin RJ-45 plug that connect to the RS-232 and CAN ports
on the DC Whistle.
The communication interface may differ according to the user’s hardware. The DC Whistle can
communicate using the following options:
• RS-232, full duplex
• CAN
RS-232 communication requires a standard, commercial 3-core null-modem cable connected
from the DC Whistle 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
45
Notes for connecting the RS-232 communication cable:
1. 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.
2. The RS-232 communication port is non-isolated.
3. The male RJ plug must have a shield cover.
4. Ensure that the shield of the cable is connected to the shield of the RJ plug.
5. The drain wire can be used to facilitate the connection.
Pin Signal Function
1, 2 — —
3 Tx RS-232 transmit
4 — —
5 COMRET Communication return
6 Rx RS-232 receive
7, 8 — —
Body Drain Wire
Pin Positions
Table 13: RS-232 Cable - Pin Assignments
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46
Figure 24: RS-232 Connection Diagram
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3.12.2. CAN Communication
Notes for connecting the CAN communication cable:
1. Use 26 or 28 AWG twisted pair shielded cables. For best results, the shield should have
aluminum foil and be covered by copper braid with a drain wire
2. 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.
3. The CAN communication port is non-isolated.
4. The male RJ plug must have a shield cover.
5. Ensure that the shield of the cable is connected to the shield of the RJ plug.
The drain wire can be used to facilitate the connection.
6. For "daisy-chain" connections, connect a termination 120-Ω resistor at each of the two
ends of the network cable.
Pin Signal Function
1 CAN_H CAN_H busline (dominant high)
47
2 CAN_L CAN_L busline (dominant low)
3 CAN_GND CAN ground
4, 5 N/A —
6 CAN_SHLD Shield, connected to the RJ plug cover
7 CAN_GND CAN Ground
8 N/A —
body Drain Wire shield
Pin Positions
Table 14: CAN Cable - Pin Assignments
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48
Figure 25: CAN Network Connection Diagram
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Caution:
DC Whistle Installation Guide Installation
3.13. Powering Up
After the cables have been connected to their devices, the DC Whistle is ready to be powered
up.
Before applying power, ensure that the DC supply is within the range specified
and that the proper plus-minus connections are in order.
3.14. Initializing the System
After the DC Whistle 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.
49
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MAN-DCWHIIG (Ver . 1.101)
Chapter 4: Technical Specifications
DC Whistle Installation Guide
This chapter provides detailed technical information regarding the DC Whistle. 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 DC Whistle’s features determine how it controls motion, as well as how it processes host
commands, feedback and other input.
• Operating power
DC power supply: 11 to 95 VDC source
• DC BUS
DC power supply
50
• Control supply
A separate DC power supply 11 to 95 VDC serves as both the auxiliary supply and
the backup supply (Option)
• Operating modes
Current, velocity and position
• Commutation alternatives
Sinusoidal vector control
Trapezoidal
DC brush
• Feedback alternatives
Incremental encoder + digital Halls
Incremental encoder only
Digital Halls
Resolver
Sin / Cos
Sin / Cos + Digital Halls
Analog Halls
Tachometer
Potentiometer
• Communication
Simultaneous operation of RS-232 and CAN DS 402 User programming
• User Programming
Third-generation programming environment (language and Elmo Studio)
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• Encoder Input
• Event capturing inputs
• Event triggered programming structure
• Analog inputs
1 differential inputs with 12-bit resolution
• Enable input, limit switches and emergency stop handling
• Smart multi-purpose inputs
Programmable as Enable, Forward and Reverse Limit Switches, Home, Capture
• Uncommitted programmable inputs
4 Inputs sharing one single common
6 Inputs sharing one single common
• Uncommitted, programmable outputs
2 separated outputs
51
• Storage memory
Large, non-volatile storage of controller parameters and user programs
• Setup, startup and tuning software
Windows-based Composer
• Automatic analysis of kinematics
• Status indication
Bi-color LED
• 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
• Motion modes
Point-to-point (PTP)
Jogging
Position-Velocity-Time (PVT)
Position-Time (PT)
Pulse-and-direction
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4.2. Built-In Protection
• Software error handling
Software-based
• Status reporting
Available for a large number of fault conditions
• Protection against:
Short circuit between motor power outputs
Short circuit between each motor power output and DC bus return
Failure of internal power supply
Heatsink over-temperature
Under/over voltage
Loss of commutation signals
Loss of velocity feedback
“Bad” commutation
Communication error
52
4.3. DC Whistle Dimensions
Figure 26 DC Whistle dimensions
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4.4.
Physical Specifications
Feature Units All Types
Weight g (oz) 55 g (1.94 oz)
Dimensions mm (in) 115 x 75 x 25.8 mm (4.53" x 2.95" x 1.02")
Mounting method PCB mount
53
4.5. Power Ratings
Feature Units 1/60 2.5/60 5/60 10/60 15/60 1/100 2.5/100 5/100 10/100 15/100 20/100
Minimum supply voltage VDC 8.5
Nominal supply voltage VDC 48
Maximum supply voltage VDC 59
Auxiliary Power supply VDC
Max. output power from
the drive without
heatsink
Efficiency at rate power %
Output Voltage %
DC and Trapezoidal
Commutation Continuous
Current Limit (Ic)
Sinusoidal Commutation
Continuous RMS Current
Limit (Ic)
W 50 120 240 480 720 75 180 400 800 1200 1600
A 1 2.5 5 10 15 1 2.5 5 10 15 20
A 0.7 1.8 3.6 7 10.7 0.7 1.8 3.6 7 10.7 14.1
11 – 95 VDC (up to 2.5 VA inc. 5 V/200 mA for encoder)
> 99
> 95% of DC bus voltage at f=22 kHz
12
85
95
Peak current limit (RMS) A
Pulse-Width Modulation
(PWM) Switching
Frequency
Switching Method
kHz
Note:
Current Ratings: The current ratings of the DC Whistle are given in units of DC amperes
2 x Ic
22 ± 5% default on the motor
Advanced Unipolar PWM
(ratings that are used for trapezoidal commutation or DC motors). The
RMS (sinusoidal commutation) value is the DC value divided by 1.41.
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DC Whistle Installation Guide Technical Specifications
Elmo now offers a 200 VDC maximum output rating selection of DC 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
54
Efficiency at rated power (at
% > 99
nominal conditions)
Maximum output voltage
Auxiliary power supply VDC
Amplitude sinusoidal/DC
A 3 6 10
> 95% of DC bus voltage at f=22 kHz
11 – 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
Digital in/Digital out/Analog in 6/2/1
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4.6. Control Specifications
4.6.1. Current Loop
Feature Details
Controller type Vector, digital
55
Current sampling time
70 to 100 µsec
Current loop bandwidth 1400 to 2500 Hz
Compensation for bus voltage
Gain scheduling
variations
Motor types AC brushless (sinusoidal)
DC brushless (trapezoidal)
DC brush
Linear brushless motor
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 step response
300 to 400 µsec
(including settling time)
Current rise time
150 to 200 µsec
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4.6.2. Velocity Loop
Feature Details
Controller type PI
56
Speed sampling time
140 to 200 µsec ( x2 current loop sample time)
Velocity loop bandwidth < 350 MHz
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
Incremental encoder only
Digital Halls
Resolver
Sin / Cos
Sin / Cos+ Digital Halls
Analog Halls
Tachometer
Potentiometer
Note: With all feedback options, 1/T with automatic
mode switching is activated (gap, frequency and
derivative).
Velocity command options Analog
Internally calculated by either jogging or step
Note: All software-calculated profiles support
on-the-fly changes.
4.6.3. Position Loop
Feature Details
Controller type 124 PIP
Position sampling time
Analog input command resolution 12-bit inputs
PWM resolution 12-bit
PWM switching frequency on the load 2/ Ts (factory default 22 kHz on the motor)
Control inputs PLC or +5V level
280 to 400 µsec ( x 4 current loop sample time)
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4.7. Feedbacks
The DC Whistle can receive and process feedback input from diverse types of devices.
4.7.1. Incremental Encoder
Feature Details
Encoder format A, B and Index
Differential
Quadrature
Interface: RS-422
57
Input resistance:
Differential: 120 Ω
Maximum incremental encoder frequency: Maximum absolute: 5 MHz single,
20 MHz quadrature
Minimum quadrature input period (PIN) 112 nsec
Minimum quadrature input high/low period
(P
HL)
56 nsec
Minimum quadrature phase period (PPH) 28 ns
Maximum encoder input voltage range
Common mode: ±7 V
Differential mode: ±7 V
4.7.2. Feedback Supply Voltage
Feature Details
Encoder/Hall supply voltage
Maximum encoder supply current 200 mA (For the main encoder only)
5 V ±5%
4.7.3. Digital Halls
Feature Details
Halls inputs HA, HB, HC
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MAN-DCWHIIG (Ver . 1.101)
Single ended inputs
DC Whistle Installation Guide Technical Specifications
Feature Details
Built in hysteresis for noise immunity
Input voltage Nominal operating range: 0 V < VIn_Hall < 5 V
Maximum absolute: -1 V < VIn_Hall < 15 V
High level input voltage: V InHigh > 2.5 V
Low level input voltage: V InLow < 1 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)
58
Maximum frequency f
: 2 kHz
MAX
4.7.4. Interpolated Analog (Sine/Cosine) Encoder
Feature Details
Analog encoder format Sine and Cosine signals
Analog input signal level Offset voltage: 2.2 V to 2.8 V
Differential, 1 V peak to peak
Input resistance
Maximum analog signal frequency f
Interpolation multipliers Programmable: x4 to x4096
Maximum “counts” frequency 80 mega-counts/sec "internally"
Automatic errors correction
Differential 120 Ω
: 250 kHz
MAX
Signal amplitudes mismatch
Signal phase shift
Signal offsets
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Technical Specifications
4.7.5. Resolver
Feature Details
Resolver format Sine/Cosine
Differential
59
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 DC Whistle
Reference current Up to ±50 mA
4.7.6. Tachometer*
Feature Details
Tachometer format Differential
Maximum operating differential voltage for TAC1+, TAC1- ± 20 V
Maximum absolute differential input voltage for TAC1+, TAC1- ± 25 V
Maximum operating differential voltage for TAC2+, TAC2- ± 50 V
Maximum absolute differential input voltage for TAC2+, TAC2- ± 60 V
Input resistance for TAC1+, TAC1- 46 kΩ
Input resistance for TAC2+, TAC2- 100 kΩ
Resolution 14 bit
* Only one Tachometer port can be used at a time (either TAC1+/TAC1- or TAC2+/TAC2-).
TAC1+/TAC1- is used in applications with 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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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Technical Specifications
4.7.7. Potentiometer
Feature Details
Potentiometer Format Single-ended
Operating Voltage Range 0 to 5 V supplied by the DC Whistle
Potentiometer Resistance 100 Ω to 1 kΩ … above this range, linearity is
affected detrimentally
Input Resistance 100 kΩ
Resolution 14 Bit
60
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MAN-DCWHIIG (Ver . 1.101)
Low level output voltage: VOL < 0.4 V
DC Whistle Installation Guide Technical Specifications
4.7.8. Auxiliary Feedback Port (output mode YA[4]= 4)
Feature Details
Emulated output A, B, Index
Differential
61
Output current capability
Maximum output current: I
High level output voltage: V
Minimum output current: I
(max) = 2 mA
OH
> 3.0 V
OH
= 2 mA
OL
Available as options Emulated encoder outputs of analog encoder
Emulated encoder outputs of 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 27: Auxiliary Feedback - Encoder Phase Diagram
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Technical Specifications
4.7.9. Auxiliary Feedback Port (input mode YA[4]= 2, 0)
Feature Details
62
Encoder input,
pulse and direction input
A, B, Index
Differential
Output current capability VIn Low: 0 V < VIL < 0.8 V
V
High: 2 V < VIH < 5 V
In
Maximum absolute voltage: 0 < V
< 5.5 V
In
Input current: ±1 µA
Encoder/Hall supply voltage
5 V + 5%
Maximum encoder supply current 200 mA
Available as options Differential Encoder inputs
Differential 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 28: Auxiliary Feedback - Encoder Phase Diagram
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Technical Specifications
4.8. I/Os
4.8.1. Digital Input Interface – 4/6 Digital Inputs
Feature Details
Type of input Optically isolated
All inputs share one signal return line
Input current for all inputs Iin = 7.35 mA @ Vin = 24 V
Input voltage level 24 V
Note: 5 V level is also available.
Minimum pulse width > 4 x TS, where TS is sampling time
63
Execution time (all inputs):
the time from application of voltage on
input until execution is complete
High-speed inputs – 5 & 6 minimum
pulse width, in high-speed mode
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.
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 29: Digital Input Schematic (PLC)
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Technical Specifications
4.8.2. Digital Output Interface – 2 Digital Outputs
Feature Details
Type of output Optically isolated
Open collector and open emitter
Maximum supply output (VCC) 30 V
64
Max. output current
I
(max) (V
out
= Low)
out
VOL at maximum output voltage (low
(max) ≤ 10 mA
I
out
V
(on) ≤ 0.3 V
out
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 30: Digital Output Schematic
4.8.3. Analog Inputs – 1 Analog Input
Feature Details
Analog input - maximum differential
mode voltage
Analog input - maximum common
mode voltage
Input resistance
+ 20 V
+ 10 V
3.74 kΩ
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Technical Specifications
4.9. Mechanical Specifications
Feature Details
65
Mounting
mounting options:
Wall Mount, along the back (can also be
mounted horizontally on a metal surface)
Book Shelf, along the side
Overall dimensions 115 x 75 x 25.8 mm (4.53" x 2.95" x 1")
Weight 273 grams (9.6 oz.)
4.10. Environmental Conditions
Feature Details
The DC Whistle designed for two standard
Operating ambient temperature
according to IEC60068-2-2
Storage temperature
Maximum non-condensing humidity
according to IEC60068-2-78
Maximum Operating Altitude
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)
Mechanical Shock
according to IEC60068-2-27
Vibration
according to IEC60068-2-6
15g / 11ms Half Sine
5 Hz ≤ f ≤ 10 Hz: ±10mm
10 Hz ≤ f ≤ 57 Hz: 4G
57 Hz ≤ f ≤ 500 Hz:5G
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Technical Specifications
4.11. 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.)
66
UL 60950
IPC-D-275
Printed wiring for electronic equipment
(clearance, creepage, spacing, conductors
sizing, etc.)
IPC-SM-782
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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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Technical Specifications
Specification Details
EMC
Approved IEC/EN 61800-3, EMC Adjustable speed electrical power drive
systems
67
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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MAN-DCWHIIG (Ver . 1.101)
Chapter 5:
Cables (Optional)
DC Whistle Installation Guide
68
5.1. Cable Photos
Main Feedback: CBL- HDRFB-001
Auxiliary Feedback: CBL- HDRAUX-001
I/O: CBL- HDRIO-001
RS-232 Com.: CBL-RJ452321
CAN Com.: CBL-RJ45CAN1
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MAN-DCWHIIG (Ver . 1.101)
DC Whistle Installation Guide Cables (Optional)
5.2. Cable Kit
The cables are all 2 m in length. Each set contains the cables listed below. Additional cable kit
and/or individual cables (in multiples of 10 each) are available from Elmo.
Cable Application Cable Part. No. QTY
Main Feedback CBL-HDRFB-001 1
Auxiliary Feedback CBL-HDRAUX-001 1
I/O CBL-HDRIO-001 1
RS-232 Communications CBL-RJ452321 1
CAN Communications CBL-RJ45CAN1 2
69
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MAN-DCWHIIG (Ver . 1.101)
Front
DC Whistle Installation Guide Cables (Optional)
5.3. Main Feedback Cable (CBL-HDRFB-001)
The Main Feedback cable (CBL-HDRFB-001) is made of a 24-AWG shielded cable with a 12-pin
Molex Header socket. It connects to the Main Feedback port on the DC Whistle. It is open on its
other side so that it can be connected to customer-specific motor connector.
Pin Color Signal Pairs
1 Brown +5V pair
2 White COMRET
3 Cyan CHA pair
4 Orange CHA-
5 Purple CHB pair
6 Black CHB-
7 Red INDEX pair
70
8 Blue INDEX-
9 Green HA pair
10 Yellow HB
11 Pink HC pair
12 Drain wire COMRET
Front View 12 pin Molex Header Socket
View
Figure 31: Single-Sided Main Feedback Cable (Part No. CBL-HDRFB-001)
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MAN-DCWHIIG (Ver . 1.101)
Front
DC Whistle Installation Guide Cables (Optional)
5.4. Auxiliary Feedback (CBL-HDRAUX-001)
The Auxiliary Feedback cable (CBL-HDRAUX-001) is made of a 24-AWG shielded cable with a 16pin Molex Header socket. It connects to the Auxiliary Feedback port on the DC Whistle.
Pin Color Signal Pairs
1 Brown +5V pair
2 White COMRET
3 Cyan CHA pair
4 Orange CHA-
5 Purple CHB pair
6 Black CHB-
7 Red INDEX pair
8 Blue INDEX-
9 Pink CHAO pair
71
10 Grey CHAO-
11 Yellow CHBO pair
12 Green CHBO-
13 White-Red INDEXO pair
14 White-Black INDEXO-
15 White-Green +5V pair
16 White- Yellow COMRET
Front View 16 pin Molex Header Socket
View
Figure 32: Single-Sided Auxiliary Feedback Cable (Part No. CBL-HDRAUX-001)
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MAN-DCWHIIG (Ver . 1.101)
Front
DC Whistle Installation Guide Cables (Optional)
5.5. I/O (CBL-HDRIO-001)
The I/O cable (CBL-HDRIO-001) is made of a 24-AWG shielded cable with a 14-pin Molex
Header socket. It connects to the I/O port on the DC Whistle.
Pin Color Signal Pairs
1 Orange OUT1 pair
2 Cyan OUTRET1/OUTRET 1,2
3 Black OUT2 pair
4 Purple OUTRET2
5 Brown IN1 pair
6 White IN2
7 Green IN3 pair
8 Yellow IN4
9 Gray IN5 pair
72
10 Pink IN6
11 Blue INRET pair
12 Red COMRET
13 White-Black ANALIN1+ pair
14 White-Red ANALIN1-
Front View 14 pin Molex Header Socket
View
Figure 33: Single-Sided I/O Cable (Part No. CBL-HDRIO-001)
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MAN-DCWHIIG (Ver . 1.101)
1
DC Whistle Installation Guide Cables (Optional)
5.6. Communication Cables
The communication cables use 26-AWG twisted pair shielded cable. They are connected using
an 8-pin RJ-45 plug. Elmo drives can communicate using the following options:
• RS-232 full duplex
• CAN
5.6.1. RS-232 Option (CBL-RJ452321)
73
RJ-45 Pin
No.
1 — —
Color D-type Female
Pin No.
Signal Description
— —
2 — — — —
3 Brown 2
Tx
RS-232 Transmit
4 — — — —
5 White
5
COMRET Communication Return
6 Green 3 Rx RS-232 Receive
7 — —
8 — —
— —
— —
body Drain Wire body shield cable shield
Note: The shields of the RJ-45 and D-type plugs are connected to each other through the
cable braid.
Figure 34: RS-232 Communications Cable (Part No. CBL-RJ452321)
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1
DC Whistle Installation Guide Cables (Optional)
5.6.2. CAN (CBL-RJ45CAN1)
74
RJ-45 Pin
No.
1 Green 7
2 Yellow 2
3 White 3
Color D-type Female
Pin No.
Signal Description
CAN-H
CAN_L
CAN_GND
CAN_H bus line
CAN_L bus line
CAN ground
4 — — — —
5 — —
— —
7 — — — —
8 — —
— —
body Drain Wire body shield cable shield
Note: The shields of the RJ-45 and D-type plugs are connected to each other through the
cable braid.
Figure 35: CAN Cable (Part No. CBL-RJ45CAN1)
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MAN-DCWHIIG (Ver . 1.101)
Caution:
DC Whistle Installation Guide Cables (Optional)
5.7. Guidelines for Making Your Own Cables
Proper wiring, grounding and shielding are essential for ensuring safe, immune and optimal
servo performance of the DC Whistle. If you do not plan to use cables provided by Elmo, follow
the instructions below carefully.
Perform the following instructions to ensure safe and proper wiring.
1. Use twisted pair shielded cables for control, feedback and communication connections. For
best results, the cable should have an aluminum foil shield covered by a copper braid and
should contain a drain wire.
The drain wire is a non-insulated wire that is in contact with parts of the cable, usually the
shield. It is used to terminate the shield and as a grounding connection.
The impedance of the wire must be as low as possible. The size of the wire must be thicker
than actually required by the carrying current. A 24, 26 or 28 AWG wire for control and
feedback cables is satisfactory although 24 AWG is recommended.
75
Use shielded wires for motor connections as well. If the wires are long, ensure that the
capacitance between the wires is not too high: C < 30 nF is satisfactory for most
applications.
Keep all wires and cables as short as possible.
Keep the motor wires as far away as possible from the feedback, control and communication
cables.
Ensure that in normal operating conditions, the shielded wires and drain carry no current. The
only time these conductors carry current is under abnormal conditions, when electrical
equipment has become a potential shock or fire hazard while conducting external EMI
interferences directly to ground, in order to prevent them from affecting the drive. Failing
to meet this requirement can result in drive/controller/host failure.
After completing the wiring, carefully inspect all wires to ensure tightness, good solder joints
and general safety.
5.7.1. Recommended Wire Cross Sections
Function Connection Details
Motor PE, M1, M2, M3 14 AWG
Feedback and Control Main Feedback Auxiliary
Feedback I/O
24 AWG twisted pair shielded
cables
Communications RS-232 CAN 26 AWG twisted pair shielded
cables
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