ElmoMC SimplIQ Digital Servo Drives-Whistle DC Installation Guide

DC Whistle

Digital Servo Drive

Installation Guide

July 2014 (Ver. 1.101)

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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

Elmo Worldwide

Head Office

Elmo Motion Control Ltd.

60 Amal St., P.O. Box 3078, Petach Tikva 49516
Israel

Tel: [phone] • Fax: [phone] • [e-mail]

North America

Elmo Motion Control Inc.

42 Technology Way, Nashua, NH 03060
USA

Tel: [phone] • Fax: [phone] • [e-mail]

Europe

Elmo Motion Control GmbH

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

Tel: [phone] • Fax: [phone] • [e-mail]

China

Elmo Motion Control Technology (Shanghai) Co. Ltd.

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

Tel: [phone] • Fax: [phone] • [e-mail]

Asia Pacific

Elmo Motion Control APAC Ltd.

B-601 Pangyo Innovalley, 621 Sampyeong-dong, Bundang-gu, Seongnam-si, Gyeonggi-do,
South Korea (463-400)

Tel: [phone] • Fax: [phone] • [e-mail]

MAN-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

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

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

6

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

18

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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