Whistle/Tweeter Digital Servo Drives Installation Guide July 2010 (Ver. 1.5) www.elmomc.
Notice This guide is delivered subject to the following conditions and restrictions: This guide contains proprietary information belonging to Elmo Motion Control Ltd. Such information is supplied solely for the purpose of assisting users of the Whistle and Tweeter servo drives in their installation. The text and graphics included in this manual are for the purpose of illustration and reference only. The specifications on which they are based are subject to change without notice.
Revision History: Ver. 1.5 July 2010 MTCR 03-010-02: Updated: Sections 3.4, A.1.8; Figure 3-29 Ver. 1.4 March 2010 MTCR 01-010-01: Figure 3-18 updated Ver. 1.3 March 2009 MTCR 01-009-38: Note added to 3.8.3; Figure 3-7 updated Ver. 1.2 April 2008 Updated Power Ratings Table in Appendix Ver. 1.1 May 2007 Added WHI-15/60, WHI-10/100 and WHI-15/100 Ver. 1.02 Oct. 2006 Correction to Interpolated Analog Encoders Ver. 1.01 July 2006 Correction to PT & PVT in standard models Ver. 1.
Whistle/Tweeter Installation Guide MAN-WHTWIG (Ver. 1.5) Contents Chapter 1: Safety Information .........................................................................................1-1 1.1 Warnings ..............................................................................................................1-2 1.2 Cautions ................................................................................................................1-2 1.3 Directives and Standards .....................................
Whistle/Tweeter Installation Guide Contents MAN-WHTWIG (Ver. 1.5) 3.10.3 Auxiliary Feedback: Single-Ended Encoder Input Option (YA[4]=2)3-22 3.10.4 Auxiliary Feedback: Pulse-and-Direction Input Option (YA[4]=0) ... 3-24 3.11 I/Os .....................................................................................................................3-26 3.11.1 Digital Input............................................................................................... 3-26 3.11.2 Digital Output ..............
Whistle/Tweeter Installation Guide Contents MAN-WHTWIG (Ver. 1.5) A.6.2.5 Tachometer* ......................................................................................... A-11 A.6.2.6 Potentiometer ....................................................................................... A-11 A.6.3 Auxiliary Feedback Port (output mode YA[4]= 4) .............................. A-12 A.6.4 Auxiliary Feedback Port (input mode YA[4]= 2, 0) ............................ A-12 A.7 I/Os .........................
Whistle/Tweeter Installation Guide MAN-WHTWIG (Ver. 1.5) Chapter 1: Safety Information In order to achieve the optimum, safe operation of the Whistle and Tweeter servo drives, it is imperative that you implement the safety procedures included in this installation guide. This information is provided to protect you and to keep your work area safe when operating the Whistle and Tweeter as well as the accompanying equipment. Please read this chapter carefully before you begin the installation process.
Whistle/Tweeter Installation Guide Safety Information MAN-WHTWIG (Ver. 1.5) 1.1 Warnings Cleaning after soldering To avoid the damage of the product's acrylic coating the Whistle/Tweeter must not be cleaned after soldering by dissolving solvents and /or "water" cleaning process. For more details: http://www.elmomc.com/applications/article/Soldering-andCleaning_Application-Note.
Whistle/Tweeter Installation Guide Safety Information MAN-WHTWIG (Ver. 1.5) 1.
Whistle/Tweeter Installation Guide Introduction MAN-WHTWIG (Ver. 1.5) Chapter 2: Introduction This installation guide describes the Whistle and Tweeter servo drives and the steps for its wiring, installation and power-up. Following these guidelines ensures maximum functionality of the drive and the system to which it is connected. 2.1 Drive Description The Whistle and Tweeter series of digital servo drives are designed to deliver “the highest density of power and intelligence”.
Whistle/Tweeter Installation Guide Introduction MAN-WHTWIG (Ver. 1.5) The Whistle and Tweeter are available in two models: The Standard models are basic servo drives which operate in current, velocity and position modes include PT & PVT. They operate simultaneously via RS-232 and CANopen DS 301, DS 305, DS 402 communications and feature a third-generation programming environment.
Whistle/Tweeter Installation Guide Introduction MAN-WHTWIG (Ver. 1.5) 2.2.5 Communication Options Whistle and Tweeter users can use two communication options: • RS-232 serial communication • CANopen for fast communication in a multi-axis distributed environment 2.2.
Whistle/Tweeter Installation Guide Introduction MAN-WHTWIG (Ver. 1.5) 2.3 System Architecture Communication RS 232 and CANopen Analog Encoder or Resolver I/Os or Main 12~95 VDC Power Supply Incremental Encoder Controller Optional 12~95 VDC Auxiliary Supply Auxiliary Encoder Protection PWM Current Feedback Power Stage Motor Figure 2-1: Whistle/Tweeter System Block Diagram 2.
Whistle/Tweeter Installation Guide Introduction MAN-WHTWIG (Ver. 1.5) Networking Programming Maestro Software Manual Maestro Installation Guide CANopen Implementation Guide SimplIQ Software Manual SimplIQ Command Reference Manual Composer User Manual Setup Installation Whistle Installation Guide Whistle Eval.
Whistle/Tweeter Installation Guide 3-1 MAN-WHTWIG (Ver. 1.5) Chapter 3: Installation 3.1 Site Requirements You can guarantee the safe operation of the Whistle and Tweeter by ensuring that they are installed in an appropriate environment. Feature Value Ambient operating temperature 0 °C to 40 °C (32 °F to 104 °F) Maximum relative humidity 90% non-condensing Operating area atmosphere No flammable gases or vapors permitted in area Models for extended environmental conditions are available.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.3.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.3.3 Connector J2 Pin Signal Function J2/1 +5V Encoder/Hall +5V supply voltage. Maximum output current: 200mA.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) Figure 3-1: The Whistle Footprint When the Whistle is not connected to a metal chassis, the application’s thermal profile may require a solution for heat dissipation due to insufficient air convection. In this case, we recommend that you connect an external heatsink. Elmo has an external heatsink (Catalog number: WHI-HEATSINK-2) that can be ordered for this purpose – see below. Figure 3-2: Whistle External Heatsink 3.4.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.5 3-6 Integrating the Whistle or Tweeter on a PCB The Whistle and Tweeter are designed to be mounted on a PCB, either by soldering its pins directly to the PCB or by using suitable socket connectors. In both cases the following rules apply: 3.5.1 Traces 1. The size of the traces on the PCB (thickness and width) is determined by the current carrying capacity required by the application.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.5.2 3-7 Grounds and Returns The “Returns” of the Whistle and Tweeter are structured internally in a star configuration. The returns in each functional block are listed below: Functional Block Return Pin Power PR (Power Return) Internal Switch Mode P.S.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3-8 7. Under normal operating conditions, the PE trace carries no current. The only time these traces carry current is under abnormal conditions (such as when the device has become a potential shock or fire hazard while conducting external EMI interferences directly to ground). When connected properly the PE trace prevents these hazards from affecting the drive. Follow these instructions to ensure safe and proper implementation.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.7 Main Power and Motor Power Pin Function Cable VP+ Pos. Power input Power PR Power return Power PE Protective earth Power Pin Positions AC Motor DC Motor Motor Motor M1 Motor phase Motor N/C M2 Motor phase Motor Motor M3 Motor phase Motor Motor PE 3-10 Protective earth When connecting several drives to several motors, all should be wired in the same motor phases and feedback sequences.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.7.2 Connecting Main Power Connect the VP+, PR and PE pins on the Whistle and Tweeter in the manner described in section 3.5 (Integrating the Whistle and Tweeter on a PCB). The source of the 12 ~ 95 VDC Main Power Supply must be isolated. Figure 3-5: Main Power Supply Connection Diagram 3.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3-12 3.8.1 Single Supply A single isolated DC power supply can provide power for both the main power and the Auxiliary (Drive Logic) Supply. The drawing below shows how a single supply is connected. Figure 3-6: Single Supply for both the Main Power Supply and the Auxiliary Supply 3.8.2 Separate Auxiliary Supply Power to the Auxiliary Supply can be provided by a separate Auxiliary Supply.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.8.3 Shared Supply A "Main" DC Power Supply can be designed to supply power to the drive's Logic as well as to the Main Power (see Figure 3-6). If backup functionality is required (for storing control parameters in case of power-outs) an additional backup supply can be connected by implementing 'diode coupling' (see the Aux. Backup Supply in Figure 3-8).
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.9 3-14 Main Feedback The Main Feedback port is used to transfer feedback data from the motor to the drive. In order to copy the setup to other drives, the phase order on all copy drives must be the same.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3-18 Figure 3-15: Main Feedback – Potentiometer Feedback Connection Diagram for Brush Motors and Voice Coils 3.10 Auxiliary Feedback For auxiliary feedback, select one of the following options: a. Single-ended emulated encoder outputs, used to provide emulated encoder signals to another controller or drive. The Emulated Encoder Output Option is only available when using a Resolver or Analog Encoder as the main feedback device.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3-19 3.10.1 Main and Auxiliary Feedback Combinations The Main Feedback is always used in motion control devices whereas Auxiliary Feedback is often, but not always used. The Auxiliary Feedback connector on the Whistle and Tweeter has three bi-directional pins (CHA, CHB and INDEX). When used in combination with Main Feedback, the Auxiliary Feedback can be set, by software, as follows: Auxiliary Feedback Main Feedback YA[4] = 4 (Aux.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.10.2 Auxiliary Feedback: Emulated Encoder Output Option (YA[4]=4) Pin Signal Function J1/4 SUPRET Supply return J1/19 INDEX+ Index output J1/18 CHBO Channel B output J1/5 CHAO Channel A output Pin Position Note: The Emulated Encoder Output Option is only available when using a Resolver or Analog Encoder as the main feedback device. Note: The Whistle and Tweeter's Auxiliary Feedback is single-ended.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.10.3 Auxiliary Feedback: Single-Ended Encoder Input Option (YA[4]=2) Pin Signal Function J1/4 SUPRET Supply return J1/19 INDEX Auxiliary index input J1/18 CHB Auxiliary channel B input J1/5 CHA Auxiliary channel A input Pin Position Note: The Whistle and Tweeter's Auxiliary Feedback is single-ended. When mounted on an integration board, circuitry can be added to make it differential.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.10.4 Auxiliary Feedback: Pulse-and-Direction Input Option (YA[4]=0) Pin Signal Function J1/4 SUPRET Supply return J1/18 DIR/CHB Direction input (push/pull 5 V or open collector) J1/5 PULS/CHA Pulse input (push/pull 5 V or open collector) Pin Position Note: The Whistle and Tweeter's Auxiliary Feedback is single-ended. When mounted on an integration board, circuitry can be added to make it differential.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.11 I/Os The Whistle and Tweeter have 6 Digital Inputs, 2 Digital Outputs and 1 Analog Input. I/O J1 J2 Total Digital Input 6 - 6 Digital Output 2 - 2 Analog Input - 1 1 3.11.1 Digital Input Each of the pins below can function as an independent input.
Whistle/Tweeter Installation Guide MAN-WHTWIG (Ver. 1.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.11.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.11.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.12 3-30 Communications The communication interface may differ according to the user’s hardware. The Whistle and Tweeter can communicate using the following options: a. RS-232, full duplex b. CANopen RS-232 communication requires a standard, commercial 3-core null-modem cable connected from the Whistle or Tweeter to a serial interface on the PC. The interface is selected and set up in the Composer software.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3-31 Figure 3-28: RS-232 Connection Diagram 3.12.2 CANopen Communication Notes for connecting the CANopen communication cable: Connect the shield to the ground of the host (PC). Usually, this connection is soldered internally inside the connector at the PC end. You can use the drain wire to facilitate connection. Ensure that the shield of the cable is connected to the shield of the connector used for communications.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) Figure 3-29: CANopen Network Diagram Caution: When installing CANopen communication, ensure that each servo drive is allocated a unique ID. Otherwise, the CANopen network may hang.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) 3.13 Powering Up After the Whistle or Tweeter is connected to its device, it is ready to be powered up. Caution: Before applying power, ensure that the DC supply is within the specified range and that the proper plus-minus connections are in order. 3.14 Initializing the System After the Whistle/Tweeter have been connected and mounted, the system must be set up and initialized.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) Whistle - 60 Series Power Dissipation 50V 40V 30V 20V 10.0 Power Dissipation (Watts 9.0 8.0 7.0 External Heatsink Required 6.0 5.0 Standard 40 °C Ambient Temp. 4.0 3.0 Heatsink not Required 2.0 1.0 0.0 0. 75 0 1. 5 2. 25 3 3. 75 4. 5 5. 25 6. 75 6 7. 5 8. 25 9. 75 9 Peak Current (A) Whistle 100 Series Power Dissipation External Heatsink Required Power Dissipation (W) 6.0 5.0 Standard 40 °C Ambient Temp. 4.
Whistle/Tweeter Installation Guide Installation MAN-WHTWIG (Ver. 1.5) • 3-35 for an ambient temperature of 40 °C , ΔT= 80°C – 40 °C = 40 °C 4. Use the chart to find the actual dissipation power of the drive. Follow the voltage curve to the desired output current and then find the dissipated power. 5. If the dissipated power is below 4 W the Whistle will need no additional cooling. Notes: 1.
Whistle/Tweeter Installation Guide A-1 MAN-WHTWIG (Ver. 1.5) Appendix: Whistle and Tweeter Technical Specifications A.1 Features A.1.1 Motion Control Modes • Current/Torque • Velocity • Position - A.1.2 up to 3.5 kHz sampling rate PTP, PT, PVT, ECAM, Follower, Dual Loop, Current Follower Fast event capturing inputs Fast output compare (OC) Motion Commands: Analog current and velocity, PWM current and velocity, digital (SW) and Pulse and Direction Advanced Filters and Gain Scheduling • • • • A.1.
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications MAN-WHTWIG (Ver. 1.5) A-2 • Provide power (5 V, 200 mA max) for one Encoder, Resolver or Hall. A.1.6 Input/Output • One Analog Input – up to 14-bit resolution • Six programmable Digital Inputs, optically isolated (two of which are fast event capture inputs).
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications MAN-WHTWIG (Ver. 1.5) A.1.9 • Status Indication Output for a bi-color LED A.1.10 Automatic Procedures • Commutation alignment • Phase sequencing • Current loop offset adjustment • Current loop gain tuning • Current gain scheduling • Velocity loop offset adjustment • Velocity gain tuning • Velocity gain scheduling • Position gain tuning A.2 Dimensions A.2.
Whistle/Tweeter Installation Guide MAN-WHTWIG (Ver. 1.5) A.2.
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications A-5 MAN-WHTWIG (Ver. 1.5) A.3 Power Ratings Units Minimum supply voltage VDC 6 7.5 12 Nominal supply voltage VDC 42 50 85 Maximum supply voltage VDC 48 59 95 Maximum continuous power output W 600 800 50 120 240 480 720 960 Efficiency at rated power (at nominal conditions) % 200 400 VDC 11 – 95 VDC (up to 2.5 VA inc.
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications MAN-WHTWIG (Ver. 1.5) A.3.2 Tweeter Feature Units 3/60 2.5/100 Minimum supply voltage VDC 7.5 12 Nominal supply voltage VDC 50 85 Maximum supply voltage VDC 59 95 Maximum continuous power output W 160 200 Efficiency at rated power (at nominal conditions) % Maximum output voltage > 99 > 95% of DC bus voltage at f=22 kHz Auxiliary power supply VDC Amplitude sinusoidal/ DC continuous current A 3.
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications MAN-WHTWIG (Ver. 1.5) A.4 Environmental Conditions Feature Details Ambient operating temperature 0 °C ~ 40 °C (32 °F ~ 104 °F) Storage temperature -20 °C ~ +85° C ( -4 °F ~ +185 °F) Maximum humidity 90% non-condensing Maximum operating altitude Up to 10,000 m (30,000 ft) Protection level IP20 A.4.
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications MAN-WHTWIG (Ver. 1.5) A.5.
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications MAN-WHTWIG (Ver. 1.5) A.6 Feedbacks A.6.1 Feedback Supply Voltage The Whistle and Tweeter have two feedback ports (Main and Auxiliary). The drives supply voltage only to the main feedback device. The user must provide a separate power supply for auxiliary feedback devices if needed. Feature Details Main encoder supply voltage 5 V +5% @ 200 mA maximum A.6.2 Main Feedback Options A.6.2.
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications MAN-WHTWIG (Ver. 1.5) A.6.2.2 Digital Halls Feature Details Halls inputs H A , H B, H C . Single ended inputs Built in hysteresis of 1 V 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.
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications MAN-WHTWIG (Ver. 1.5) Feature Details Resolver transfer ratio 0.5 Reference frequency 1/Ts (Ts = sample time in seconds) Reference voltage Supplied by the Whistle and Tweeter Reference current Up to ±50 mA Encoder outputs See Auxiliary Encoder Output specifications (A.6.3) A-11 A.6.2.
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications MAN-WHTWIG (Ver. 1.5) A.6.3 Auxiliary Feedback Port (output mode YA[4]= 4) Feature Details Emulated output Output current capability Available as options A, B, Index Single ended Maximum output current: IOH (max) = 2 mA High level output voltage: VOH > 3.0 V Minimum output current: IOL = 2 mA Low level output voltage:VOL < 0.
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications MAN-WHTWIG (Ver. 1.
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications A-14 MAN-WHTWIG (Ver. 1.5) A.7 I/Os The Whistle and Tweeter have: A.7.1 6 Digital Inputs 2 Digital Outputs 1 Analog Input Digital Input Interfaces Feature Details Type of input Input current for all inputs Iin = 2.4 mA @ Vin = 5 V High-level input voltage 2.
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications MAN-WHTWIG (Ver. 1.5) A.7.2 Digital Output Interface Feature Details Type of output Optically isolated Open collector and open emitter Maximum supply output (Vcc) 30 V Max. output current Iout (max) (Vout = Low) Iout (max) ≤ 10 mA VOL at maximum output voltage (low level) Vout (on) ≤ 0.3 V RL External resistor RL must be selected to limit output current to no more than 10 mA.
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications MAN-WHTWIG (Ver. 1.5) A-16 A.8 Communications Specification Details RS-232 Signals: RxD , TxD , Gnd Full duplex, serial communication for setup and control. Baud Rate of 9,600 ~ 57,600 bit/sec. CANbus Signals: CAN_H, CAN_L, CAN_GND Maximum Baud Rate of 1 Mbit/sec. CANopen Version: DS 301 V4.01 Layer Setting Service and Protocol Support: DS 305 Device Profile (drive and motion control): DS 402 A.
Whistle/Tweeter Installation Guide Whistle and Tweeter Technical Specifications MAN-WHTWIG (Ver. 1.5) A-17 A.10.3 Safety Specification Description In compliance with UL508c Power conversion equipment In compliance with UL840 Insulation coordination, including clearance and creepage distances of electrical equipment In compliance with UL60950 Safety of information technology equipment, including electrical business equipment In compliance with EN60204-1 Low voltage directive, 72/23/EEC A.10.
Whistle/Tweeter Installation Guide I-1 MAN-WHTWIG (Ver. 1.
Whistle/Tweeter Installation Guide Index MAN-WHTWIG (Ver. 1.
