Duo Integrated Solution Installation Guide June 2007 (Ver. 1.
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 Duo 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.
Duo Installation Guide MAN-DUOIG (Ver. 1.0) i Contents Chapter 1: Safety Information .......................................................................................... 1-1 1.1 Warnings ............................................................................................................. 1-2 1.2 Cautions............................................................................................................... 1-2 1.3 Directives and Standards...............................................
Duo Installation Guide Contents MAN-DUOIG (Ver. 1.0) 3.11.2 Digital Output....................................................................................................... 3-29 3.11.3 Analog Input ......................................................................................................... 3-29 3.12 Communications............................................................................................... 3-30 3.12.1 RS232 Communication............................................
Duo Installation Guide Contents MAN-DUOIG (Ver. 1.0) B.5 I/O (CBL-HDRIO-001)....................................................................................... B-5 B.6 Communication Cables...................................................................................... B-6 B.6.1 RS-232 Option (CBL-RJ452321)............................................................................. B-6 B.6.2 CAN Open (CBL-RJ45CAN1) .............................................................................
Duo Installation Guide MAN-DUOIG (Ver. 1.0) Chapter 1: Safety Information In order to achieve the optimum, safe operation of the Duo, 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 Duo and accompanying equipment. Please read this chapter carefully before you begin the installation process.
Duo Installation Guide Safety Information MAN-DUOIG (Ver. 1.0) 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 Duo from all voltage sources before it is opened for servicing. The Duo contains grounding conduits for electric current protection.
Duo Installation Guide Safety Information MAN-DUOIG (Ver. 1.0) 1.
Duo Installation Guide Introduction MAN-DUOIG (Ver. 1.0) Chapter 2: Introduction This installation guide describes the Duo 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 Duo series of servo drives enhances Elmo’s range of digital servo drives, recognized for having the highest power density and intelligence.
Duo Installation Guide Introduction MAN-DUOIG (Ver. 1.0) 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.
Duo Installation Guide Introduction MAN-DUOIG (Ver. 1.
Duo Installation Guide Introduction MAN-DUOIG (Ver. 1.
Duo User Guide 3-1 MAN-DUOUG (Ver. 1.0) Chapter 3: Installation 3.1 Site Requirements You can guarantee the safe operation of the Duo by ensuring that it is installed in an appropriate environment. Feature Value Ambient operating temperature 0° to 40°C (32° to 104°F) Maximum operating altitude 10,000m (30,000ft) Maximum relative humidity 90% non-condensing Operating area atmosphere No flammable gases or vapors permitted in area Models for extended environmental conditions are available.
Duo User Guide 3-2 MAN-DUOUG (Ver. 1.
Duo User Guide 3-3 MAN-DUOUG (Ver. 1.0) 3.4 Connecting the Cables 3.4.1 Wiring the Duo Once the Duo 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 Duo. Follow these instructions to ensure safe and proper wiring Use twisted pair shielded cables for control, Feedback and communication connections.
Duo User Guide 3-4 MAN-DUOUG (Ver. 1.
Duo User Guide 3-5 MAN-DUOUG (Ver. 1.0) 3.5 Duo Connectors type Type Qty Conn. 1 Main Power On Board Connector Phoenix 5-pin Header P/N:MSTBA 2.5HC/5-G Motor Power 2 Main Feedback 2 I/O 2 Auxiliary Feedback 2 CANopen Comm. 2 8-pin RJ-45 Socket RS232 Comm. 2 8-pin RJ-45 Socket Phoenix 4-pin Header P/N:MSTBA 2.5/4G-5.
Duo User Guide 3-6 MAN-DUOUG (Ver. 1.0) 3.6 Hardware Requirements The components that you will need to install your Duo are: Component Main Power Motor Power Main Feedback I/O Qty Conn. Mating Connector 1 Phoenix 5-pin Plug P/N:MSTBT 2.5HC/5-ST 2 2 Phoenix 4-pin Plug P/N:MSTBT 2.5/4-ST-5.08 12-pin Molex Plug P/N:90142-0012 Function Described in section VL, VP+, PR, PR, PE PE VL 2 PE Feedback B.3 I/O B.
Duo User Guide 3-7 MAN-DUOUG (Ver. 1.0) 3.
Duo User Guide 3-8 MAN-DUOUG (Ver. 1.0) 3.8 The Main Power and Motor Power Connectors Pin Function Cable PE Protective earth Power PR Power return Power PR Aux. Supply Input Return VP+ Pos. Power input VL Aux. Supply Input Auxiliary Power Auxiliary AC Motor Cable DC Motor Cable M3 Motor phase Motor Motor M2 Motor phase Motor Motor M1 Motor phase Motor N/C PE Motor Motor Protective earth Pin Positions Table 3-6: Connectors for Main Power and Motors 3.8.
Duo User Guide 3-9 MAN-DUOUG (Ver. 1.0) 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: The source of the 0 ~ 95 VDC Power Supply must be isolated. 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.
Duo User Guide 3-10 MAN-DUOUG (Ver. 1.0) 3.8.3 Low power Auxiliary Supply (optional) Notes for 12 ~ 95 VDC Auxiliary Supply connections: The source of the 12 ~ 95 VDC Auxiliary Supply must be isolated from the Main. For safety reasons, connect the return (common) of the Auxiliary Supply source to the closest ground near the Auxiliary Supply source. Connect the cable shield to the closest ground near the Auxiliary Supply source. Before applying power, first verify the polarity of the connection.
Duo User Guide 3-11 MAN-DUOUG (Ver. 1.
Duo User Guide 3-12 MAN-DUOUG (Ver. 1.0) 3.9 Main Feedback The Main Feedback port is used to transfer Feedback data from the motor to the drive. The Duo accepts the following as a Main Feedback mechanism: Incremental encoder only Incremental encoder with digital hall sensors Digital hall sensors only Incremental analog (sine/cosine) encoder (option) Resolver (option) Tachometer and potentiometer (option) Analog Halls The Main Feedback port on the Duo has a 12-pin Molex Header plug.
Duo User Guide MAN-DUOUG (Ver. 1.
Duo User Guide 3-14 MAN-DUOUG (Ver. 1.
Duo User Guide MAN-DUOUG (Ver. 1.
Duo User Guide MAN-DUOUG (Ver. 1.
Duo User Guide MAN-DUOUG (Ver. 1.0) 3.10 3-17 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.
Duo User Guide 3-18 MAN-DUOUG (Ver. 1.0) 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: Auxiliary Feedback: Output YA[4] = 4 Main Feedback (Auxiliary Feedback: output) Incremental Encoder Input N.
Duo User Guide 3-19 MAN-DUOUG (Ver. 1.
Duo User Guide 3-20 MAN-DUOUG (Ver. 1.0) 3.10.2 Auxiliary Feedback – Emulated, Differential Buffered Encoder Output Option (YA[4]=4) 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 Whistle is used as a current amplifier to provide position data to the position controller.
Duo User Guide MAN-DUOUG (Ver. 1.
Duo User Guide 3-22 MAN-DUOUG (Ver. 1.0) 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.
Duo User Guide 3-23 MAN-DUOUG (Ver. 1.
Duo User Guide MAN-DUOUG (Ver. 1.
Duo User Guide 3-25 MAN-DUOUG (Ver. 1.0) 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.
Duo User Guide MAN-DUOUG (Ver. 1.
Duo User Guide 3-27 MAN-DUOUG (Ver. 1.0) 3.11 I/O Each Whistle on the Duo 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.
Duo User Guide 3-28 MAN-DUOUG (Ver. 1.0) 3.11.1 Digital Input The Default Digital Input level Signal is set to 24v (PLC). Note: 5v is also available (TTL).
Duo User Guide 3-29 MAN-DUOUG (Ver. 1.0) 3.11.2 Digital Output Figure 3-19: Digital Output Connection Diagram 3.11.
Duo User Guide 3-30 MAN-DUOUG (Ver. 1.0) 3.12 Communications The communication cables use an 8-pin RJ-45 plug that connect to the RS232 and CANopen ports on the Duo. The communication interface may differ according to the user’s hardware. The Duo can communicate using the following options: 1. RS232, full duplex 2. CANopen RS232 communication requires a standard, commercial 3-core null-modem cable connected from the Duo to a serial interface on the PC.
Duo User Guide 3-31 MAN-DUOUG (Ver. 1.0) Figure 3-21: RS232 Connection Diagram 3.12.2 CANopen Communication Notes for connecting the CANopen communication cable: 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 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.
Duo User Guide 3-32 MAN-DUOUG (Ver. 1.0) Caution: Figure 3-22: CANopen Network Connection Diagram When installing CANopen communications, ensure that each servo drive is allocated a unique ID. Otherwise, the CANopen network may hang.
Duo User Guide MAN-DUOUG (Ver. 1.0) 3-33 3.13 Powering Up After the cables have been connected to their devices, the Duo 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 Duo 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.
Duo Installation Guide Appendix A: Technical Specifications A.
Duo Installation Guide MAN-DUOIG (Ver. 1.
Duo Installation Guide MAN-DUOIG (Ver. 1.0) A.
Duo Installation Guide MAN-DUOIG (Ver. 1.0) A.
Duo Installation Guide A-5 MAN-DUOIG (Ver. 1.0) A.4 Power Ratings Unit Minimum supply voltage VDC 8.5 12 Nominal supply voltage VDC 48 85 Maximum supply voltage VDC 59 95 Max. output power from the drive without heatsink W Efficiency at rate power % > 99 Output Voltage % > 95% of supply VDC at f=22 KHz DC and Trapezoidal Commutation Continuous Current Limit (Ic) Sinusoidal Commutation Continuous RMS Current Limit (Ic) Peak current limit (RMS) PWM Switching Frequency 1/60 50 2.
Duo Installation Guide A-6 MAN-DUOIG (Ver. 1.0) A.5 Control Specifications A.5.
Duo Installation Guide A-7 MAN-DUOIG (Ver. 1.0) A.5.
Duo Installation Guide A-8 MAN-DUOIG (Ver. 1.0) A.6 Feedbacks A.6.
Duo Installation Guide A-9 MAN-DUOIG (Ver. 1.0) A.6.3 Digital Halls Feature Details Halls inputs HA, HB, HC. Single ended inputs Built in hysteresis for noise immunity. Input voltage Nominal operating range: 0V < VIn_Hall < 5V Maximum absolute: -1V < VIn_Hall < 15V High level input voltage: V InHigh > 2.5V Low level input voltage: V InLow < 1V Input current Sink current (when input pulled to the common): 3ma Source current: 1.
Duo Installation Guide A-10 MAN-DUOIG (Ver. 1.0) A.6.5 Resolver Feature Details Resolver format Sine/Cosine Differential Input resistance Differential 2.49 KΩ Resolution Programmable: 10 ~ 15 bits Maximum electrical frequency (RPS) 512 revolutions/sec Resolver transfer ratio 0.5 Reference frequency 1/Ts (Ts = sample time in seconds) Reference voltage Supplied by the Whistle Reference current Up to ±50 mA A.6.
Duo Installation Guide A-11 MAN-DUOIG (Ver. 1.0) A.6.7 Potentiometer Feature Details Potentiometer Format Single-ended Operating Voltage Range 0 ~ 5V supplied by the Whistle Potentiometer Resistance 100Ω ~ 1 KΩ … above this range, linearity is affected detrimentally Input Resistance 100KΩ Resolution 14 Bit A.6.
Duo Installation Guide A-12 MAN-DUOIG (Ver. 1.0) A.6.9 Auxiliary Feedback Port (input mode YA[4]= 2, 0) Feature Details Encoder input, pulse and direction input A, B, Index Differential Output current capability VIn Low: 0V < VIL < 0.8V VIn High: 2V < VIH < 5V Maximum absolute voltage: 0 < VIn < 5.
Duo Installation Guide A-13 MAN-DUOIG (Ver. 1.0) A.7 I/Os A.7.1 Digital Input Interface – 6 Digital Inputs Feature Details Type of input Input current for all inputs Iin = 6.
Duo Installation Guide A-14 MAN-DUOIG (Ver. 1.0) A.7.2 Digital Output Interface – 2 Digital Outputs Feature Details Type of output Optically isolated Open collector and open emitter Maximum supply output (Vcc) 30 V 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.
Duo Installation Guide A-15 MAN-DUOIG (Ver. 1.0) A.8 Mechanical Specifications Feature Mounting Details The Duo designed for two standard mounting options: Overall dimensions “Wall Mount” along the back (can also be mounted horizontally on a metal surface) “Book Shelf” along the side 150 X 105 X 25.4 (5.9 X 4.13 X 1 in) ~ 450 grams Weight A.
Duo Installation Guide A-16 MAN-DUOIG (Ver. 1.0) A.10.2 Safety Specification Details Recognized 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, 73/23/EEC A.10.
Duo Installation Guide B-1 Appendix B: Cables (Optional) B.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.
Duo Installation Guide B-2 MAN-DUO (Ver. 1.0) B.2 Cable Kit The cables are all 2m 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.
Duo Installation Guide B-3 MAN-DUO (Ver. 1.0) B.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 Duo. It is open on its other side so that it can be connected to customer-specific motor connector. Pin No.
Duo Installation Guide B-4 MAN-DUO (Ver. 1.0) B.4 Auxiliary Feedback (CBL-HDRAUX-001) The Auxiliary Feedback cable (CBL-HDRAUX-001) is made of a 24-AWG shielded cable with a 16-pin Molex Header socket. It connects to the Auxiliary Feedback port on the Duo. Pin No.
Duo Installation Guide B-5 MAN-DUO (Ver. 1.0) B.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 Duo. Pin No.
Duo Installation Guide B-6 MAN-DUO (Ver. 1.0) B.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 CANopen B.6.1 RS-232 Option (CBL-RJ452321) RJ45 Pin No. D-type Female Pin No.
Duo Installation Guide B-7 MAN-DUO (Ver. 1.0) B.6.2 RJ45 Pin No. CAN Open (CBL-RJ45CAN1) Color D-type Female Pin No. Signal Description 1 Green 7 CAN-H CAN_H bus line 2 Yellow 2 CAN_L CAN_L bus line 3 White 3 CAN_GND CAN ground 4 — — — — 5 — — — — 7 — — — — 8 — — — — body Drain Wire body shield 1 cable shield The shields of the RJ-45 and D-type plugs are connected to each other through the cable braid. Figure A-5: CAN Cable (Part No.
Duo Installation Guide B-8 MAN-DUO (Ver. 1.0) B.7 Guidelines for Making Your Own Cables Proper wiring, grounding and shielding are essential for ensuring safe, immune and optimal servo performance of the Duo. If you do not plan to use cables provided by Elmo, follow the instructions below carefully. Follow these instructions to ensure safe and proper wiring: Use twisted pair shielded cables for control, feedback and communication connections.
