Gold Duo Digital Servo Drive Installation Guide EtherCAT July 2014 (Ver. 1.500) 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 Gold 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.
Cable Kit Catalog number: CBL-GDUOKIT01 (can be ordered separately) For further details, see the MAN-G-DUO-CBLKIT documentation for this cable kit. Revision History Version Date Details Ver. 1.
Table of Contents MAN-G-DUOIG-E (Ver. 1.500) Chapter 1: This Installation Guide .................................................................................6 Chapter 2: Safety Information ......................................................................................6 2.1. 2.2. 2.3. 2.4. Warnings .................................................................................................................... 7 Cautions ....................................................................
6.6.1. 6.6.2. 6.6.3. Incremental Encoder .................................................................................36 Halls Sensor ...............................................................................................36 Absolute Serial Encoder.............................................................................37 6.6.3.1. Hiperface ..................................................................................38 6.7. Feedback Port B Per Axis ...................................
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6 Chapter 1: This I nstallation Guide This installation Guide details the technical data, pinouts, and power connectivity of the Gold Duo. For a comprehensive detailed description of the functions refer to the MAN-G-Panel Mounted Drives Hardware manual which describes Panel Mounted products.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 2.1. 7 Warnings • To avoid electric arcing and hazards to personnel and electrical contacts, never connect/disconnect the servo drive while the power source is on. • Power cables can carry a high voltage, even when the motor is not in motion. Disconnect the Gold Duo from all voltage sources before servicing. • The high voltage products within the Gold Line range contain grounding conduits for electric current protection.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 8 Chapter 3: Product Description The Gold Duo is an advanced high power density servo drive delivering up to 1.6 kW of continuous power or 3.2 kW of peak power per axis in a 394 cc (24.0 in³) package (150 x 105 x 25.8 mm or 5.9" x 4.1" x 1.0"). The Gold Duo is a highly compact integrated solution containing two drives in a single package. The solution operates under a single power supply and is designed for applications with up to two axes.
Gold Duo Installation Guide 9 MAN-G-DUOIG-E (Ver. 1.500) Chapter 4: Technical I nform ation 4.1. Physical Specifications Feature Weight Dimensions Units All Types g (oz) 479 g (16.9 oz) mm (in) 150 x 105 x 25.8 mm (5.9" x 4.13" x 98") Mounting method Wall Mount / Book Shelf 4.2.
Gold Duo Installation Guide 10 MAN-G-DUOIG-E (Ver. 1.
Gold Duo Installation Guide 11 MAN-G-DUOIG-E (Ver. 1.500) 4.2.2. Product Features Per Axis Main Feature Details Presence and No. STO TTL, or √ PLC Source √ TTL, or 6 PLC Source, or 6 PLC Sink 6 TTL, or 4 PLC Source, or 4 PLC Sink 4 Analog Input Differential ±10V 1 Feedback Standard Port A, B, & C √ Communication Option USB √ EtherCAT √ Digital Input Digital Output Table of Contents ||Technical Data Per Axis|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 12 Chapter 5: I nstallation The Gold Duo must be installed in a suitable environment and properly connected to its voltage supplies and the motor. 5.1. Unpacking the Drive Components Before you begin working with the Gold Duo, verify that you have all of its components, as follows: • The Gold Duo servo drive • The Elmo Application Studio software and software manual The Gold Duo is shipped in a cardboard box with Styrofoam protection.
Gold Duo Installation Guide 13 MAN-G-DUOIG-E (Ver. 1.500) 5.2. Connectors Types The Gold Duo has 15 connectors. Connector Pins Type Function Bottom Connectors J13 5 Phoenix, 5 mm Pitch ‘HC’ Main Power J12 2 Phoenix 3.81 mm Pitch Auxiliary supply J14, J15 4 Phoenix 5 mm Pitch ‘HC’ (2) Motor phases Front Connectors J2, J5 24 2.54 mm Pitch Molex (2) I/O and Port C J3, J6 8 2.54 mm Pitch Molex (2) Feedback Port B J1, J4 12 2.
Gold Duo Installation Guide 14 MAN-G-DUOIG-E (Ver. 1.500) Connector Pins Type Function Top Connectors J9, J10 5 USB Device Mini-B (2) USB J7 8 RJ-45 EtherCAT in J8 8 RJ-45 EtherCAT out J11 3 2.54 mm Pitch Molex STO Table 2: Connector Types Table of Contents ||Connectors Types|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 15 5.3. Mounting the Gold Duo The Gold Duo 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 Gold Duo (see the diagram below). Figure 1: Mounting the Gold Duo Table of Contents ||Mounting the Gold Duo|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 5.4. The Gold Duo Connection Diagram Figure 2: The Gold Duo Connection Diagram Table of Contents ||The Gold Duo Connection Diagram|www.elmomc.
Gold Duo Installation Guide 17 MAN-G-DUOIG-E (Ver. 1.500) Chapter 6: W iring Once the product 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 drive. The following table legend describes the wiring symbols detailed in all installation guides. Wiring Symbol Description Earth connection (PE) Protective Earth Connection Common at the Controller Shielded cable with drain wire.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.1. 6.1.1. 18 Basic Recommendations General 1. Use shielded cables. For best results, the cable should have an aluminum foil shield covered by copper braid, and should contain a drain wire. Use 24, 26 or 28 AWG twisted-pair shielded with drain wire cables. 2. Keep the cable as short as possible. Do not mount the power cables of the motor and power bus in the proximity of the control and feedback cables. 3.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.1.2. 19 Feedback Cable Port A and Port B Connector 1. On the motor side connections, ground the shield to the motor chassis. 2. At least One COMRET (Common Return) must be connected to the PE. Implement the following steps to connect the COMRET to the PE: a. At the drive, connect the feedback drain wire to one of the COMRET terminals in the Molex feedback connector (Figure 4. b.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.1.3. 20 Feedback Cable Port C Connector 1. At the controller side connections, follow the controller manufacturer’s recommendations concerning the shield. 2. The connection of the Drain wire to the Port C is not mandatory. Figure 6: Feedback Port C Cable Assemblies 6.1.4. IO Cable Connector It is recommended to use shielded cable, but is not mandatory. Figure 7: Feedback IO Cable Assemblies Table of Contents ||Basic Recommendations|www.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.1.5. STO (Port C) Cable Connector It is recommended to use shielded cable, but is not mandatory. Figure 8: STO Cable Assemblies Table of Contents ||Basic Recommendations|www.elmomc.
Gold Duo Installation Guide 22 MAN-G-DUOIG-E (Ver. 1.500) 6.2. Motor Power Connector Pinouts See Chapter 8 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Gold Duo Installation Guide 23 MAN-G-DUOIG-E (Ver. 1.500) See Chapter 8 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) Figure 10: Brushed Motor Power Connection Diagram Table of Contents ||Motor Power Connector Pinouts|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 25 6.3. Main and Auxiliary Power 6.3.1. Description The Gold Duo receives power from main and auxiliary supplies and delivers power to the motor. Note: There are multiple voltage ratings of the Gold Duo (12 V to 195 V), so you must use the correct power supply according to the maximum operating voltage of the Gold Duo. Refer to Chapter 4: Technical Information.
Gold Duo Installation Guide 26 MAN-G-DUOIG-E (Ver. 1.500) 6.3.2. Main Power Pin Signal Function Cable (Wires) J13/1 VP+ Pos. Power input DC Power J13/2 VP+ Pos. Power input DC Power J13/3 PR Power return DC Power J13/4 PR Power return DC Power J13/5 PE Protective earth DC Power 5-Pin Phoenix Plug-in Connector 5-Pin Phoenix 5 mm Pitch ‘HC’ Table 5: Main Power Pin Assignments Connect the DC power cable to the VP+ and PR terminals on the Main Power Connector.
Gold Duo Installation Guide 27 MAN-G-DUOIG-E (Ver. 1.500) 6.3.3. Auxiliary Power Supply Pin Signal Function Cable (Wires) J12/1 VL+ Auxiliary Supply Input Auxiliary Power J12/2 PR Auxiliary Supply Return Auxiliary Power 2-Pin Phoenix Plug-in Connector 2-Pin Phoenix 3.81 mm Pitch Table 6: Auxiliary Supply Pin Assignments Caution: Power from the Gold Duo to the motor must come from the Main Supply and not from the Auxiliary Supply.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.3.3.1. 28 Power Rating 200 V For Power Rating 200 V, two power isolated DC power sources are required, main power 12 - 195V and auxiliary Power 12-95V for the logic. Figure 11: 200 VDC Power Source Connection Diagram Table of Contents ||Main and Auxiliary Power|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.3.3.2. Power Rating 100 V 6.3.3.2.a Single Power Supply 29 For power rating 100 V , a single Power Supply is required which contains a “smart” control-supply algorithm, enabling the Gold Duo to operate with only one power supply with no need for an auxiliary power supply for the logic. Figure 12: Main Power Supply Connection Diagram Table of Contents ||Main and Auxiliary Power|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.3.3.2.b Optional Backup Supply Figure 13: Main Power Supply Connection Diagram with Auxiliary Supply Table of Contents ||Main and Auxiliary Power|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.4. Drive Status Indicator Figure 14 shows the position of the red/green dual LED, which is used for immediate indication of the Initiation and Working states. For details refer to Chapter 7 Drive Status Indicator, in the MAN-G-Panel Mounted Drives Hardware manual.
Gold Duo Installation Guide 32 MAN-G-DUOIG-E (Ver. 1.500) 6.5. STO (Safe Torque Off) See Chapter 9 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details. Pin (J11) Signal Function J11/1 STO1 STO1 input (default 24 V) J11/2 STO2 STO2 input (default 24 V) J11/3 STO_RET STO signal return 3-Pin Molex Plug This cable is included in the cable kit described in Section 3.1.1 3-Pin 2.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.5.1. Source Mode – PLC Voltage Level Refer to the diagrams below for the PLC Source option connection. Figure 15: STO Molex Type Input Connection – PLC Source Option 6.5.2. TTL Mode – TTL Voltage Level Refer to the diagrams below for TTL option connection. Figure 16: STO Input Connection – TTL Option Table of Contents ||STO (Safe Torque Off)|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.5.3. 34 Sink Mode – PLC Voltage Level Refer to the diagrams below for the PLC Sink option connections which is not fully certified for STO. This option is not recommended for new designs. Figure 17: STO Input Connection – Sink Option Table of Contents ||STO (Safe Torque Off)|www.elmomc.
Gold Duo Installation Guide 35 MAN-G-DUOIG-E (Ver. 1.500) 6.6. Feedback Port A Per Axis See Section 10.3 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.6.1. 36 Incremental Encoder Figure 18: Port A Molex Type Incremental Encoder Input – Recommended Connection Diagram 6.6.2. Halls Sensor Figure 19: Molex Type Hall Sensors Connection Diagram Table of Contents ||Feedback Port A Per Axis|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.6.3. 37 Absolute Serial Encoder The following figures describe the connections at Port A for the Absolute Serial type encoders. Figure 20: Absolute Serial Encoder – Recommended Connection Diagram for EnDAT, Biss, SSI Figure 21: Absolute Serial Encoder – Recommended Connection Diagram for Sensors Supporting Data Line Only (NRZ types, e.g., Panasonic / Mitutoyo / Sanyo Danki / Tamagawa) Table of Contents ||Feedback Port A Per Axis|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.6.3.1. Hiperface The following figure describes the connection diagram. Figure 22: Absolute Serial Encoder – Recommended Molex Type Connection Diagram for Stegmann Hiperface Table of Contents ||Feedback Port A Per Axis|www.elmomc.
Gold Duo Installation Guide 39 MAN-G-DUOIG-E (Ver. 1.500) 6.7. Feedback Port B Per Axis See Section 10.4 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.7.1. Incremental Encoder The following figure describes the connections at Port B for the Incremental encoder. Figure 23: Port B Incremental Encoder Input – Recommended Connection Diagram Table of Contents ||Feedback Port B Per Axis|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.7.2. Interpolated Analog Encoder The following figure describes the connections at Port B for the Interpolated Analog encoder. Figure 24: Port B - Interpolated Analog Encoder Molex Type Connection Diagram Table of Contents ||Feedback Port B Per Axis|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.7.3. Resolver Figure 25: Port B – Resolver Molex Type Connection Diagram Table of Contents ||Feedback Port B Per Axis|www.elmomc.
Gold Duo Installation Guide 43 MAN-G-DUOIG-E (Ver. 1.500) 6.8. Feedback Port C and I/O The Port C connector includes the following functions: • Port C: Refer to Sections 10.5 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details • I/O: Refer to Chapter 11 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details. • Analog input: See Section 11.2 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 44 Connector Location 24-Pin Molex Plug This cable is included in the cable kit described in Section 3.1.1. 24-Pin 2.54 mm Pitch Molex Table 10: Port C Feedback Out and I/O Table of Contents ||Feedback Port C and I/O|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.8.1. Port C – Emulated Encoder Output The following figure describes the connections at Port C for the Emulated Encoder Differential. Figure 26: Emulated Encoder Differential Output – Recommended Connection Diagram Note that the user is required to connect a 120 Ω termination at the end of each differential line. Table of Contents ||Feedback Port C and I/O|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.8.2. Analog Input The following circuit describes the internal interface of the Analog input. Figure 27: Differential Analog Input Table of Contents ||Feedback Port C and I/O|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.8.3. Digital Input and Output TTL Mode The following figure describes the connections at the I/O Port for the Digital Input and Output TTL Mode. Figure 28: Digital Input TTL Mode Connection Diagram Table of Contents ||Feedback Port C and I/O|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) Figure 29: Digital Output Connection Diagram – TTL Option Table of Contents ||Feedback Port C and I/O|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.8.4. 49 Digital Input and Output PLC Source Mode The following figure describes the connections at the I/O Port for the Digital Input and Output PLC Mode. Figure 30: Digital Input Connection Diagram – Source PLC Option Table of Contents ||Feedback Port C and I/O|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) Figure 31: Digital Output Connection Diagram – Source PLC Option Table of Contents ||Feedback Port C and I/O|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.8.5. 51 Digital Input and Output Sink Mode The following figure describes the connections at the I/O Port for the Digital Input and Output Sink Mode. Figure 32: Digital Input Sink Mode – PLC voltage level Molex Type Connection Diagram Table of Contents ||Feedback Port C and I/O|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) Figure 33: Digital Output as Sink Configuration Molex Type Connection Diagram Table of Contents ||Feedback Port C and I/O|www.elmomc.
Gold Duo Installation Guide 53 MAN-G-DUOIG-E (Ver. 1.500) 6.9. USB 2.0 Communication per Axis See Section 12.1 in the in the MAN-G-Panel Mounted Drives Hardware manual for full details. Pin (A-2, A-1) Signal Function 1 USB VBUS USB VBUS 5 V 2 USBD- USB _N line 3 USBD+ USB _P line 5 USB COMRET USB communication return Connectors USB Device Mini-B Plug Mini-USB Type B Table 11: USB 2.0 Pin Assignments Figure 34: USB Network Diagram Table of Contents ||USB 2.0 Communication per Axis|www.
Gold Duo Installation Guide 54 MAN-G-DUOIG-E (Ver. 1.500) 6.10. EtherCAT Communication Version Fieldbus communications are industrial network protocols for real-time distributed control that allows connection of servo drives. 6.10.1. EtherCAT IN/Ethernet Pin Assignments Refer to section 12.2 in the MAN-G-Panel Mounted Drives Hardware manual for more details.
Gold Duo Installation Guide 55 MAN-G-DUOIG-E (Ver. 1.500) 6.10.2. EtherCAT OUT Pin Assignments See Section 12.2 in the MAN-G-Panel Mounted Drives Hardware manual for the electrical diagram. Pin Signal Function 1 EtherCAT_OUT_TX+ EtherCAT out transmit + 2 EtherCAT_OUT_TX- EtherCAT out transmit - 3 EtherCAT_OUT_RX+ EtherCAT out receive + 4, 5 6 7, 8 N/A EtherCAT_OUT_RX- EtherCAT out receive - N/A Connector Location Standard CAT5e Ethernet Cable Table 12: EtherCAT Pin Assignments 6.10.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.10.4. 56 EtherCAT Status Indicator Figure 36: EtherCAT Status LED The EtherCAT status indicator is a single red/green dual bi-colored LED that combines the green RUN indicator and the red ERROR indicator of the EtherCAT state machine. For further details, see the EtherCAT Application Manual. Table of Contents ||EtherCAT Communication Version|www.elmomc.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) 6.11. Powering Up After the Gold Duo 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. 6.12. Initializing the System After the Gold Duo has been connected and mounted, the system must be set up and initialized. This is accomplished using the EASII, Elmo’s Windows-based software application.
Gold Duo Installation Guide MAN-G-DUOIG-E (Ver. 1.500) Chapter 7: Dim ensions This chapter provides detailed technical information regarding the Gold Duo. Table of Contents ||www.elmomc.
Table of Contents ||www.elmomc.
