Elmo 95VDC User manual

Duo
Integrated Solution
Installation Guide
June 2007 (Ver. 1.0)

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.
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-DUOIG
Copyright ©2007
Elmo Motion Control Ltd.
All rights reserved.
Duo Catalog Number: DUO- AXXAXX/YYYZZ
Axis 1 Version :
Blank = Standard
A=Advanced
Axis 2 Version :
Blank = Standard
A = Advanced
Axis 1
Continuous Current(Amps)
Axis 2
Continuous Current(Amps)
Axis 1 Feedbacks:
E- Incremental Encoder and/or Halls
R- Resolver
I- Interpolated Analog Encoder
T- Tachometer and Potentiometer
Maximum DC
Operating Voltage
Axis 2 Feedbacks:
E- Incremental Encoder and/or Halls
R- Resolver
I- Interpolated Analog Encoder
T- Tachometer and Potentiometer
Cable Kit Catalog No. CBL-BRDKIT-001 (kit optional)
Revision History:
Ver. 1.0 June 2007 First Release (MAN- DUOIG.PDF)
Elmo Motion Control Ltd.
64 Gisin St., P.O. Box 463
Petach Tikva 49103
Tel: [phone]
Fax: [phone]
Elmo Motion Control Inc.
1 Park Drive, Suite 12
Westford, MA 01886
USA
Tel: [phone]
Fax: [phone]
Elmo Motion Control GmbH
Steinkirchring 1
D-78056, Villingen-Schwenningen
Germany
Tel: [phone]
Fax: [phone]
www.elmomc.com

Contents
Chapter 1: Safety Information.......................................................................................... 1-1
1.1 Warnings ............................................................................................................. 1-2
1.2 Cautions............................................................................................................... 1-2
1.3 Directives and Standards................................................................................... 1-3
1.4 CE Mark Conformance....................................................................................... 1-3
1.5 Warranty Information........................................................................................ 1-3
Chapter 2: Introduction..................................................................................................... 2-1
2.1 Product Description ........................................................................................... 2-1
2.2 Product Features................................................................................................. 2-2
2.2.1 Current Control ...................................................................................................... 2-2
2.2.2 Velocity Control...................................................................................................... 2-2
2.2.3 Position Control...................................................................................................... 2-2
2.2.4 Advanced Position Control (in Advanced model only)......................................... 2-2
2.2.5 Communication Options ....................................................................................... 2-2
2.2.6 Feedback Options ................................................................................................... 2-2
2.2.7 Fault Protection....................................................................................................... 2-3
2.3 How to Use this Guide....................................................................................... 2-3
Chapter 3: Installation....................................................................................................... 3-1
3.1 Site Requirements............................................................................................... 3-1
3.2 Unpacking the Drive Components ................................................................... 3-1
3.3 Mounting the Duo .............................................................................................. 3-2
3.4 Connecting the Cables ....................................................................................... 3-3
3.4.1 Wiring the Duo ....................................................................................................... 3-3
3.5 Duo Connectors type.......................................................................................... 3-5
3.6 Hardware Requirements.................................................................................... 3-6
3.7 Duo Block Diagram ............................................................................................ 3-7
3.8 The Main Power and Motor Power Connectors.............................................. 3-8
3.8.1 Connecting Motor Power ...................................................................................... 3-8
3.8.2 Connecting Main Power ........................................................................................ 3-9
3.8.3 Low power Auxiliary Supply (optional)........................................................... 3-10
3.9 Main Feedback.................................................................................................. 3-12
3.10 Auxiliary Feedback (bi-directional)................................................................ 3-17
3.10.1 Main and Auxiliary Feedback Combinations................................................... 3-18
3.10.2 Auxiliary Feedback – Emulated, Differential Buffered Encoder Output Option
(YA[4]=4) ............................................................................................................... 3-20
3.10.3 Auxiliary Feedback - Differential Encoder Input Option (YA[4]=2)............. 3-22
3.10.4 Auxiliary Feedback – Differential Pulse-and-Direction Input Option (YA[4]=0)3-25
3.11 I/O….................................................................................................................. 3-27
3.11.1 Digital Input .......................................................................................................... 3-28
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3.11.2 Digital Output....................................................................................................... 3-29
3.11.3 Analog Input ......................................................................................................... 3-29
3.12 Communications............................................................................................... 3-30
3.12.1 RS232 Communication......................................................................................... 3-30
3.12.2 CANopen Communication ................................................................................. 3-31
3.13 Powering Up ..................................................................................................... 3-33
3.14 Initializing the System...................................................................................... 3-33
Appendix A: Technical Specifications ..............................................................................A-1
A.1 Features............................................................................................................... A-1
A.2 Built-In Protection ............................................................................................. A-3
A.3 Duo Dimensions ................................................................................................ A-4
A.4 Power Ratings .................................................................................................... A-5
A.5 Control Specifications ....................................................................................... A-6
A.5.1 Current Loop...........................................................................................................A-6
A.5.2 Velocity Loop ..........................................................................................................A-7
A.5.3 Position Loop ..........................................................................................................A-7
A.6 Feedbacks ........................................................................................................... A-8
A.6.1 Incremental Encoder ..............................................................................................A-8
A.6.2 Feedback Supply Voltage ......................................................................................A-8
A.6.3 Digital Halls.............................................................................................................A-9
A.6.4 Interpolated Analog Encoder (Sine/Cosine) ......................................................A-9
A.6.5 Resolver..................................................................................................................A-10
A.6.6 Tachometer* ..........................................................................................................A-10
A.6.7 Potentiometer........................................................................................................A-11
A.6.8 Auxiliary Feedback Port (output mode YA[4]= 4)...........................................A-11
A.6.9 Auxiliary Feedback Port (input mode YA[4]= 2, 0) .........................................A-12
A.7 I/Os..............................................................................................................…..A-13
A.7.1 Digital Input Interface – 6 Digital Inputs ..........................................................A-13
A.7.2 Digital Output Interface – 2 Digital Outputs ...................................................A-14
A.7.3 Analog Inputs – 1 Analog Input..........................................................................A-14
A.8 Mechanical Specifications............................................................................... A-15
A.9 Environmental Conditions ............................................................................. A-15
A.10 Compliance Standards ............................................................................. A-15
A.10.1 Design ....................................................................................................................A-15
A.10.2 Safety......................................................................................................................A-16
A.10.3 EMC........................................................................................................................A-16
Appendix B: Cables (Optional).........................................................................................B-1
B.1 Cable Photos........................................................................................................ B-1
B.2 Cable Kit .............................................................................................................. B-2
B.3 Main Feedback Cable (CBL-HDRFB-001) ........................................................ B-3
B.4 Auxiliary Feedback (CBL-HDRAUX-001)........................................................ B-4
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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) ............................................................................... B-7
B.7 Guidelines for Making Your Own Cables........................................................ B-8
B.7.1 Recommended Wire Cross Sections..................................................................... B-8
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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.
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 Duo 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.
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:
Warning:
This information is needed to avoid a safety hazard, which might cause
bodily injury.
Caution:
This information is necessary for preventing damage to the product or
to other equipment.
Note:
This is auxiliary information that ensures the correct operation of the
equipment.

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. 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 Duo contains hot surfaces and electrically-charged components
during operation.
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 Duo to an approved 12 ~ 95VDC (8.5 ~ 67VAC)
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 Duo, verify that all safety precautions have been
observed and that the installation procedures in this manual have been
followed.
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1.3 Directives and Standards
The Duo conforms to the following industry safety standards:
Safety Standard Item
In compliance with UL508c Power Conversion Equipment
In compliance with UL840 Insulation Coordination, Including Clearance and
Creepage Distances of Electrical Equipment
In compliance with UL60950-1
(formerly UL1950)
Safety of Information Technology Equipment,
Including Electrical Business Equipment
In compliance with EN60204-1 Low Voltage Directive, 73/23/EEC
The Duo 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 Mark Conformance
The Duo 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 EN60204-1 and EN292-2 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 Duo 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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Duo Installation Guide Introduction
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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. The 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.
The Duo 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 two fully separated digital motion
controllers that feature:
•CANopen-based networking operating simultaneously via RS-232 and CANopen
DS 301, DSP 305, DSP 402 communications and featuring a third-generation
programming environment
•Current, velocity and position control loops including PT and PVT
•Commutation types
•Position feedbacks
The benefits are high dynamics and increased precision for dual axis automated
machines such as robots, feeders, up- and down-loaders, conveyor belts and production
lines.
Power to the various Duo models is provided by a 0 - 95VDC source. A “smart” control-
supply algorithm enables the Duo to operate with only one power supply and there is no
need for an auxiliary power supply for the logic.
If back-up functionality is required for storing control parameters in case of power-loss,
an external 12 ~ 95VDC supply should be connected (via the +VL terminal on the Duo)
providing maximum flexibility and backup functionality when needed.
Note: This back-up power supply can operate from any voltage source within the
12 ~ 95VDC range. This is much more flexible than a standard 24VDC power supply
requirement.
The Duo series fully complies with all relevant safety and EMC regulations.

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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
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)
2.2.5 Communication Options
Depending on the application, Duo users can select from two communication
options:
RS232 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

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•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
•Resolver
Programmable 10~15 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 Duo 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
2.3 How to Use this Guide
In order to install and operate your Elmo Duo, 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 Duo.
The Appendices list all the drive ratings and specifications as well as information on the
relevant cables.
Upon completing the instructions in this guide, your Duo 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
following figure describes the accompanying documentation that you will require.

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Figure 2-1: Elmo Digital Servo Drive Documentation Hierarchy
As depicted in the previous figure, this installation guide is an integral part of the Duo
documentation set, comprising:
The Duo Installation Guide contains information about how to use the Duo
and Cable Kit
The Composer Software Manual, which includes explanations of all the
software tools that are part of Elmo’s Composer software environment
The SimplIQ Command Reference Manual, which describes, in detail, each
software command used to manipulate the Whistle motion controllers
The SimplIQ Software Manual, which describes the comprehensive software
used with the Whistles

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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.
The Whistle on the Duo dissipates its heat by convection. The maximum
operating ambient temperature of 0°to 40°C (32°to 104°F) must not be
exceeded. Refer to the Heat Dissipation section of the Whistle Installation Guide
for more information.
3.2 Unpacking the Drive Components
Before you begin working with the Duo, verify that you have all of its components, as
follows:
The Duo.
The Composer software and software manual.
The Duo is shipped in a cardboard box with styrofoam protection.
To unpack the Duo:
1. Carefully remove the Duo from the box and the Styrofoam.
2. Check the Duo 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 Duo.
3. To ensure that the Duo you have unpacked is the appropriate type for your requirements,
locate the part number sticker on the side of the Duo. It looks like this:
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The part number at the top gives the type designation as follows:
DUO- AXXAXX/YYYZZ
Axis 1 Version :
Blank = Standard
A = Advanced
Axis 2 Version :
Blank = Standard
A = Advanced
Axis 1
Continuous Current(Amps)
Axis 2
Continuous Current(Amps)
Axis 1 Feedbacks:
E- Incremental Encoder and/or Halls
R- Resolver
I- Interpolated Analog Encoder
T- Tachometer and Potentiometer
Maximum DC
Operating Voltage
Axis 2 Feedbacks:
E- Incremental Encoder and/or Halls
R- Resolver
I- Interpolated Analog Encoder
T- Tachometer and Potentiometer
Verify that the Duo type is the one that you ordered, and ensure that the voltage meets your
specific requirements.
3.3 Mounting the Duo
The 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 Duo
(see the diagram below).
Figure 3-1: Mounting the Duo
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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.
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.
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.
The following connectors are used for wiring the Duo:
Type Function Connector Location
Main Power VL, VP+, PR, PR, PE
Motor Power PE, M1, M2, M3
Table 3-1: Connectors on the “Bottom” of the Duo
Motor Main
Power
Power

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Type Function Connector Location
Main
Feedback
Feedback
I/O I/O
Auxiliary
Feedback
Auxiliary
Feedback
Table 3-2: Connectors on the “Front” of the Duo
Type Function Connector Location
CANopen CANopen IN
CANopen CANopen OUT
RS232
RS232-1
RS232-2
Table 3-3: Connectors on the “Top” of the Duo
Auxiliar
y
Main Auxiliar
y
Main I/O
I/O
Feedback
Feedback
Feedback
Feedback
CANopen
IN
CANopen
OUT
RS232-1RS232-2
Axis 2
Axis 1

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3.5 Duo Connectors type
Type On Board Connector
Qty Conn.
1
Main Power Phoenix 5-pin Header P/N:MSTBA 2.5HC/5-G
Motor
Power
2 Phoenix 4-pin Header P/N:MSTBA 2.5/4G-5.08
Main
Feedback
2 12-pin Molex Header P/N:90130-3212
I/O 2 14-pin Molex Header P/N:90130-3214
2
Auxiliary
Feedback 16-pin Molex Header P/N:90130-3216
2 8-pin RJ-45 Socket
CANopen
Comm.
RS232
Comm.
2 8-pin RJ-45 Socket
Connector Location
Motor
Main
Power Power Axis 1
Motor
Power Axis 2
CAN
Table 3-4: Connector Types
I/O
Axis 2
Main
Feedback
Axis 2
RS232
Axis 1
RS232
Axis 2
Auxiliary
Axis 1
Feedback
Axis 2

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3.6 Hardware Requirements
The components that you will need to install your Duo are:
Described
in section
Cable
Drawing
Qty
Conn.
Component Mating Connector Function
VL, VP+, PR, PR, PE
Phoenix 5-pin Plug
P/N:MSTBT 2.5HC/5-ST
Main Power 1
Plug
PE
VL
Motor
Power 2
Phoenix 4-pin Plug
P/N:MSTBT 2.5/4-ST-5.08
PE, M1, M2, M3
Plug
M3
PE
12-pin Molex Plug
P/N:90142-0012
Main
Feedback
Feedback
2 B.3
Pin P/N: 90119-2121
I/O 2
14-pin Molex Plug
P/N:90142-0014 I/O
B.5
Pin P/N: 90119-2121
16-pin Molex Plug
P/N:90142-0016
Auxiliary
Feedback 2 Auxiliary Feedback B.4
Pin P/N: 90119-2121
RS232-1
RS232
Comm. 2 8-pin RJ-45 Plug B.6.1
RS232-2
CANopen IN
CANopen
Comm. 2 8-pin RJ-45 Plug B.6.2
CANopen OUT
Table 3-5: Connector Cross Reference

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3.7 Duo Block Diagram
Figure 3-2: Duo Block Diagram

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3.8 The Main Power and Motor Power Connectors
Pin Function Cable Pin Positions
PE Protective earth Power
PR Power return Power
PR Aux. Supply Input Return Auxiliary
VP+ Pos. Power input Power
VL Aux. Supply Input Auxiliary
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
Table 3-6: 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:
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.
Connect the shield of the cable to the closest ground connection at the motor end.
Be sure that the motor chassis is properly grounded.
Figure 3-3: AC Motor Power Connection Diagram for each AXIS.