Elmo Gold Lion 100 User manual

Gold Lion 100
Network Motion Controller
Installation Guide
For Harsh Environments
(-40°C to +70°C, Vibrations up to 14GRMS)
May 2018 (Ver. 1.004) www.elmomc.com

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Notice
This guide is delivered subject to the following conditions and restrictions:
•
This guide contains proprietary information belonging to Elmo Motion Control Ltd. Such
information is supplied solely for the purpose of assisting users of the Gold Lion 100 servo
drive in its installation.
•
The text and graphics included in this manual are for the purpose of illustration and
reference only. The specifications on which they are based are subject to change without
notice.
•
Information in this document is subject to change without notice.
Elmo Motion Control and the Elmo Motion Control logo are registered
trademarks of Elmo Motion Control Ltd.
EtherCAT®is a registered trademark and patented technology, licensed by
Beckhoff Automation GmbH, Germany.
CANopen compliant. CANopen®is a registered trademark and patented
technology, licensed by CAN in Automation (CiA) GmbH, Kontumazgarten
3, DE-90429 Nuremberg, Germany.
Document no. MAN-G-LION 100 PrelIG (Ver. 1.004)
Copyright 2018
Elmo Motion Control Ltd.
All rights reserved.
Catalog Number
GOLD-LION100
Motion Controller for Harsh Environments
(-40°C to+70°C, Vibrations up to 14GRMS)
13VDC - 96VDC
Revision History
Version
Date
Details
Ver. 1.000 Oct 2015 Initial Release
Ver. 1.003 Aug. 2017 Update
Ver. 1.004 May. 2018 Update

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Chapter 1: Safety Information ......................................................................................5
1.1 Cautions......................................................................................................................5
1.2 Directives and Standards............................................................................................6
1.3 Warranty Information ................................................................................................6
Chapter 2: Product Description.....................................................................................7
2.1 Description .................................................................................................................7
Chapter 3: Technical Specifications...............................................................................8
3.1 Processor module.......................................................................................................8
3.2 Communications.........................................................................................................8
3.3 Power Supply..............................................................................................................8
3.4 Physical Specifications................................................................................................9
3.5 General .......................................................................................................................9
Chapter 4: Gold Lion 100 Software Specifications........................................................10
4.1 Operating System .....................................................................................................10
4.2 Axes ..........................................................................................................................10
4.3 Motion Modes and Interfaces..................................................................................10
4.4 Drive Communication Bridge Support......................................................................11
4.5 Network Encoders ....................................................................................................12
4.6 Position Error Mapping ............................................................................................12
Chapter 5: How to Use this Guide ...............................................................................12
Chapter 6: Installation................................................................................................13
6.1 Environmental Conditions........................................................................................13
6.2 Unpacking the Components .....................................................................................14
6.3 Connectors ...............................................................................................................15
6.3.1 Connector Types........................................................................................15
6.4 Connector Pinouts....................................................................................................16
6.4.1 GPIO&VL ....................................................................................................16
6.4.2 EtherCAT Connector ..................................................................................17
6.4.3 Ethernet Host ............................................................................................18
6.4.4 CAN Connector ..........................................................................................19
6.4.5 USB 2.0 (Standard).....................................................................................19
Chapter 7: Mounting the Gold Lion 100 ......................................................................20
7.1.1 Wall Mount................................................................................................20
7.1.2 Surface Mount...........................................................................................20
7.2 Connecting the Cables..............................................................................................21
7.2.1 Wiring the Gold Lion 100...........................................................................21

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7.2.2 Connecting the DC Power Supply..............................................................21
7.2.3 Ethernet.....................................................................................................22
7.2.4 USB 2.0 Communication............................................................................23
7.2.5 CAN Communication .................................................................................24
7.2.6 EtherCAT Communication .........................................................................25
7.3 Powering Up .............................................................................................................27
7.4 Initializing the System ..............................................................................................27
Chapter 8: Gold Lion 100 Dimensions..........................................................................28
Chapter 9: Other Compliant Standards .......................................................................29

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Chapter 1:
Safety Information
In order to achieve the optimum, safe operation of the Gold Lion 100 Multi-Axis Controller, 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 Gold
Lion 100 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.
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.
1.1 Cautions
•
The Gold Lion 100 must be connected to an approved 24 VDC power supply through a line
that is separated from hazardous line voltages using reinforced or double insulation in
accordance with approved safety standards.
•
Before switching on the Gold Lion 100, verify that all safety precautions have been observed
and that the installation procedures in this manual have been followed.

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1.2 Directives and Standards
The Gold Lion 100 conforms to the following industry safety standards:
Safety Standard Item
In compliance with EN 60204-1 Low Voltage Directive 73/23/EEC
In compliance with CE 2006/95/EC Low-voltage directive 2006/95/EC
In compliance with IEC/EN 61800-5-1 Adjustable speed electrical power drive systems
Safety requirements – Electrical, thermal and energy
In compliance with IEC 61800-3 EMC requirements and specific test methods
The Gold Lion 100 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.
1.3 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. The Gold Lion 100 is warranted for a period of 12 months from the
date of shipment. 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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Chapter 2:
Product Description
This specification describes the Gold Lion 100 Network Motion Controller.
2.1 Description
The Gold Lion 100 is Elmo’s rugged network motion controller, designed to operate at extreme
environmental conditions such -40C to +70C and vibrations up to 14GRMS, functioning in a network
based system in conjunction with Elmo’s intelligent servo drives to provide a total multi-axis motion
control system solution in extreme environmental conditions.
The Gold Lion 100 is designed to support both the existing SimplIQ drives, based on standard CAN
network architecture, as well as the new Gold Line, adding EtherCAT networking.
While being a true network controller, the Gold Lion 100 shares the motion processing workload
with Elmo’s SimplIQ and Gold Line drives, forming a distributed motion control system. The best
servo and system performance is achieved combining the Gold Family drives, and the new real-time
motion control capabilities of the Gold Lion 100 controller.
The Gold Lion 100 provides:
•
Full, real-time, multi-axis motion synchronization
•
Advanced user programming capabilities based on the leading standards
•
Time deterministic control over motion, I/Os and processes in the system
The Gold Lion 100 offers real-time motion control support for full multi-axis system synchronization,
using the well known industry interface PLCopen for Motion Control standard.
Various programming capabilities, such as the IEC-61131-3 standard languages, as well as native C
programming support, dramatically accelerate user level program execution. Standard solutions
were selected for ease of use.
Low level communication with drives and I/O devices over the device network uses the CAN
industry standard (DS 301, DS 401 for I/O devices, and DS 402 for drives and motion device
profiles). These are used over standard CAN networks, as well as with the new EtherCAT CoE (CAN
over EtherCAT) protocols.
Host interfaces are implemented using industry standard communications protocols, such as
Ethernet TCP/IP and higher level protocols such as Ethernet/IP and Modbus.
Standardization in protocols, definitions and APIs allows users rapid system level integration and
opens the system to third party devices on the device network.

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Chapter 3:
Technical Specifications
3.1 Processor module
Feature Details
Processor PowerPC, 333 MHz, with double precision floating point
support by hardware.
Memory Flash Flash: 32 MB
Memory 64 MB (DDR2, 333 MHz)
3.2 Communications
Specification Details
Ethernet for Host 1 port, Standard Ethernet, 10/100 Mbps, automatically
detected
USB One port, USB 2.0, 12 Mbps
Used only for setup and determining IP address.
EtherCAT for device network 2 x EtherCAT master ports 100base-T, with redundancy support
(optional)
CAN for device network CANopen master port
Maximum Baud Rate of 1 Mbits/sec.
3.3 Power Supply
Feature Details
Supply input voltage 13 V to 96 V
Supply input power 4.5 W

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3.4 Physical Specifications
Feature Details
Weight 259 g (9.14 oz)
Dimensions 117.5 x 79 x 25.8 mm (4.63" x 3.11" x 1.02")
Mounting Method (with adapter) Wall Mount (“Bookshelf”)
3.5 General
Feature Details
I/O System All I/O interfaces are handled via the device network
Internal System BIT The Gold Lion 100 supports internal hardware BIT (Built-in-
tests) procedures to check the system integrity level on
each power up.
Diagnostic LEDs EtherCAT and Ethernet activity

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Chapter 4:
Gold Lion 100 Software Specifications
4.1 Operating System
•
Linux Operating System, with Elmo’s RT extension for real-time motion control support
•
Motion Programming and Debugging
Native C Programming, running on the target CPU. Compiling and debugging via the
Eclipse IDE using GCC under Cygwin
IEC 61131-3 with PLCopen Motion Library extension, using Elmo IDE. The following
languages are supported:
•Structured text (ST), textual
•Function block diagram (FBD), graphical
•Ladder diagram (LD), graphical
•Sequential function chart (SFC), has elements to organize programs for sequential
and parallel control processing.
4.2 Axes
•
Up to 96 axes, allowing mixed single axis, multiple axis and coordinated axes motions
•
Axis Types
Intelligent Servo Drives (Elmo), supporting both the SimplIQ and Gold lines
Operation in Numeric Control – NC - (real-time master synchronization) as well as
non-NC modes
DS 402 CoE for EtherCAT and standard DS 402 drives for CANopen
•
Control System Update Rate
EtherCAT
•Cycle Update Rate: ≥ 500 µs (up to 16 axes can be updated simultaneously at a
rate of 500 µs)
•Cycle Jitter: < 1 µs, based on Master DC (Distributed Clock) support, for the full
network
CAN
•Cycle Update Rate ≥ 1 ms (CAN physical network limitations only)
•Cycle Jitter: < 100 µs for CAN Sync message initiation (actual jitter dependent on
the CAN network’s physical limitations)
4.3 Motion Modes and Interfaces
•
The Gold Lion 100 motion interfaces use the PLCopen Standard.
64 bit, real-time, double precision profile calculations, allowing full on-the-fly control
over speed, acceleration, deceleration and jerk
Complex motion schemes, including look-ahead optimizing of trajectory speed
calculations, for complex vector motions

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Cyclic buffer for 1,000 function blocks (a buffer for 1,000 motion segments). The
cyclical buffer removes any practical limit on the number of function blocks.
•
Communication Protocols
Host
•Ethernet TCP-IP/UDP for operational modes
•Telnet communication for setup and configuration
•USB: Using binary protocol (maintenance)
•Application level: Ethernet-IP/Modbus
Device Network
•EtherCAT: CoE/EoE/FoE, supports distributed clock master
•CAN: CANopen device profiles, e.g., DS 301, DS 305, DS 402, DS 401 (I/O device
profile)
•
Host and Internal Software Interface
TCP/IP interface from Host Computer. Software Library is provided for easy TCP/IP
communication interface.
Future version will also support Ethernet-IP and Modbus over the TCP-IP.
Internal Software libraries, for "C" user programs are provided, to write user code
running on the Gold Lion 100 target processor (native mode).
•
Data Recording
4 MB data recording
Up to 32 vectors can be recorded simultaneously.
Supports more than 10 advanced triggering options and real-time scope capabilities
Very fast data upload using Ethernet
•
Upload/Download Support
Firmware update support (Gold Lion 100 and drives)
System resource files
Axis parameter files
4.4 Drive Communication Bridge Support
•
The Gold Lion 100 supports full communication with any specific drive (EtherCAT and CAN),
for the purpose of simple tuning or configuration at the drive level, i.e. there is no need for
direct communication with the drive.
•
Spatial Position-Based Pulse Generation
The Gold Lion 100 supports spatial (along the path) position-based pulse generation.
This is a unique feature, required for the generation of position-based events in 3D
scanning systems.
The Gold Lion 100 system, with Elmo’s intelligent Gold servo drives, can support single
axis and spatial enhanced position-based compare functions, resulting in trigger output
signals accurate to 1 encoder count along the trajectory path.

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4.5 Network Encoders
•
Supports master based motion on network encoders
4.6 Position Error Mapping
•
Supports 1-D and 2-D position-based error mapping compensation
•
System Boot up Time: < 30 sec
Chapter 5:
How to Use this Guide
This manual is part of a documentation set that can be used to set up and program the motion of
any machine whose motors are controlled by Elmo’s SimplIQ or Gold Line servo drives. When used
in conjunction with the Gold Maestro Software Manual it describes everything needed to get the
Gold Lion 100 up and running. Please read the safety instructions in the first chapter before
starting.
After you have successfully mounted and installed the Gold Lion 100 we suggest that you read the
Gold Maestro Software Manual. If you have not already done so, follow the instructions in the
Installation Guide that arrived with your servo drive, and install a drive. At least one drive needs to
be connected to the Gold Lion 100 in order for it to function as a motion controller.

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Chapter 6:
Installation
6.1 Environmental Conditions
You can guarantee the safe operation of the Gold Lion 100 by ensuring that it is installed in an
appropriate environment.
Warning: During operation the Gold Lion 100 becomes hot to the touch
(the case can heat up to 50 °C). Care should be taken when handling it.
Caution:
The Gold Lion 100 dissipates its heat by convection. The maximum ambient
operating temperature of 70 °C (160 °F) must not be exceeded.
The Gold Lion 100 supports the following extended environmental conditions.
Feature Operation Conditions Range
Ambient
Temperature
Range
Non-operating conditions -50 °C to +100 °C (-58 °F to 212 °F)
Operating conditions -40 °C to +70 °C (-40 °F to 160 °F)
Temperature
Shock
Non-operating conditions -40 °C to +70 °C (-40 °F to 160 °F)
within 3 min
Altitude Non-operating conditions Unlimited
Operating conditions -400 m to 12,000 m (-1312 to 39370 feet)
Maximum
Humidity
Non-operating conditions Up to 95% relative humidity
non-condensing at 35 °C (95 °F)
Operating conditions Up to 95% relative humidity non-condensing
at 25 °C (77 °F), up to 90% relative humidity
non-condensing at 42 °C (108 °F)
Vibration Operating conditions 20 Hz to 2,000 Hz, 14.6 g
Mechanical
Shock
Non-operating conditions ±40g; Half sine, 11 msec
Operating conditions ±20g; Half sine, 11 msec
Protection level IP32
The Gold Lion 100 servo drive 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.

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6.2 Unpacking the Components
Before you begin working with the Gold Lion 100 system, verify that you have all of its components,
as follows:
•
The Gold Lion 100 multi-axis controller
•
Gold Lion 100 software which may be downloaded from www.elmomc.com
The Gold Lion 100 is shipped in a cardboard box with Styrofoam protection.
To unpack the Gold Lion 100:
1. Carefully remove the Gold Lion 100 from the box.
2. Check the Gold Lion 100 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 controller.
3. To ensure that the Gold Lion 100 you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Gold Lion 100 as shown
below.
The part number at the top gives the type designation as follows:
GOLD-LION100
4. Verify that the Gold Lion 100 type is the one that you ordered.

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6.3 Connectors
6.3.1 Connector Types
The Gold Lion 100 has the following connectors:
Pins Type Function
Front Connectors
9 D-Type Male
EtherCAT1
EtherCAT2
9 D-Type Male Ethernet
9 D-Type Female CAN
Bottom Connectors
4
USB
USB
15 D-Type
GPIO (not in use)
VL+ /VL-
Table 1: Connector Types

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6.4 Connector Pinouts
6.4.1 GPIO&VL
Pin Signal Function
15 VL+ DC Power +24 V Supply Input Positive
14 VL- DC Power 24 V Supply Input Return
8 VL Shield Drain wire cable
1, 2, 3, 4, 5, 6, 7, 9, 10, 11, 12, 13 Reserved
Pin Positions
15-Socket High Density D-Type Connector
15-Pin High Density D-Type
Male Connector
Table 2: Gold Lion 100 General Connector

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6.4.2 EtherCAT Connector
Pin Signal Function
1 Ethernet1_TX+ Ethernet1 transmit+
2 Ethernet1_RX+ Ethernet1 receive+
3 Ethernet2_TX+ Ethernet2 transmit+
4 Ethernet2_RX+ Ethernet2 receive+
5 Shield Drain wire cable
6 Ethernet1_TX- Ethernet1 transmit-
7 Ethernet1_RX- Ethernet1 receive-
8 Ethernet2_TX- Ethernet2 transmit-
9 Ethernet2_RX- Ethernet2 receive-
Pin Positions
9-Pin male D-Type
9-Pin Female D-Type
Table 3: EtherCAT Pin Assignments

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6.4.3 Ethernet Host
Pin Signal Function
1 Ethernet_Host_TX+ Ethernet Host transmit+
2 Ethernet_Host_RX+ Ethernet Host receive+
3 Not used
4 Not used
5 Shield Drain wire cable
6 Ethernet_Host_TX- Ethernet Host transmit-
7 Ethernet_Host_RX- Ethernet Host receive-
8 Not used
9 Not used
Pin Positions
9-Pin male D-Type
9-Pin Female D-Type
Table 4: Ethernet Host Pin Assignments

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6.4.4 CAN Connector
Pin Signal Function
1, 3 CAN_H CAN_H bus line (dominant high)
6, 8 CAN_L CAN_L bus line (dominant low)
7, 9 CAN_RET CAN Return
5 CAN_Shield Drain wire cable
Pin Positions
9-Pin D-Type Female Connector
9-Pin D-Type Male
Connector
Table 5: CAN Pin Assignments
6.4.5 USB 2.0 (Standard)
USB Pin Signal Function
1 USB VBUS USB VBUS From Host
2 USBD- USB _N line
3 USBD+ USB _P line
4 USB COMRET USB communication return
Pin Postions Cable Connector
USB Device Type B Plug
Table 6: USB 2.0 Pin Assignments

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Chapter 7:
Mounting the Gold Lion 100
The Gold Lion 100 has three mounting options:
•
Wall mount
•
Surface mount
7.1.1 Wall Mount
Two M4 round head screws, one through each opening in the heat sink, are used to mount the Gold
Maestro (see the diagram below) on a wall.
Figure 1: Wall Mounting the Gold Lion 100
7.1.2 Surface Mount
Use four M4 round head screws, one through each opening in the heat sink to connect the Gold
Maestro to a surface.
Figure 2: Surface Mounting the Gold Lion 100