Elmo ExtrIQ line User manual

Falcon
Digital Servo Drive
Installation Guide
July 2012 (Ver. 1.5)
www.elmomc.com

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 Falcon 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.
•Elmo Motion Control and the Elmo Motion Control logo are registered trademarks of
Elmo Motion Control Ltd.
•Information in this document is subject to change without notice.
Document no. MAN-FALIG (Ver. 1.5)
Copyright 2012
Elmo Motion Control Ltd.
All rights reserved.
Catalog Number
Maximum DC
Operating Voltage
Continuous Current
(Amps) Feedback:
Blank =Incremental
Encoder
and/or Halls
R = Resolver
FAL- XX/YYY
R
T = Tachometer &
Potentiometer
I = Interpolated
Analog
Encoder
Q= Encoder
Absolute
Cable Kits
Catalog Numbers:
•CBL-CELKIT01 (can be ordered separately)
•CBL-CELKIT02 (can be ordered separately)
For further details, see the documentation for these cable kits (MAN-CBLKIT-CEL.pdf).

Revision History
Version Details
1.0 Initial Release
1.2 August 2008 Added 3.4.7.4: Differential Pulse-and-Direction Input
1.3 September
2008
MTCR 00-100-29: Added Table 7, Figure 16 and Figure 17
1.4 March 2010 MTCR 07-009-56: Added note to 3.4.8.2
1.5 July 2011 Formatted according to the new template

Elmo Worldwide
Head Office
Elmo Motion Control Ltd.
60 Amal St., P.O. Box 3078, Petach Tikva 49516
Israel
Tel: [phone] • Fax: [phone] • [e-mail]
North America
Elmo Motion Control Inc.
42 Technology Way, Nashua, NH 03060
USA
Tel: [phone] • Fax: [phone] • [e-mail]
Europe
Elmo Motion Control GmbH
Hermann-Schwer-Strasse 3, 78048 VS-Villingen
Germany
Tel: [phone] • Fax: [phone] • [e-mail]
China
Elmo Motion Control Technology (Shanghai) Co. Ltd.
Room 1414, Huawen Plaza, No. 999 Zhongshan West Road, Shanghai (200051)
China
Tel: [phone] • Fax: [phone] • info-[email protected]
Asia Pacific
Elmo Motion Control
#807, Kofomo Tower, 16-3, Sunae-dong, Bundang-gu, Seongnam-si, Gyeonggi-do,
South Korea
Tel: [phone] • Fax: [phone] • [e-mail]

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Table of Contents
Chapter 1: Safety Information .......................................................................................... 7
1.1. Warnings......................................................................................................................... 8
1.2. Cautions.......................................................................................................................... 8
1.3. Directives and Standards................................................................................................ 9
1.4. CE Marking Conformance.............................................................................................10
1.5. Warranty Information .................................................................................................. 10
Chapter 2: Introduction ................................................................................................. 11
2.1. ExtrIQ Product Family ...................................................................................................11
2.2. Drive Description ..........................................................................................................12
2.3. Product Features ..........................................................................................................13
2.3.1. Current Control.............................................................................................. 13
2.3.2. Velocity Control .............................................................................................13
2.3.3. Position Control .............................................................................................13
2.3.4. Communication Options................................................................................ 13
2.3.5. Feedback Options .......................................................................................... 14
2.3.6. Fault Protection .............................................................................................14
2.4. System Architecture .....................................................................................................15
2.5. How to Use this Guide.................................................................................................. 15
Chapter 3: Installation ................................................................................................... 17
3.1. Before You Begin ..........................................................................................................17
3.1.1. Site Requirements .........................................................................................17
3.1.2. Hardware Requirements ...............................................................................17
3.2. Unpacking the Drive Components................................................................................ 19
3.3. Mounting the Falcon .................................................................................................... 20
3.4. Connecting the Cables.................................................................................................. 21
3.4.1. Wiring the Falcon........................................................................................... 21
3.4.2. Connecting the Power Cables........................................................................24
3.4.2.1. Connecting the Motor Cable ........................................................24
3.4.2.2. Connecting the Main Power Cable ............................................... 25
3.4.3. Connecting the Optional Backup Supply Cable (24v) .................................... 26
3.4.4. Feedback and Control Cable Assemblies....................................................... 27
3.4.5. Main Feedback Cable (FEEDBACK A) .............................................................27
3.4.6. Main and Auxiliary Feedback Combinations .................................................35
3.4.7. Auxiliary Feedback (FEEDBACK B).................................................................. 36
3.4.7.1. Main Encoder Buffered Outputs or Emulated Encoder Outputs
Option on FEEDBACK B (YA[4]=4) ................................................. 36
3.4.7.2. Differential Auxiliary Encoder Input Option on FEEDBACK B
(YA[4]=2) ....................................................................................... 39
3.4.7.3. Single-Ended Auxiliary Input Option on FEEDBACK B (YA[4]=2)...41

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3.4.7.4. Pulse-and-Direction Input Option on FEEDBACK B (YA[4]=0)....... 43
3.4.8. I/O Cables ......................................................................................................47
3.4.8.1. General I/O Port (J1).....................................................................47
3.4.8.2. General Input Port (J2) .................................................................49
3.4.9. Communication Cables..................................................................................51
3.4.9.1. RS-232 Communication ................................................................51
3.4.9.2. CANopen Communication ............................................................52
3.5. Powering Up .................................................................................................................54
3.6. Initializing the System................................................................................................... 54
Chapter 4: Technical Specifications ................................................................................ 55
4.1. Features........................................................................................................................55
4.1.1. Motion Control Modes ..................................................................................55
4.1.2. Advanced Positioning Motion Control Modes ..............................................55
4.1.3. Advanced Filters and Gain Scheduling...........................................................55
4.1.4. Fully Programmable....................................................................................... 55
4.1.5. Feedback Options .......................................................................................... 56
4.1.6. Input/Output ................................................................................................. 56
4.1.7. Built-In Protection .........................................................................................57
4.2. Falcon Dimensions........................................................................................................ 58
4.3. Power Ratings...............................................................................................................59
4.4. Environmental Conditions............................................................................................60
4.5. Falcon Connections ...................................................................................................... 60
4.5.1. Backup Supply (Optional) .............................................................................. 61
4.6. Control Specifications...................................................................................................62
4.6.1. Current Loop..................................................................................................62
4.6.2. Velocity Loop ................................................................................................. 63
4.6.3. Position Loop .................................................................................................63
4.7. Feedbacks .....................................................................................................................64
4.7.1. Feedback Supply Voltage............................................................................... 64
4.7.2. Incremental Encoder Input............................................................................ 64
4.7.3. Digital Halls .................................................................................................... 65
4.7.4. Interpolated Analog (Sine/Cosine) Encoder .................................................. 65
4.7.5. Resolver ......................................................................................................... 66
4.7.6. Tachometer....................................................................................................66
4.7.7. Potentiometer ...............................................................................................67
4.7.8. Encoder Outputs............................................................................................67
4.8. I/Os ............................................................................................................................... 68
4.8.1. Digital Input Interfaces .................................................................................. 68
4.8.2. Digital Output Interface.................................................................................69
4.8.3. Analog Input .................................................................................................. 70
4.9. Communications........................................................................................................... 71
4.10. Pulse-Width Modulation (PWM).................................................................................. 71
4.11. Mechanical Specifications ............................................................................................71
4.12. Compliance with Standards..........................................................................................72

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Chapter 1:
Safety Information
In order to achieve the optimum, safe operation of the Falcon servo drive, 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 Falcon 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 Falcon servo drive 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.

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1.1. 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 Falcon from all voltage sources before it is opened for servicing.
•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 Falcon servo drive contains hot surfaces and electrically-charged components during
operation.
•The maximum DC power supply connected to the instrument must comply with the
parameters outlined in this guide.
•The Falcon can operate only through an isolated power source, using an isolated
transformer and a rectifier circuit. Power to this device must be supplied by DC voltage,
within the boundaries specified for the Falcon. High voltages may damage the drive.
The DC power supply voltage range is defined in the table in Section 4.3.
Safety margins must be considered in order to avoid activating the under- or over-voltage
protection against line variations and/or voltage drop under load. The transformer should
be able to deliver the required power to the drive (including peak power) without
significant voltage drops (10% maximum). While driving high-inertia loads, the power
supply circuit must be equipped with a shunt regulator; otherwise, the drive will be
disabled whenever the capacitors are charged above the maximum voltage.
•Before switching on the Falcon, 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 Falcon conforms to the following industry safety standards:
Safety Standard Item
Approved IEC/EN 61800-5-1, Safety Adjustable speed electrical power drive systems
Recognized UL 508C Power Conversion Equipment
In compliance with UL 840 Insulation Coordination Including Clearances and
Creepage Distances for Electrical Equipment
In compliance with UL 60950-1
(formerly UL 1950)
Safety of Information Technology Equipment
Including Electrical Business Equipment
In compliance with EN 60204-1 Low Voltage Directive 73/23/EEC
The Falcon also conforms to the following military qualitative standards:
Military Qualitative Standard Item
In compliance with MIL-STD-704 Aircraft, Electric Power Characteristics
In compliance with MIL-STD-810 Environmental Engineering Considerations and
Laboratory Tests
In compliance with MIL-STD-1275 Characteristics of 28 Volt DC Electrical Systems in
Military Vehicles
In compliance with MIL-STD-461 Requirements for the Control of Electromagnetic
Interference Characteristics of Subsystems and
Equipment
In compliance with MIL-HDBK-217 Reliability Prediction of Electronic Equipment
In compliance with ISO-9001:2008 Quality Management
The Falcon 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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1.4. CE Marking Conformance
The Falcon servo drive 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 EN 60204-1 and EN 292-2 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
Falcon 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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Chapter 2:
Introduction
This installation guide describes the Falcon servo drive and the steps for its wiring, installation
and powering up. Following these guidelines ensures maximum functionality of the drive and
the system to which it is connected.
2.1.
ExtrIQ
Product Family
Elmo Motion Control’s ExtrIQ product family is a set of durable motion control products for
applications operating under extreme environmental conditions. The products are capable of
withstanding the following extreme 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 +71 °C (-40 °F to 160 °F)
Temperature
Shock
Non-operating conditions -40 °C to +71 °C (-40 °F to 160 °F) within 3 min
Altitude Non-operating conditions Unlimited
Operating conditions -400 m to 155,000 m (-1,300 ft to 510,000 ft)
Humidity Non-operating conditions Up to 95% non-condensing humidity at 35 °C
(95 °F)
Operating conditions Up to 95% non-condensing humidity at 25 °C
(77 °F), up to 90% non-condensing humidity at
42 °C (108 °F)
Vibration Operating conditions 20 Hz to 2000 Hz, 14.6 g
Mechanical
Shock
Non-operating conditions ±40 g; Half sine, 11 msec
Operating conditions ±20 g; Half sine, 11 msec

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ExtrIQ products have a high power density in the range from 50 W to 18,000 W and a current
carrying capacity of up to 140 A (280 A peak).
All ExtrIQ servo drives have been tested using methods and procedures specified in a variety of
extended environmental conditions (EEC) standards, including:
•MIL-STD-704 – Aircraft, Electric Power Characteristics
•MIL-STD-810 – Environmental Engineering Considerations and Laboratory Tests
•MIL-STD-1275 – Characteristics of 28 Volt DC Electrical Systems in Military Vehicles
•MIL-STD-461 – Requirements for the Control of Electromagnetic Interference
Characteristics of Subsystems and Equipment
•MIL-HDBK-217 – Reliability Prediction of Electronic Equipment
•ISO-9001:2008
Based on Elmo Motion Control's innovative ExtrIQ core technology, they support a wide range
of motor feedback options, programming capabilities and communication protocols.
2.2. Drive Description
The Falcon is a series of highly durable and intelligent servo drives. Designed for OEMs, the
Falcon is part of the Elmo’s ExtrIQ product line designed to endure extended environmental
operating conditions.
The digital drives are based on Elmo's advanced ExtrIQ motion control technology. They
operate from a DC power source in current, velocity, position and advanced position modes, in
conjunction with a permanent-magnet synchronous brushless motor, DC brush motor, linear
motor or voice coil. They are designed for use with any type of sinusoidal and trapezoidal
commutation, with vector control. The Falcon can operate as a stand-alone device or as part of
a multi-axis system in a distributed configuration on a real-time network.
The Falcon drive is set up and tuned using Elmo’s Composer software. This Windows-based
application enables users to quickly and simply configure the servo drive for optimal use with
their motor.
Power to the Falcon is provided by a 10 to 195 VDC source. A smart control-supply algorithm
enables the Falcon to operate with the power supply only, with no need for an auxiliary 24 Volt
supply. If backup functionality is required for storing control parameters in case of power-outs,
an external 24 VDC power supply can be connected, providing maximum flexibility and optional
backup functionality when needed.

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2.3. Product Features
2.3.1. 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
2.3.2. 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
2.3.3. 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 time: four times that of current loop
•Fast event capturing inputs
•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)
2.3.4. Communication Options
Depending on the application, Falcon users can select from two communication options:
•RS-232 serial communication
•CANopen for fast communication in a multi-axis distributed environment

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2.3.5. Feedback Options
•Incremental Encoder – up to 20 Megacounts (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
•Absolute Encoder
•Interpolated Analog (Sine/Cosine) Encoder – up to 250 kHz (analog signal)
Internal Interpolation – programmable up to x4096
Automatic Correction of:
•amplitude mismatch
•phase mismatch
•signals offset
Encoder outputs, buffered, differential.
•Resolver
Programmable 10 to 15 bit resolution
Up to 512 revolutions per second (RPS)
Encoder outputs, buffered, differential
•Tachometer and Potentiometer
Two inputs for Tachometer Feedback:
Up to ±50 VDC
Up to ±20 VDC
Potentiometer Feedback:
0 V to 5 V voltage range
Resistance: 100 Ω to 1000 Ω
•Elmo drives provide supply voltage for all the feedback options.
2.3.6. Fault Protection
The Falcon 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

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2.4. System Architecture
Auxiliary
Power
Supply
PWM
Controller
Power Stage
Protection Current
Feedback
Incremental
Encoder
24 VDC
I/Os
Incremental Encoder
Buffered Output
or
Emulated Output
Resolver
Analog
Encoder
Auxiliary
Encoder
or
or
Potentiometer
Tachometer
or
or
Communication
RS 232 and CANopen
Figure 1: Falcon System Block Diagram
2.5. How to Use this Guide
In order to install and operate your Elmo Falcon servo drive, 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 Falcon.
Chapter 4, Technical Specifications,lists all the drive ratings and specifications.
Upon completing the instructions in this guide, your Falcon servo drive 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: Elmo Documentation Hierarchy
As depicted in the previous figure, this installation guide is an integral part of the Falcon
documentation set, comprising:
•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 Falcon motion controller.
•The SimplIQ Software Manual, which describes the comprehensive software used with the
Falcon.

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Chapter 3:
Installation
The Falcon must be installed in a suitable environment and properly connected to its voltage
supplies and the motor.
3.1. Before You Begin
3.1.1. Site Requirements
You can guarantee the safe operation of the Falcon by ensuring that it is installed in an
appropriate environment.
Feature Value
Ambient operating temperature -40 °C to +70 °C (-40 °F to 160 °F)
Maximum operating altitude 155,000 m (510,000 ft)
Maximum non-condensing humidity 95%
Operating area atmosphere No flammable gases or vapors permitted in area
Models for extended environmental conditions are available.
Caution: The Falcon dissipates its heat by natural convection. The maximum ambient
operating temperature of -40 °C to +70 °C (-40 °F to 160 °F) must not be exceeded.
3.1.2. Hardware Requirements
The components that you will need to install your Falcon are:
Component Wire Described
in Section
Drawing
Main Power
Cable
VP+ - red
PR- black
3.4.2.2
Motor Cable M1 M2 M3-
white
3.4.2.1

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Component Wire Described
in Section
Drawing
Backup Supply
Cable (if
needed)
24 V-
red/black
3.4.3
Main
Feedback
Cable
FEEDBACK A 3.4.5
Auxiliary
Feedback
Cable
(if needed)
FEEDBACK B 3.4.7
Digital I/O
Cable
(if needed)
GENERAL
I/O
J1
3.4.8.1
Digital Inputs
and
Analog Inputs
Cable
(if needed)
GENERAL
I/O
J2
3.4.8.2
RS232
Communicatio
n Cable
RS232 3.4.9.1

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Component Wire Described
in Section
Drawing
CANopen
Communicatio
n cable(s) (if
needed)
CAN (in)
CAN (out)
3.4.9.2
PC for drive
setup and
tuning
Motor data
sheet or
manual
3.2. Unpacking the Drive Components
Before you begin working with the Falcon system, verify that you have all of its components, as
follows:
•The Falcon servo drive
•The Composer software and software manual
The Falcon is shipped in a cardboard box with Styrofoam protection.
To unpack the Falcon:
1. Carefully remove the servo drive from the box and the Styrofoam.
2. Check the drive 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 drive.
3. To ensure that the Falcon you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Falcon. It looks like this:

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The P/N number at the top gives the type designation as follows:
Maximum DC
Operating Voltage
Continuous Current
(Amps) Feedback:
Blank =Incremental
Encoder
and/or Halls
R = Resolver
FAL- XX/YYYR
T = Tachometer &
Potentiometer
I = Interpolated
Analog
Encoder
Q= Encoder
Absolute
4. Verify that the Falcon type is the one that you ordered, and ensure that the voltage meets
your specific requirements.
3.3. Mounting the Falcon
The Falcon 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
Falcon (see the diagram below).
Figure 3: Mounting the Falcon