Elmo GOLD-MAESTRO01 User manual

Gold Maestro
Network Motion Controller
Installation Guide
October 2012 (Ver. 1.300)
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 Gold
Maestro 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 Conformance Tested. EtherCAT®is a registered
trademark and patented technology, licensed by Beckhoff
Automation GmbH, Germany.
Document no. MAN-GOLD-MAESTRO-IG (Ver. 1.300)
Copyright 2012
Elmo Motion Control Ltd.
All rights reserved.
Catalog Number
GOLD-MAESTRO01
13 to 96 VDC power supply
GOLD-MAESTRO02 20 to 196 VDC power supply
Revision History
Version Date Details
Ver. 1.0 6th May 2010 Initial Release
Ver. 1.1 13th May 2010 Minor updates
Ver. 1.2 July 2010 Updates to Chapter 3 and Chapter 4 (Appendix)
Ver. 1.300 Oct. 2012 Updates to Chapter 3 and minor updates in other
chapters.

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] • info-[email protected]

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Table of Contents
Chapter 1: Safety Information...................................................................................... 6
1.1. Cautions......................................................................................................................6
1.2. Directives and Standards............................................................................................7
1.3. Warranty Information ................................................................................................7
Chapter 2: Product Description .................................................................................... 8
2.1. Description .................................................................................................................8
2.2. Specifications..............................................................................................................9
2.2.1. Gold Maestro Hardware ..............................................................................9
2.2.2. Gold Maestro Software ............................................................................ 10
2.3. Communication Options.......................................................................................... 12
2.4. How to Use this Guide............................................................................................. 12
Chapter 3: Installation ............................................................................................... 13
3.1. Before You Begin ..................................................................................................... 13
3.1.1. Site Requirements .................................................................................... 13
3.1.2. Working Environment............................................................................... 13
3.2. Unpacking the Components .................................................................................... 13
3.3. Connectors............................................................................................................... 14
3.3.1. Connector Types....................................................................................... 14
3.3.2. Pinouts ...................................................................................................... 15
3.3.2.1. Power Connector ..................................................................... 15
3.3.2.2. EtherCAT In Connector ............................................................ 16
3.3.2.3. EtherCAT Out Connector ......................................................... 16
3.3.2.4. CANopen Connectors............................................................... 17
3.3.2.5. Ethernet Connector ................................................................. 17
3.3.2.6. USB 2.0 Connector................................................................... 18
3.4. Mounting the Gold Maestro.................................................................................... 18
3.4.1. Wall Mount............................................................................................... 18
3.4.2. Surface Mount .......................................................................................... 20
3.4.3. Installation on a DIN Rail .......................................................................... 20
3.5. Connecting the Cables............................................................................................. 21
3.5.1. Wiring the Gold Maestro .......................................................................... 21
3.5.2. Connecting the DC Power Supply ............................................................. 22
3.5.3. Ethernet.................................................................................................... 23
3.5.4. USB 2.0 Communication........................................................................... 24
3.5.5. CANopen Communication ........................................................................ 25
3.5.6. EtherCAT Communication ........................................................................ 27
3.6. Powering Up ............................................................................................................ 28
3.7. Initializing the System.............................................................................................. 28
Chapter 4: Technical Specifications ............................................................................ 29

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4.1. Gold Maestro Dimensions ....................................................................................... 29
4.2. General Specifications ............................................................................................. 29
4.3. Environmental Conditions....................................................................................... 29
4.4. Power Supply........................................................................................................... 30
4.5. Communications...................................................................................................... 30
4.6. Compliance with Standards..................................................................................... 31

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Chapter 1:
Safety Information
In order to achieve the optimum, safe operation of the Gold Maestro 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 Maestro 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.
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.
1.1. Cautions
•The Gold Maestro 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 Maestro, 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 Maestro 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 Gold Maestro 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 Maestro is 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:
Product Description
This installation guide describes the Gold Maestro Network Motion Controller and the steps for
its wiring, installation and power up. Following these guidelines ensures maximum functionality
of the system to which it is connected.
2.1. Description
The Gold Maestro is Elmo’s network motion controller. It works in a network based system in
conjunction with Elmo’s intelligent servo drives to provide a total multi-axis motion control
system solution.
The Gold Maestro is designed to support both the existing SimplIQ drives, based on standard
CANopen network architecture, as well as the new Gold Line, adding EtherCAT networking.
While being a true network controller, the Gold Maestro 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 Maestro controller.
The Gold Maestro 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 Maestro 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
CANopen 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 (CANopen 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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2.2. Specifications
2.2.1. Gold Maestro Hardware
•Hardware: Stand-alone
•Power Supply: Single DC supply, with two product options available:
13 VDC to 96 VDC
20 VDC to 196 VDC
•Processor: PowerPC, 333 MHz, with double precision floating point support by
hardware.
•Memory
Flash: 32 MB
RAM: 64 MB (DDR2, 333 MHz)
•Communication Hardware
Host:
•Ethernet: 1 port, Standard Ethernet, 10/100 Mbps, automatically detected
•USB: 1 port, USB2.0, 12 Mbps
Device Networks:
•EtherCAT: 2 x EtherCAT master ports, with redundancy support (optional)
•CAN: CANopen master port
•I/O System: All I/O interfaces are handled via the device network.
•Internal System BIT: The Gold Maestro supports internal hardware BIT (Built-in-tests)
procedures to check the system integrity level on each power up.
•Diagnostic LEDs: EtherCAT and Ethernet activity
•Dimensions: 115 mm x 75 mm x 25.4 mm (4.53" x 2.95" x 1")
•Weight: 250 g ( 8.75 oz)
•Operational Temperature: 0 °C to 40 °C

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2.2.2. Gold Maestro Software
•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.
•Number of 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 dependant on the
CAN network’s physical limitations)
•Motion Modes and Interfaces: The Gold Maestro 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
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

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•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 Maestro 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 Maestro and drives)
System resource files
Axis parameter files
•Drive Communication Bridge Support: The Gold Maestro 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 Maestro 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 Maestro 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.
•Network Encoders: Supports master based motion on network encoders
•Position Error Mapping: Supports 1-D and 2-D position-based error mapping
compensation
•System Boot up Time: < 30 sec

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2.3. Communication Options
The Gold Maestro can communicate with a host PC through either a standard Ethernet port or
through USB using a binary protocol for maintenance.
The Gold Maestro communicates with its network devices using either EtherCAT or CANopen
networks.
Figure 1: The Gold Maestro Network Connections
2.4. 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 Maestro up and running. Please read the safety instructions in the first
chapter before starting.
After you have successfully mounted and installed the Gold Maestro 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 Maestro in order for it to function as a motion controller.

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Chapter 3:
Installation
3.1. Before You Begin
3.1.1. Site Requirements
For safe operation of the Gold Maestro make sure it is installed in an appropriate environment.
Feature Value
Ambient operating temperature 0 °C to 40 °C (32 °F to 104 °F)
Maximum non-condensing humidity 90%
Operating area atmosphere No flammable gases or vapors permitted in area
3.1.2. Working Environment
Warning: During operation the Gold Maestro becomes hot to the touch (the case
can heat up to 50 °C). Care should be taken when handling it.
Caution: The Gold Maestro dissipates its heat by natural convection. The maximum
ambient operating temperature must not be exceeded.
3.2. Unpacking the Components
Before you begin working with the Gold Maestro system, verify that you have all of its
components, as follows:
•The Gold Maestro multi-axis controller
•Gold Maestro software which may be downloaded from www.elmomc.com
The Gold Maestro is shipped in a cardboard box with Styrofoam protection.
To unpack the Gold Maestro:
1. Carefully remove the Gold Maestro from the box.
2. Check the Gold Maestro 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.

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3. To ensure that the Gold Maestro you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Gold Maestro as shown
below.
4. The part number at the top gives the type designation as follows:
GOLD-MAESTRO01: 13 to 96 VDC power supply
GOLD-MAESTRO02: 20 to 196 VDC power supply
5. Verify that the Gold Maestro type is the one that you ordered.
6. Verify that you have CAN termination resistors (dongles), illustrated below.
3.3. Connectors
3.3.1. Connector Types
The Gold Maestro has the following connectors:
Pins Type Function
Bottom Connector
3 Phoenix 3.81 mm Pitch
Header
Power and ground
Front Connectors
8 RJ-45 EtherCAT In

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Pins Type Function
8 RJ-45 EtherCAT Out
8 RJ-45 CAN1
8 RJ-45 CAN2
Bottom Connectors
8 RJ-45 Ethernet
4 USB USB
Table 1: Connector Types
3.3.2. Pinouts
3.3.2.1. Power Connector
See Section 3.5.2 for full details.
Pin Function
PE Protective Earth
PR Power Return
VL+ Positive Power Input
Connector Location Cable Connector
3-Pin 3.81 mm Pitch Phoenix Header
(MC 1.5/3-G-3.81)
3-Pin Phoenix Plug
(MC 1.5/3-ST-3.81)
Table 2: Gold Maestro Power and Ground Connectors

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3.3.2.2. EtherCAT In Connector
See Section 3.5.6 for full details.
Pin Signal Function
1 EtherCAT_IN/Ethernet_TX+ EtherCAT in/Ethernet transmit +
2 EtherCAT_IN/Ethernet_TX- EtherCAT in/Ethernet transmit -
3 EtherCAT_IN/Ethernet_RX+ EtherCAT in/Ethernet receive +
4,5 N/A
6 EtherCAT_IN/Ethernet_RX- EtherCAT in/Ethernet receive -
7, 8 N/A
Connector Location Cable Connector
8-Pin RJ-45 Connector
Standard CAT5e Ethernet Cable
Table 3: EtherCAT In Pin Assignments
3.3.2.3. EtherCAT Out Connector
See Section 3.5.6 for full details.
Pin Signal Function
1 EtherCAT_OUT_TX+ EtherCAT in transmit +
2 EtherCAT_OUT_TX- EtherCAT in transmit -
3 EtherCAT_OUT_RX+ EtherCAT in receive +
4,5 N/A
6 EtherCAT_OUT_RX- EtherCAT in receive -
7, 8 N/A
Connector Location Cable Connector
8-Pin RJ-45 Connector
Standard CAT5e Ethernet Cable
Table 4: EtherCAT Out Pin Assignments

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3.3.2.4. CANopen Connectors
See Section 3.5.5 for full details.
Pin Signal Function
1 CAN_H CAN_H bus line (dominant high)
2 CAN_L CAN_L bus line (dominant low)
3 CAN_COMRET CAN Communication Return
4,5 N/A —
6 CAN_SHLD Shield, connected to the RJ-45 plug cover
7 CAN_COMRET CAN Communication Return
8 N/A —
Connector Location Cable Connector
8-Pin RJ-45 Connector
Standard CAT5e Ethernet Cable
Table 5: CANopen Pin Assignments
3.3.2.5. Ethernet Connector
See Section 3.5.3 for full details.
Pin Signal Function
1 TX+ Ethernet transmit +
2 TX- Ethernet transmit -
3 RX+ Ethernet receive +
4,5 N/A
6 RX- Ethernet receive -
7, 8 N/A
Connector Location Cable Connector
8-Pin RJ-45 Connector
Standard CAT5e Ethernet Cable

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Table 6: Ethernet Pin Assignments
3.3.2.6. USB 2.0 Connector
See Section 3.5.4 for full details.
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
Connector Location Cable Connector
USB 2.0 Connector
USB Device Type B Plug
Table 7: USB Pin Assignments
3.4. Mounting the Gold Maestro
The Gold Maestro has three mounting options:
1. Wall mount
2. Surface mount
3. Mounting on a DIN rail
3.4.1. 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.

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Figure 2: Wall Mounting the Gold Maestro

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3.4.2. 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 3: Surface Mounting the Gold Maestro
3.4.3. Installation on a DIN Rail
Use one M3x5 round head screw to connect the DIN rail mounting clip to the back of the Gold
Maestro.
Figure 4: Mounting the Gold Maestro on a DIN Rail