Elmo Cello User manual

Cello
Digital Servo Drive
Installation Guide
March 2010 (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 Cello 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 trademarks of
Elmo Motion Control Ltd.
Information in this document is subject to change without notice.
Document No. MAN-CELIG
Copyright ©2010
Elmo Motion Control Ltd.
All rights reserved
Cello Catalog
Number:
Maximum DC
Operating Voltage
Continuous Current
(Amps)
Version :
Blank = Standard
A = Advanced
Feedback:
Blank = Incremental
Encoder
and/or Halls
R=Resolver
CEL- AXX/YYYR
T=Tachometer &
Potentiometer
I = Interpolated
Analog
Encoder
Q=Encoder
Absolute
Cable Kit Catalog No. CBL-CELKIT01 & CBL-CELKIT02 (kit available upon request)
Related Document MAN-CBLKIT-CEL (available on our website)
Elmo Motion Control Ltd.
64 Gissin St., P.O. Box 463
Petach Tikva 49103
Israel
Tel: [phone]
Fax: [phone]
[email protected]
Elmo Motion Control Inc.
42 Technology Way
Nashua, NH 03060
USA
Tel: [phone]
Fax: [phone]
[email protected]
Elmo Motion Control GmbH
Steinkirchring 1
D-78056, Villingen-Schwenningen
Germany
Tel: [phone]
Fax: [phone]
[e-mail]
www.elmomc.com

Revision History:
Version Release Date Changes/Remarks
Ver. 1.5 March 2010 MTCR 07-009-56: Added note to 3.4.8.2
Ver. 1.4 August 2008 Added 3.4.7.4: Differential pulse-and–direction input
Ver. 1.3 April 2008 Updated Power Ratings Table in Appendix

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 Drive Description ........................................................................................... 2-1
2.2 Product Features............................................................................................. 2-1
2.2.1 Current Control .........................................................................................2-1
2.2.2 Velocity Control.........................................................................................2-1
2.2.3 Position Control.........................................................................................2-2
2.2.4 Advanced Position Control (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 System Architecture ....................................................................................... 2-3
2.4 How to Use this Guide................................................................................... 2-4
Chapter 3: Installation ............................................................................................................ 3-1
3.1 Before You Begin ............................................................................................ 3-1
3.1.1 Site Requirements......................................................................................3-1
3.1.2 Hardware Requirements ..........................................................................3-1
3.2 Unpacking the Drive Components ............................................................... 3-3
3.3 Mounting the Cello ........................................................................................ 3-4
3.4 Connecting the Cables ................................................................................... 3-4
3.4.1 Wiring the Cello.........................................................................................3-4
3.4.2 Connecting the Power Cables..................................................................3-8
3.4.2.1 Connecting the Motor Cable.......................................................... 3-8
3.4.2.2 Connecting the Main Power Cable................................................ 3-9
3.4.3 Connecting the Optional Back-up Supply Cable (24v) ......................3-10
3.4.4 Feedback and Control Cable Assemblies.............................................3-11
3.4.5 Main Feedback Cable (FEEDBACK A).................................................3-11
3.4.6 Main and Auxiliary Feedback Combinations......................................3-20
3.4.7 Auxiliary Feedback (FEEDBACK B).....................................................3-22
3.4.7.1 Main Encoder Buffered Outputs or Emulated Encoder
Outputs Option on FEEDBACK B (YA[4]=4)............................. 3-22
3.4.7.2 Differential Auxiliary Encoder Input Option on FEEDBACK B
(YA[4]=2)........................................................................................ 3-24
3.4.7.3 Single-ended Auxiliary Input Option on FEEDBACK B
(YA[4]=2)........................................................................................ 3-26
3.4.7.4 Pulse-and-Direction Input Option on FEEDBACK B (YA[4]=0)3-28
3.4.8 I/O Cables ................................................................................................3-31
3.4.8.1 General I/O Port (J1) .................................................................... 3-32
3.4.8.2 General Input Port (J2) ................................................................. 3-34
3.4.9 Communication Cables ..........................................................................3-36
3.4.9.1 RS-232 Communication ................................................................ 3-36
Cello Installation Guide Contents
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3.4.9.2 CANopen Communication .......................................................... 3-37
3.5 Powering Up ................................................................................................. 3-39
3.6 Initializing the System ................................................................................. 3-39
Appendix: Technical Specifications.................................................................................... A-1
A.1 Features .......................................................................................................... A-1
A.1.1 Motion Control Modes ........................................................................... A-1
A.1.2 Advanced Positioning Motion Control Modes ................................... A-1
A.1.3 Advanced Filters and Gain Scheduling................................................ A-1
A.1.4 Fully Programmable ............................................................................... A-1
A.1.5 Feedback Options.................................................................................... A-1
A.1.6 Input/Output........................................................................................... A-2
A.1.7 Built-In Protection ................................................................................... A-2
A.2 Cello Dimensions........................................................................................... A-3
A.3 Power Ratings................................................................................................ A-4
A.4 Environmental Conditions ........................................................................... A-4
A.5 Cello Connections.......................................................................................... A-5
A.5.1 Backup Supply (Optional)...................................................................... A-6
A.6 Control Specifications ................................................................................... A-6
A.6.1 Current Loop............................................................................................ A-6
A.6.2 Velocity Loop........................................................................................... A-7
A.6.3 Position Loop ........................................................................................... A-7
A.7 Feedbacks ....................................................................................................... A-8
A.7.1 Feedback Supply Voltage....................................................................... A-8
A.7.2 Incremental Encoder Input .................................................................... A-8
A.7.3 Digital Halls ............................................................................................. A-9
A.7.4 Interpolated Analog Encoder (Sine/Cosine)....................................... A-9
A.7.5 Resolver .................................................................................................. A-10
A.7.6 Tachometer* ........................................................................................... A-10
A.7.7 Potentiometer......................................................................................... A-11
A.7.8 Encoder Outputs.................................................................................... A-11
A.8 I/Os............................................................................................................... A-12
A.8.1 Digital Input Interfaces......................................................................... A-12
A.8.2 Digital Output Interface ....................................................................... A-13
A.8.3 Analog Input .......................................................................................... A-13
A.9 Communications.......................................................................................... A-14
A.10 Pulse Width Modulation (PWM) ............................................................... A-14
A.11 Mechanical Specifications........................................................................... A-14
A.12 Standards Compliance ................................................................................ A-15
A.12.1 Quality Assurance................................................................................. A-15
A.12.2 Design ..................................................................................................... A-15
A.12.3 Safety....................................................................................................... A-15
A.12.4 EMC......................................................................................................... A-15
A.12.5 Workmanship ........................................................................................ A-15
A.12.6 PCB .......................................................................................................... A-16
A.12.7 Packing.................................................................................................... A-16
A.12.8 WEEE*..................................................................................................... A-16
A.12.9 RoHS ....................................................................................................... A-16
Index...........................................................................................................................................I-1
Cello Installation Guide Contents
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Cello Installation Guide
MAN-CELIG (Ver. 1.5)
1-1
Chapter 1: Safety Information
In order to achieve the optimum, safe operation of the Cello 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 Cello 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 Cello 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.
Note:
This is auxiliary information that ensures the correct operation of
the equipment.

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 Cello 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 Cello 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 Cello 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
Cello. High voltages may damage the drive.
The DC power supply voltage range is defined in Table A.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 Cello, verify that all safety precautions have
been observed and that the installation procedures in this manual
have been followed.
Cello Installation Guide Safety Information
MAN-CELIG (Ver. 1.5)
1-2

1.3 Directives and Standards
The Cello conforms to the following industry safety standards:
Safety Standard Item
In compliance with UL508c
In compliance with UL840
Conformance to the following safety standards:
Power Conversion Equipment
Insulation Coordination, Including
Clearance and Creepage Distances of
Electrical Equipment
In compliance with UL60950
(formerly UL1950)
Safety of Information Technology Equipment,
Including Electrical Business Equipment
In compliance with EN60204-1 Low Voltage Directive, 73/23/EEC
The Cello 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.
1.4 CE Mark Conformance
The Cello 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 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 Cello meets the provisions outlined in Council Directive
73/23/EEC. The party responsible for ensuring that the equipment meet 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.
Cello Installation Guide Safety Information
MAN-CELIG (Ver. 1.5)
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Cello Installation Guide Introduction
MAN-CELIG (Ver. 1.5)
2-1
Chapter 2: Introduction
This installation guide describes the Cello 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 Drive Description
The Cello is a powerful servo drive that operates in digital current, velocity, position
and advanced position modes, in conjunction with a permanent-magnet synchronous
brushless motor or DC brush motor. The Cello features flexible sinusoidal and
trapezoidal commutation, with vector control. The Cello can operate as a stand-alone
device or as part of a multi-axis network in a distributed configuration.
The Cello 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 Cello is provided by a 10 to 195 VDC source. A “smart” control-supply
algorithm enables the Cello 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.
Two variations of the Cello are available: the Standard version and the Advanced
version, which features advanced positioning capabilities. Both versions operate with
RS-232 and/or CANopen communication.
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

Cello Installation Guide Introduction
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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 time: four times that of current loop
Fast event capturing inputs
2.2.4 Advanced Position Control (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, Cello users can select from two communication options:
RS-232 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
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 10~15 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 ~ 5 V voltage range
•Resistance: 100 Ωto 1000 Ω
Elmo drives provide supply voltage for all the feedback options