Elmo Gold Bell User manual

Gold Bell
Digital Servo Drive
Installation Guide
April 2018 (Ver. 1.200) 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 Bell 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.
Document no. MAN-G-BELIG (Ver. 1.200)
Copyright 2018
Elmo Motion Control Ltd.
All rights reserved.
Catalog Number

Table of Contents
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Table of Contents
Chapter 1: This Installation Guide .....................................................................................5
Chapter 2: Safety Information ..........................................................................................5
2.1 Warnings......................................................................................................................... 6
2.2 Cautions .......................................................................................................................... 6
2.3 CE Marking Conformance ............................................................................................... 6
2.4 Warranty Information..................................................................................................... 6
Chapter 3: Product Description .........................................................................................7
3.1.1 Accessories ...................................................................................................... 7
Chapter 4: Technical Information......................................................................................8
4.1 Physical Specifications .................................................................................................... 8
4.2 Technical Data................................................................................................................. 8
4.2.1 Control Supply ................................................................................................. 9
4.2.2 Product Features ........................................................................................... 10
4.2.3 Environmental Conditions............................................................................. 11
4.2.4 Gold Line Standards....................................................................................... 12
Chapter 5: Installation....................................................................................................13
5.1 Unpacking the Drive Components................................................................................ 13
Chapter 6: Mounting the Gold Bell..................................................................................14
Chapter 7: Integrating the Gold Bell on a PCB..................................................................15
7.1 Power Returns (PR)....................................................................................................... 15
7.2 COMRET ........................................................................................................................ 15
7.3 Earth Connection (PE)................................................................................................... 15
7.4 Power Return (PR), Common Return (COMRET) and Earth Connections (PE) ............. 16
7.5 Power Conductors PCB layout ...................................................................................... 17
Chapter 8: The Gold Bell Connection Diagram .................................................................18
Chapter 9: PCB Connections............................................................................................19
9.1 Wiring legend................................................................................................................ 19
9.2 Connector Types ........................................................................................................... 21
9.2.1 Connector Types............................................................................................ 21
9.3 Drive Status Indicator ................................................................................................... 22
9.4 Motor Power Connector Pinouts.................................................................................. 22
9.5 Main Power and Control Connector............................................................................. 25
9.5.1 Main Power ................................................................................................... 25
9.5.2 Control Supply ............................................................................................... 26
9.5.3 Power Supply for the Power Rating 200 V .................................................... 27
9.5.4 Power Supply for power rating 100 V ........................................................... 28

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9.5.4.1 Single Power Supply ..................................................................... 28
9.5.4.2 Shared Supply............................................................................... 30
9.6 Connector J2 - Feedback, Analog Inputs, RS-232, USB, EtherCAT, Ethernet, and CAN 31
9.6.1 Feedback Port A ............................................................................................ 34
9.6.1.1 Incremental Encoder .................................................................... 34
9.6.1.2 Hall Sensors .................................................................................. 35
9.6.1.3 Absolute Serial Encoder ............................................................... 36
9.6.1.4 Hiperface ...................................................................................... 38
9.6.2 Feedback Port B............................................................................................. 39
9.6.2.1 Incremental Encoder .................................................................... 39
9.6.2.2 Interpolated Analog (Sine/Cosine) Encoder................................. 40
9.6.2.3 Resolver........................................................................................ 41
9.6.3 Port C – Emulated Encoder Output ............................................................... 42
9.6.4 Analog Inputs................................................................................................. 42
9.6.4.1 Analog Input 1 .............................................................................. 43
9.6.4.2 Analog Input 2 .............................................................................. 44
9.6.5 RS232 TTL Logic Level.................................................................................... 44
9.6.6 USB 2.0 .......................................................................................................... 46
9.6.7 EtherCAT/Ethernet ........................................................................................ 47
9.6.8 CAN................................................................................................................ 48
9.7 Connector J1 - Digital I/O, Analog Inputs, LEDs, and STO............................................. 49
9.7.1 Digital Inputs ................................................................................................. 51
9.7.1.1 TTL voltage level ........................................................................... 51
9.7.2 Digital Outputs............................................................................................... 52
9.7.2.1 Isolated Open Collector and Open Emitter .................................. 52
9.7.3 Analog Inputs................................................................................................. 52
9.7.4 STO Input Interfaces - TTL Mode................................................................... 53
9.7.5 EtherCAT Status Indicator ............................................................................. 53
Chapter 10: Powering Up..................................................................................................54
10.1 Initializing the System................................................................................................... 54
Chapter 11: Heat Dissipation ............................................................................................55
11.1 Thermal Data ................................................................................................................ 55
11.2 Heat Dissipation Data ................................................................................................... 55
11.3 How to Use the Charts.................................................................................................. 56
Chapter 12: Dimensions ...................................................................................................57

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Chapter 1: This Installation Guide
This installation Guide details the technical data, pinouts, and power connectivity of the Gold Bell.
For a comprehensive detailed description of the functions and connections of the Board Level
Module (BLM) drive, refer to the MAN-G-Board Level Modules Hardware Manual.
Chapter 2: Safety Information
In order to achieve the optimum, safe operation of the Gold Bell, 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 Bell 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 Gold Bell 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 and all Elmo Motion Control manuals:
Warning:
This information is needed to avoid a safety hazard, which might cause bodily injury
or death as a result of incorrect operation.
Caution:
This information is necessary to prevent bodily injury, damage to the product or to
other equipment.
Important:
Identifies information that is critical for successful application and understanding of
the product.

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2.1 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
Gold Bell from all voltage sources before servicing.
•The high voltage products within the Gold Line range contain grounding conduits for electric
current protection. Any disruption to these conduits may cause the instrument to become hot
(live) and dangerous.
•After shutting off the power and removing the power source from your equipment, wait at least
1 minute before touching or disconnecting parts of the equipment that are normally loaded
with electrical charges (such as capacitors or contacts). Measuring the electrical contact points
with a meter, before touching the equipment, is recommended.
2.2 Cautions
•The maximum DC power supply connected to the instrument must comply with the parameters
outlined in this guide.
•When connecting the Gold Bell to an approved isolated control power supply, connect it
through a line that is separated from hazardous live voltages using reinforced or double
insulation in accordance with approved safety standards.
•Before switching on the Gold Bell, verify that all safety precautions have been observed and
that the installation procedures in this manual have been followed.
•Make sure that the Safe Torque Off is operational
2.3 CE Marking Conformance
The Gold Bell 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 2006/42/EC as amended, and with those of the most recent versions of
standards EN 60204-1 and EN ISO 12100 at the least, and in accordance with 2006/95/EC.
Concerning electrical equipment designed for use within certain voltage limits, the Gold Bell meets
the provisions outlined in 2006/95/EC. The party responsible for ensuring that the equipment
meets the limits required by EMC regulations is the manufacturer of the end product.
2.4 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 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 3: Product Description
The Gold Bell is an advanced high power density servo drive delivering up to 1.6 kW of continuous
power or 3.2 kW of peak power in a 49.4 cc (3.02 in3) package (55 x 59 x 15 mm or 2.17” x 2.32” x
0.6”). The Gold Bell is designed to be mounted on a PCB by soldering its pins directly to the PCB.
This advanced, high power density servo drive provides top performance, advanced networking and
built-in safety, as well as a fully featured motion controller and local intelligence. Power to the Gold
Bell is provided by a DC power source which is isolated from the Mains. The Gold Bell can operate
with single or dual power supplies. If separation between the main DC power source and a control
supply is required, then a control supply (isolated from the Mains) is required.
The drive 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 Gold Bell drive is easily set up and tuned using the Elmo Application Studio (EASII) software
tools. As part of the Gold product line, it is fully programmable with the Elmo motion control
language. For more information about software tools refer to the Elmo Application Studio Software
Manual.
The Gold Bell is available in a variety of models. There are multiple power rating options, two
different communications options, a number of feedback options and different I/O configuration
possibilities.
3.1.1 Accessories
•Cable Kit (TBD)

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Chapter 4: Technical Information
4.1 Physical Specifications
Feature Units All Types
Weight g (oz) 55 g (1.94 oz)
Dimension mm (in) 48.5 cc (2.96 in3) package
(55±0.2 x 58.5±0.2 x 14.9±0.5 mm or 2.17” x 2.30” x 0.59”)
Mounting method PCB mount
4.2 Technical Data
Feature Units 1/100 2.5/100 5/100 10/100 15/100 20/100
Minimum supply voltage VDC 12
Nominal supply voltage VDC 85
Maximum supply voltage VDC 95
Maximum continuous power
output
W 80 200 400 800 1200 1600
Efficiency at rated power (at
nominal conditions)
% > 99
Maximum output voltage > 95% of DC bus voltage at f = 22 kHz
Control supply VDC 12 to 95 VDC
(up to 6 VA inc. 5 V/2 x 200 mA for encoder)
Amplitude sinusoidal/DC
continuous current
A 1.0 2.5 5 10 15 20
Sinusoidal continuous RMS
current limit (Ic)
A 0.7 1.8 3.5 7 10.6 14.1
Peak current limit A 2 x Ic
Table 1: Technical Data
Note on current ratings: The current ratings of the Gold Bell are given in units of DC
amperes (ratings that are used for trapezoidal commutation or DC motors). The RMS (sinusoidal
commutation) value is the DC value divided by 1.41.

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Elmo offers a 200 VDC maximum output rating selection of Gold Bell, according to the following
technical data:
Feature Units 3/200 6/200 9/200
Minimum supply voltage VDC 12
Nominal supply voltage VDC 170
Maximum supply voltage VDC 195
Maximum continuous power output W 480 960 1450
Efficiency at rated power (at
nominal conditions)
% > 99
Maximum output voltage > 95% of DC bus voltage at f = 22 kHz
Control supply VDC 12 to 95 VDC
(up to 6 VA inc. 5 V/2 x 200 mA for
encoder)
Amplitude sinusoidal/DC
continuous current
A 3 6 9
Sinusoidal continuous RMS current
limit (Ic)
A 2.1 4.2 6.3
Peak current limit A 2 x Ic
4.2.1 Control Supply
Feature Details
Control supply Isolated DC source only
Control supply input voltage 12 V to 95 V
Control supply input power ≤4 VA without external loading
≤6 VA with full external loading

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4.2.2 Product Features
Main Feature Details Presence / No.
STO TTL √
Digital Input
Option
TTL 6
Digital Output
Option
Open Collector-emitter (isolated) 2
TTL 3.3V(Non Isolation) 2
Analog Input Differential ±10V 1
Single Ended 1
Feedback Standard Port A, B, & C √
Communication
Option
USB √
EtherCAT √
CAN √
RS-232 TTL level √

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4.2.3 Environmental Conditions
You can guarantee the safe operation of the Gold Bell by ensuring that it is installed in an
appropriate environment.
Feature Details
Operating ambient temperature
according to IEC60068-2-2
0 °C to 40 °C (32 °F to 104 °F)
Storage temperature -20 °C to +85 °C ( -4 °F to +185 °F)
Maximum non-condensing humidity
according to IEC60068-2-78
95%
Maximum Operating Altitude 2,000 m (6562 feet)
It should be noted that servo drives capable of
higher operating altitudes are available on
request.
Mechanical Shock
according to IEC60068-2-27
15g / 11ms Half Sine
Vibration
according to IEC60068-2-6
5 Hz ≤ f ≤ 10 Hz: ±10mm
10 Hz ≤ f ≤ 57 Hz: 4G
57 Hz ≤ f ≤ 500 Hz:5G

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4.2.4 Gold Line Standards
The following table describes the Main Standards of the Gold Bell servo drive. For further details
refer to Chapter 17 in the MAN-G-Board Level Modules Hardware Manual.
Main Standards Item
The related standards below apply to the performance of the servo drives as stated in the
environmental conditions in section 4.2.3 Environmental Conditions above.
STO IEC 61800-5-2:2007 SIL 3 Adjustable speed electrical power drive systems –
Safety requirements – Functional
EN ISO 13849-1:2008 PL e, Cat 3 Safety of machinery — Safety-related parts of control
systems.
Approved IEC/EN 61800-5-1 Adjustable speed electrical power drive systems
Safety requirements – Electrical, thermal and energy
Recognized UL61800-5-1 Adjustable speed electrical power drive systems
Safety requirements – Electrical, thermal and energy
Recognized UL 508C Power Conversion Equipment
In compliance with UL 840 Insulation Coordination Including Clearances and
Creepage Distances for Electrical Equipment
Conformity with CE 2006/95/EC Low-voltage directive 2006/95/EC
Recognized CSA C22.2 NO. 14-13 Industrial Control Equipment

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Chapter 5: Installation
The Gold Bell must be installed in a suitable environment and properly connected to its voltage
supplies and the motor.
5.1 Unpacking the Drive Components
Before you begin working with the Gold Bell, verify that you have all of its components, as follows:
•The Gold Bell servo drive
•The Elmo Application Studio (EAS) software and software manual
The Gold Bell is shipped in a cardboard box with Styrofoam protection.
To unpack the Gold Bell:
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 Gold Bell you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Gold Bell. It looks like this:
4. Verify that the Gold Bell type is the one that you ordered, and ensure that the voltage meets
your specific requirements.
The part number at the top provides the type designation. Refer to the appropriate part
number in the section Catalog Number at the beginning of the installation guide.

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Chapter 6: Mounting the Gold Bell
The Gold Bell was designed for mounting on a printed circuit board (PCB) via 1.27 mm pitch 0.41
mm square pins and 2 mm pitch 0.51 mm square pins. When integrating the Gold Bell into a device,
be sure to leave about 1 cm (0.4") outward from the heat sink to enable free air convection around
the drive. We recommend that the Gold Bell be soldered directly to the board. Alternatively, though
this is not recommended, the Gold Bell can be attached to socket connectors mounted on the PCB.
If the PCB is enclosed in a metal chassis, we recommend that the Gold Bell be screw-mounted to it
as well to help with heat dissipation. The Gold Bell has screw-mount holes on each corner of the
heat sink for this purpose – see below.
All measurements are in mm.
Figure 1: Gold Bell Dimensions

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Chapter 7: Integrating the Gold Bell on a PCB
The Gold Bell is designed to be mounted on a PCB by soldering its pins directly to the PCB. Refer to
Chapter 5 in the MAN-G-Board Level Modules Hardware Manual and the drawings in the Gold Line
Whistle Design Guide MAN-G-WHIIDG for further information.
7.1 Power Returns (PR)
In the Gold Bell, the power stage and control stage are internally connected, and the negative node
of the DC power bus is designates as PR
The maximum realistic Power Return is achieved using a plane, which connects between the Gold
Drive and the power source. The impedance on this plane must be as low as possible to reduce the
impedance between the “Grounds”. This effectively reduces the levels of common mode
differences, interferences, EMI etc.
7.2 COMRET
For details of the COMRET, refer to the section 5.4 in the MAN-G-Board Level Modules Hardware
Manual.
7.3 Earth Connection (PE)
The PE (Earth connection) terminal is connected internally in the drive to the Gold Bell’s chassis
(heat-sink + metal cover) which serves as an EMI common plane. Any other assembly metallic parts
(such as the chassis) should also be connected to the PE.
Under normal operating conditions, the PE trace carries no current. The only time these traces carry
current is under unusual conditions (such as when the device has become a potential shock or fire
hazard while conducting external EMI interferences directly to ground). When connected properly
the PE trace prevents these hazards from affecting the drive.

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7.4 Power Return (PR), Common Return (COMRET) and Earth
Connections (PE)
Safety regulations (UL61800-5-1, IEC61800-5-1, and UL508C) require that the servo drive, as a
“stand alone”, must withstand breakdown voltages of 2KV for the 200V models, and 1.7KV for the
100V models, between PE to PR. However, the connections between PE to PR and the COMRET are
essential for the safe operation of the servo drive. Therefore the following topology must be used:
Figure 2: Gold Bell Earth Connections
The connections to PE are essential, but must be done externally to the integration board.

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7.5 Power Conductors PCB layout
The PCB virtually divided into two zones; Power Zone, and Control & Communication Zone.
•Power Zone
This area is dedicated to Power conductors only: VP+, PR, PE, VL+, VL-, VN- and motor leads.
•Control and Communication Zone
This area of the PCB is dedicated to Control low level signals
Figure 3: Gold Bell Power Conductors PCB layout
For more details, refer to the section 5.4 in the MAN-G-Board Level Modules Hardware Manual.

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Chapter 8: The Gold Bell Connection Diagram
Figure 4: The Gold Bell Connection Diagram

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Chapter 9: PCB Connections
9.1 Wiring legend
The following table legend describes the wiring symbols detailed in all installation guides. All the
wiring diagrams show wiring for D-TYPE connectors.
Wiring Symbol Description
Earth connection (PE)
Earth Connection
Common at the Controller
Shielded cable with drain wire.
The drain wire is a non-insulated wire that is in
direct contact with the braid (shielding).
Shielded cable with drain wire significantly
simplifies the wiring and earthing.
Shielded cable braid only, without drain wire.
Twisted-pair wires

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Wiring Symbol Description
Encoder Earthing.
The cable`s shield is connected to the
chassis (PE) in the connector.
Earthing the Encoder and connecting
the Earth (PE) to the drive COMRET is
mandatory to insure reliable
operation, high noise immunity and
rejection of voltage common mode
interferences.