Elmo Gold DC Trombone User manual

Gold DC Trombone
Digital Servo Drive
Installation Guide
EtherCAT and CAN
July 2019 (Ver. 1.906) 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 DC Trombone
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-DCTROIG-EC (Ver. 1.906)
Copyright 2019
Elmo Motion Control Ltd.
All rights reserved.
Catalog Number

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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
Chapter 4: Technical Information..................................................................................8
4.1 Physical Specifications................................................................................................8
4.2 Technical Data for the 400 V Type .............................................................................8
4.3 Technical Data for the 800 V Type .............................................................................9
4.4 Auxiliary Supply ........................................................................................................10
4.5 Product Features ......................................................................................................10
4.6 Environmental Conditions........................................................................................11
4.6.1 Gold Line....................................................................................................11
4.7 Gold Line Standards..................................................................................................12
Chapter 5: Installation................................................................................................13
5.1 Unpacking the Drive Components ...........................................................................13
5.2 Connector Types.......................................................................................................14
5.2.1 Mating Connector Types ...........................................................................16
5.3 Mounting the Gold DC Trombone............................................................................17
5.4 Connection Diagrams ...............................................................................................18
5.4.1 Connection Diagrams for EtherCAT Version..............................................19
5.4.2 Connection Diagrams for CAN Version......................................................21
Chapter 6: Wiring.......................................................................................................23
6.1 Basic Recommendations ..........................................................................................25
6.1.1 General ......................................................................................................25
6.1.2 Feedback Cable Port A and Port B Connector ...........................................26
6.1.3 Feedback Cable Port C Connector .............................................................27
6.1.4 IO Cable Connector....................................................................................27
6.1.5 STO (Port C) Cable Connector....................................................................28
6.2 Motor Power Connector Pinouts .............................................................................29
6.3 Main Power ..............................................................................................................31
6.3.1 Direct-to-Mains Power Source ..................................................................33
6.3.1.1 Three-Phase Direct-to-Mains Connection Topology ................33
6.3.1.2 Single-Phase Direct-to-Mains Connection Topology................34
6.3.1.3 Multiple Connections Topology................................................
35
6.3.2 Battery Power Supply ................................................................................36

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6.4 Auxiliary Power.........................................................................................................37
6.5 Port A........................................................................................................................39
6.5.1 Incremental Encoder .................................................................................40
6.5.2 Hall Sensor.................................................................................................40
6.5.3 Absolute Serial Type Encoder....................................................................41
6.6 Port B........................................................................................................................43
6.6.1 Incremental Encoder .................................................................................44
6.6.2 Interpolated Analog Encoder ....................................................................45
6.6.3 Resolver .....................................................................................................46
6.7 Port C, Analog Input, and STO ..................................................................................47
6.7.1 Port C .........................................................................................................49
6.7.2 Analog Input ..............................................................................................49
6.7.3 STO.............................................................................................................50
6.7.3.1 Source Mode PLC Voltage Level ...............................................50
6.7.3.2 TTL Mode TTL Voltage Level .....................................................50
6.7.3.3 SINK Mode – PLC Voltage Level................................................51
6.8 Digital Inputs and Outputs .......................................................................................52
6.8.1 Digital Input and Output TTL Mode...........................................................54
6.8.2 Digital Input and Output PLC Source Mode ..............................................56
6.8.3 Digital Input and Output Sink Mode..........................................................58
6.9 USB 2.0 .....................................................................................................................60
6.10 Drive Status Indicator...............................................................................................61
6.11 EtherCAT Communications Version .........................................................................62
6.11.1 EtherCAT IN/Ethernet Pinouts...................................................................62
6.11.2 EtherCAT OUT Pinouts...............................................................................63
6.11.3 EtherCAT Wiring ........................................................................................63
6.11.4 EtherCAT Link Indicators ...........................................................................64
6.11.5 EtherCAT Status Indicator .........................................................................64
6.12 CAN Communications Version .................................................................................65
6.12.1 CAN Wiring ................................................................................................66
6.13 Heat Dissipation .......................................................................................................67
6.13.1 Gold DC Trombone Thermal Data .............................................................67
6.13.2 Heat Dissipation Data ................................................................................67
6.13.3 How to Use the Charts...............................................................................68
Chapter 7: Powering Up .............................................................................................69
7.1 Initializing the System ..............................................................................................69
Chapter 8: Gold DC Trombone Dimensions .................................................................70

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Chapter 1: This Installation Guide
This installation Guide details the technical data, pinouts, wiring, and power connectivity of the
Gold DC Trombone. For a comprehensive detailed description of the functions refer to the
MAN-G-Panel Mounted Drives Hardware manual which describes Panel Mounted products.
Chapter 2: Safety Information
In order to achieve the optimum, safe operation of the Gold DC Trombone, 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 DC Trombone 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 DC Trombone 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 DC Trombone 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 DC Trombone to an approved isolated auxiliary 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 DC Trombone, 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 DC Trombone 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 DC
Trombone 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 DC Trombone series of digital servo drives are highly resilient and operate from a DC
Power Voltage Input source. They are designed to deliver the highest density of power and
intelligence. The Gold DC Trombone delivers up to 10 kW of continuous power or 16 kW of peak
power in a compact package.
The digital drives are part of Elmo’s advanced Gold Line. 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 Gold DC
Trombone 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 drive is easily set up and tuned using Elmo Application Studio (EASII) software tools. The
Windows based application enables users to quickly and simply configure the servo drive for
optimal use with their motor. The Gold DC Trombone, as part of the Gold Line, is fully
programmable with Elmo’s motion control language.
Power to the drives is provided by a DC power source (not included with the Gold DC Trombone).
Since the power stage is fully isolated from the control stage, the DC rectifier can be fed directly
from the mains, without the need for a bulky and expensive transformer.
If backup functionality is required to store control parameters in the event of a mains power
outage, then an A, H, S, or T optional Gold DC Trombone should be used, with an external 24 VDC
isolated supply connected to it.
Note: The backup functionality can operate from an isolated voltage source within the range of
18 to 30 VDC.
Whenever backup functionality is not required, Gold DC Trombone models with the 0 or 1 Option
(only for 400 V models) in the catalog number (section Catalog Number) can be used, i.e., they do
not have a 24 V control supply. In these models, a smart control-supply algorithm enables the Gold
DC Trombone to operate with only the main power supply VP+ and VN-, with no need for a 24 VDC
auxiliary power supply for the logic.
The Gold DC Trombone is a stand-alone version of the Gold Trombone module (PCB-mounted).
Another pluggable version, the Gold Solo Trombone is also available.

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Chapter 4: Technical Information
4.1 Physical Specifications
Feature Units All Types
Weight g (oz) 650 g (22.9 oz) for standard L shape
1100 g (38.8 oz) for L shape fins and fan
Dimensions mm (in) 105 x 140 x 47 (4.13" x 5.51" x 1.85")
Mounting method Panel / Wall Mounted
4.2 Technical Data for the 400 V Type
Feature Units 6/400 12/400 16/400 R17/400 R22/400
Minimum supply voltage
VDC
A, H, S, or T in P/N*: 50
0 or 1 Option in P/N: 100
Nominal supply voltage
VDC
325
Maximum supply voltage
VDC
400
Maximum continuous power
output
kW
2
4
5
5.5
7
Efficiency at rated power (at
nominal conditions)
%
> 98
Auxiliary supply voltage option
VDC
18 V to 30 V
Only for Control Supply A/H/S/T Option Models
Auxiliary power supply
VA
7
Continuous current limit (Ic)
Amplitude sinusoidal/DC
trapezoidal commutation
A
6
12
16
17
22
Sinusoidal continuous RMS
current limit (Ic)
A
4.2
8.5
11.3
12
15.5
Peak current limit
A
2 x Ic
No peak

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4.3 Technical Data for the 800 V Type
Feature Units 8/800 12/800 R11/800 R16/800
Minimum supply voltage
VDC
A, H, S, or T Option in P/N*: 95+
Nominal supply voltage
VDC
560 for 400 VAC
680 for 480 VAC
Maximum supply voltage
VDC
780
Maximum continuous power
output
kW
5
7.5
7
10
Efficiency at rated power (at
nominal conditions)
%
> 98
Auxiliary supply voltage option
VDC
18 V to 30 V
Only for Control Supply A/H/S/T Option
Models
Auxiliary power supply
VA
7
Continuous current limit (Ic)
Amplitude sinusoidal/DC
trapezoidal commutation
A
8
12
11
16
Sinusoidal continuous RMS
current limit (Ic)
A
5.7
8.5
7.8
11.3
Peak current limit
A
2 x Ic
No peak
*See section Catalog Number for details on the part number. The A, H, S, or T Option appears in
models where there is a 24 V control supply. If there is a 0 or 1 Option, the control power supply
operates from the main power.
Note on current ratings:The current ratings of the Gold DC Trombone 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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4.4 Auxiliary Supply
Feature Details
Auxiliary power supply
Isolated DC source only
Auxiliary supply input voltage
18 VDC to 30 VDC
Auxiliary supply input power
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4.5 Product Features
Main Feature Details Presence and No.
STO TTL, or √
PLC Source, or √
PLC Sink (is not fully certified, and
not recommended for new designs)
√
Digital Input
Option
TTL, or 6
PLC Source, or 6
PLC Sink 6
Digital Output
Option
TTL, or 4
PLC Source, or 4
PLC Sink 4
Analog Input Differential ±10V 1
Feedback Standard Port A, B, & C √
Communication
Option
USB √
EtherCAT, or √
CAN √

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4.6 Environmental Conditions
You can guarantee the safe operation of the Gold DC Trombone by ensuring that it is installed in an
appropriate environment.
4.6.1 Gold Line
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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4.7 Gold Line Standards
The following table describes the Main Standards of the Gold DC Trombone servo drive. For further
details refer to the MAN-G-Panel Mounted Drives 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 4.6.1 Gold Line 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 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 DC Trombone 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 DC Trombone, verify that you have all of its components, as
follows:
•The Gold DC Trombone servo drive
•The Elmo Application Studio (EAS) software and software manual
The Gold DC Trombone is shipped in a cardboard box with Styrofoam protection.
To unpack the Gold DC Trombone:
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 DC Trombone you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Gold DC Trombone. It looks
like this:
Figure 1: Gold DC Trombone Part Number Sticker
4. Verify that the Gold DC Trombone 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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5.2 Connector Types
The Gold DC Trombone has the following ten connectors.
Pins Type Function
Bottom Connectors
2 5.08 mm Phoenix high current 24 V
4 7.62 mm Phoenix high current Motor Connector
3 7.62 mm Phoenix high current Power Connector

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Pins Type Function
Front Connectors
Front Connectors - EtherCAT
Front Connectors - CAN

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Pins Type Function
15 Socket D-Type Port A
9 Socket D-Type Port B
15 Socket High Density D-Type Port C and Safety
15 Pin High Density D-Type I/O
4 USB Device Type Mini B USB communication
EtherCAT Version
8 RJ-45 EtherCAT_IN/Ethernet communication
8 RJ-45 EtherCAT OUT communication
CAN Version
8 RJ-45 CAN
8 RJ-45 CAN
Table 1: Connector Types
The pinouts in Chapter 6: Wiring describe the function of each pin in the Gold DC Trombone
connectors that are listed in Table 1.
5.2.1 Mating Connector Types
Mating Pin Connector Function Manufacturing P/N (Pheonix)
2 Pin VL MSTB 2,5/ 2-ST-5,08
3 Pin Main DC Input GMSTB 2,5 HCV/ 3-ST-7,62
4 Pin Motor Power GMSTB 2,5 HCV/ 4-ST-7,62

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5.3 Mounting the Gold DC Trombone
The Gold DC Trombone 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 Gold DC
Trombone (see the diagram below).
Figure 2: Mounting the Gold DC Trombone with standard L-shape heat-sink
Figure 3: Mounting the Gold DC Trombone with L-shape heat-sink fins and fan

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5.4 Connection Diagrams
There are two connection diagrams for EtherCAT and two for CAN that show the two different ways
of connecting the power supply:
•400 V and 800 V A, H, S, or T options (the catalog number has an A, H, S, or T option) that
feature backup functionality and require an auxiliary 24 V backup supply. The drive will not be
operative without the external 24 VDC supply.
•400 V model without backup functionality with a 0 or 1 option. The drive’s internal DC/DC
converter is fed from the VP+ and VN- of the internal drive’s bus line.

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5.4.1 Connection Diagrams for EtherCAT Version
The following describes the connection diagrams for the EtherCAT version.
Figure 4: Gold DC Trombone EtherCAT Connection Diagram – with Backup Functionality
(A, H, S, or T options)

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Figure 5: Gold DC Trombone EtherCAT Connection Diagram – 400 V without Backup Functionality
for Model Drives with 0 or 1 Options