Elmo Gold DC Whistle Series User manual

Gold DC Whistle
Digital Servo Drive
Installation Guide
EtherCAT and CAN
August 2017 (Ver. 1.705) 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 DC Whistle 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-DCWHIIG-EC (Ver. 1.705)
Copyright 2017
Elmo Motion Control Ltd.
All rights reserved.
Catalog Number

Cable Kit
Catalog number: CBL-GDCWHIKIT02 (can be ordered separately).
For further details, see the documentation for this cable kit (MAN-G-DCWHI-CBLKIT.pdf).
Revision History
Version Date
Ver. 1.700 Jun 2014
Ver. 1.701 Jan 2015
Ver. 1.702 Jul 2015
Ver. 1.703 Oct 2015
Ver. 1.704 May 2016
Ver.1.705 Aug 2017

Table of Contents
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Chapter 1: This Installation Guide.................................................................................6
Chapter 2: Safety Information ......................................................................................6
2.1. Warnings ....................................................................................................................7
2.2. Cautions......................................................................................................................7
2.3. CE Marking Conformance...........................................................................................7
2.4. Warranty Information ................................................................................................7
Chapter 3: Product Description.....................................................................................8
3.1.1. Accessories ..................................................................................................8
Chapter 4: Technical Information..................................................................................9
4.1. Physical Specifications................................................................................................9
4.2. Technical Data ............................................................................................................9
4.2.1. Auxiliary Supply .........................................................................................10
4.2.2. Product Features .......................................................................................11
4.3. Environmental Conditions........................................................................................12
4.3.1. Gold Line....................................................................................................12
4.4. Gold Line Standards..................................................................................................13
Chapter 5: Installation................................................................................................14
5.1. Unpacking the Drive Components ...........................................................................14
5.2. Connector Types.......................................................................................................15
5.3. Mounting the Gold DC Whistle ................................................................................18
5.4. The Gold DC Whistle Connection Diagram...............................................................19
Chapter 6: Wiring.......................................................................................................21
6.1. Basic Recommendations ..........................................................................................22
6.1.1. General ......................................................................................................22
6.1.2. Feedback Cable Port A and Port B Connector...........................................23
6.1.3. Feedback Cable Port C Connector .............................................................24
6.1.4. IO Cable Connector....................................................................................24
6.1.5. STO (Port C) Cable Connector....................................................................25
6.2. Motor Power Connector Pinouts (J14).....................................................................26
6.3. Main and Auxiliary Power ........................................................................................28
6.3.1. Description ................................................................................................28
6.3.2. Main Power (J13).......................................................................................29
6.3.3. Auxiliary Power Supply (J12) .....................................................................30
6.3.4. Connectivity...............................................................................................31
6.3.4.1. Power Rating 200 V ..................................................................31
6.3.4.2. Power Rating 100 V ..................................................................32
6.4. Drive Status Indicator...............................................................................................34

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6.5. STO (Safe Torque Off) (J11) ......................................................................................35
6.5.1. Source Mode – PLC Voltage Level .............................................................36
6.5.2. TTL Mode – TTL Voltage Level ...................................................................36
6.5.3. Sink Mode – PLC Voltage Level..................................................................37
6.6. Port A (J1) .................................................................................................................38
6.6.1. Incremental Encoder .................................................................................39
6.6.2. Halls Sensor ...............................................................................................39
6.6.3. Absolute Serial Encoder.............................................................................40
6.6.3.1. Hiperface ..................................................................................41
6.7. Port B (J3) .................................................................................................................42
6.7.1. Incremental Encoder .................................................................................43
6.7.2. Interpolated Analog Encoder ....................................................................44
6.7.3. Resolver .....................................................................................................45
6.8. Port C, Digital I/Os, and Analog Inputs (J2) ..............................................................46
6.8.1. Port C – Emulated Encoder Output ...........................................................48
6.8.2. Analog Input ..............................................................................................49
6.8.3. Digital Input and Output TTL Mode...........................................................50
6.8.4. Digital Input and Output PLC Source Mode ..............................................52
6.8.5. Digital Input and Output Sink Mode..........................................................54
6.9. USB 2.0 (J9)...............................................................................................................56
6.10. EtherCAT Communication Version...........................................................................57
6.10.1. EtherCAT IN/Ethernet Pin Assignments (J7)..............................................57
6.10.2. EtherCAT OUT Pin Assignments (J8)..........................................................58
6.10.3. EtherCAT Wiring ........................................................................................58
6.10.4. EtherCAT Status Indicator .........................................................................59
6.11. CAN Communication Version ...................................................................................60
6.11.1. CAN Wiring ................................................................................................61
6.12. Powering Up .............................................................................................................62
6.13. Initializing the System ..............................................................................................62
Chapter 7: Dimensions ...............................................................................................63

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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 Whistle. 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 Whistle, 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 Whistle 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 Whistle 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 Whistle 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 Whistle 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 Whistle, 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 Whistle 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 Whistle
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 Whistle is an advanced high power density servo drive which delivers up to 1.6 kW of
continuous power or 3.2 kW of peak power in a 222.5 cc (13.58 in³) package (115 x 75 x 25.8 mm
or 4.5" x 3.0" x 1").
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. The Gold DC
Whistle is powered by a single 12 V – 195 V isolated DC power source (not included) and a “smart”
control-supply algorithm enables the drive to operate up to 95V with only one power supply with
no need for an auxiliary power supply for the logic.
The Gold DC Whistle 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 DC Whistle drive is easily set up and tuned using Elmo Application Studio (EAS) software
tools. As part of the Gold product line, it is fully programmable with the Elmo motion control
language. For more about software tools, refer to the Elmo Application Studio Software Manual.
The Gold DC Whistle is available in a variety of options. There are multiple power rating options,
two different communications options, a variety of feedback selections and I/O configuration
possibilities.
3.1.1. Accessories
Cable Kit, catalog number: CBL-GDCWHIKIT02 (can be ordered separately)
For further details, see the documentation for this cable kit (MAN-G-DCWHI-CBLKIT.pdf).

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Chapter 4:
Technical Information
4.1. Physical Specifications
Feature Units All Types
Weight g (oz) 267 g (9.42 oz)
Dimensions mm (in) 115 x 75 x 25.8 mm (4.5" x 3.0" x 1")
Mounting method Wall Mount / Book Shelf
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
Auxiliary power supply VDC 12 – 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: Power Ratings
Note on current ratings: The current ratings of the Gold DC Whistle 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.small

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Elmo now offers a 200 VDC maximum output rating selection of Gold DC Whistle, 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
Auxiliary power 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. Auxiliary Supply
Feature Details
Auxiliary power supply Isolated DC source only
Auxiliary supply input voltage 12 V to 95 V
Auxiliary 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 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 option √
CAN option √

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4.3. Environmental Conditions
You can guarantee the safe operation of the Gold DC Whistle by ensuring that it is installed in an
appropriate environment.
4.3.1. 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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4.4. Gold Line Standards
The following table describes the Main Standards of the Gold DC Whistle 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 4.3.1 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 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 DC Whistle 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 Whistle, verify that you have all of its components, as
follows:
•The Gold DC Whistle servo drive
•The Elmo Application Studio software and software manual
The Gold DC Whistle is shipped in a cardboard box with Styrofoam protection.
To unpack the Gold DC Whistle:
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 Whistle you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Gold DC Whistle. It looks
like this:
4. Verify that the Gold DC Whistle 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 Whistle has ten connectors.
No. Pins Type Function
Bottom Connectors
4 Phoenix 5 mm Pitch ‘HC’ Motor phases
3 Phoenix 5 mm Pitch ‘HC’ Main Power
2 Phoenix 3.81 mm Pitch ‘HC’ Auxiliary supply input
Front Connectors
Front Connectors - EtherCAT

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No. Pins Type Function
Front Connectors - CAN
3 2.54 mm Pitch Molex STO
24 2.54 mm Pitch Molex Feedback port C and I/O
8 2.54 mm Pitch Molex Feedback port B
12 2.54 mm Pitch Molex Feedback port A
Top Connectors
Top Connectors - EtherCAT

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No. Pins Type Function
Top Connectors - CAN
5 USB Device Mini-B USB
EtherCAT Version
8 RJ-45 EtherCAT in
8 RJ-45 EtherCAT out
CAN Version
8 RJ-45 CAN
8 RJ-45 CAN
Table 2: Connector Types
The pinouts in Chapter 6: Wiring describe the function of each pin in the Gold DC Whistle
connectors that are listed in Table 2.

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5.3. Mounting the Gold DC Whistle
The Gold DC Whistle 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
Whistle (see the diagram below).
Figure 1: Mounting the Gold DC Whistle

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5.4. The Gold DC Whistle Connection Diagram
Figure 2: The Gold DC Whistle Connection Diagram – EtherCAT

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Figure 3: The Gold DC Whistle Connection Diagram - CAN