Elmo Gold Whistle Series User manual

Gold Whistle
Digital Servo Drive
Installation Guide
April 2018 (Ver. 1.400) 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 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-WHI (Ver. 1.400)
Copyright 2018
Elmo Motion Control Ltd.
All rights reserved.
Catalog Number

Table of Contents
MAN-G-WHI (Ver. 1.400)3
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 ............................................................................................................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 Whistle........................................................................14
Chapter 7: Integrating the Gold Whistle on a PCB........................................................16
7.1. Power Returns (PR) ..................................................................................................16
7.2. COMRET....................................................................................................................16
7.3. Earth Connection (PE) ..............................................................................................16
7.4. Power Return (PR), Common Return (COMRET) and Earth Connections (PE).........17
7.5. Power Conductors PCB layout..................................................................................18
Chapter 8: The Gold Whistle Connection Diagram .......................................................19
Chapter 9: PCB Connections........................................................................................20
9.1. Wiring legend ...........................................................................................................20
9.2. Connector Types.......................................................................................................22
9.2.1. Connector Types........................................................................................22
9.3. Drive Status Indicator...............................................................................................22
9.4. Motor Power Connector Pinouts .............................................................................23
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
9.5.4.1. Single Power Supply .................................................................28

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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.............................................................................................43
9.6.4.1. Analog Input 1 ..........................................................................43
9.6.4.2. Analog Input 2 ..........................................................................44
9.6.5. RS232 TTL Logic Level ................................................................................45
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
Whistle. 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 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 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 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 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 source connected to the instrument must comply with the
parameters outlined in this guide.
•When connecting the Gold Whistle to an approved control 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 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 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 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 Whistle 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 38.0 cc (2.32 in³) package (55 x 46 x 15 mm or 2.2"
x 1.8" x 0.6"). The Gold Whistle 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
Whistle is provided by a DC power source which is isolated from the Mains. The Gold Whistle 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 Whistle 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 (EASII)
User Guide.
The Gold Whistle 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.

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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) 55 x 46 x 15 mm (2.2" x 1.8" x 0.6")
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 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.

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Elmo offers a 200 VDC maximum output rating selection of Gold 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
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 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 and No.
STO TTL √
Digital Input TTL 6
Digital Output 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 Whistle 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 Whistle 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 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 Whistle, verify that you have all of its components, as
follows:
•The Gold Whistle servo drive
•The Elmo Application Studio (EASII) software and user guide
The Gold Whistle is shipped in a cardboard box with Styrofoam protection.
To unpack the Gold 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 Whistle you have unpacked is the appropriate type for your
requirements, locate the part number sticker on the side of the Gold Whistle. It looks like
this:
4. Verify that the Gold 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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Chapter 6:
Mounting the Gold Whistle
The Gold Whistle 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 Whistle 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 Whistle be soldered directly to the board.
Alternatively, though this is not recommended, the Gold Whistle can be attached to socket
connectors mounted on the PCB. If the PCB is enclosed in a metal chassis, we recommend that the
Gold Whistle be screw-mounted to it as well to help with heat dissipation. The Gold Whistle has
screw-mount holes on each corner of the heat-sink for this purpose – see below.
All measurements are in mm
Figure 1: Gold Whistle Dimensions
When the Gold Whistle is not connected to a metal chassis, the application’s thermal profile may
require a solution for heat dissipation due to insufficient air convection. In this case, we recommend

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that you connect an external heat sink. Elmo has an external heat sink (Catalog number: WHI-HEAT-
SINK-2) that can be ordered for this purpose, see Figure 2 below.
Figure 2: Gold Whistle External Heat Sink

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Chapter 7:
Integrating the Gold Whistle on a PCB
The Gold Whistle 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 Whistle, 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 Whistle’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 3: Gold Whistle Earth Connections
The connections to PE are essential, but must be done externally to the integration board.
The COMRET should be connected to the PR in 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 4: Gold Whistle 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 Whistle Connection Diagram
Figure 5: The Gold Whistle 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