Elmo SimplIQ Series User manual

Cello
Digital Servo Drive
Installation Guide
July 2012 (Ver. 1.6)
www.elmomc.com

Notice
This guide is delivered subject to the following conditions and restrictions:
•This guide contains proprietary information belonging to Elmo Motion Control Ltd.
Such information is supplied solely for the purpose of assisting users of the Cello
servo drive in its installation.
•The text and graphics included in this manual are for the purpose of illustration and
reference only. The specifications on which they are based are subject to change
without notice.
•Elmo Motion Control and the Elmo Motion Control logo are trademarks of Elmo
Motion Control Ltd.
•Information in this document is subject to change without notice.
Document no. MAN-CELIG (Ver. 1.6)
Copyright 2012
Elmo Motion Control Ltd.
All rights reserved.
Catalog Number
Cable Kits
Catalog Numbers:
•CBL-CELKIT01 (can be ordered separately)
•CBL-CELKIT02 (can be ordered separately)
For further details, see the documentation for these cable kits (MAN-CBLKIT-CEL.pdf) .

Revision History
Version Details
1.0 Initial Release
1.3 (April 2008), updated Power Ratings table in Chapter 4:
1.4 (August 2008), added Section 3.4.7.4: Differential Pulse-and-Direction Input
1.5 (March 2010) MTCR 07-009-56: Added note to Section 3.4.8.2
1.6 (July 2012), formatted according to new template, updated Catalog Number

Elmo Worldwide
Head Office
Elmo Motion Control Ltd.
60 Amal St., POB 3078, Petach Tikva 49516
Israel
Tel: [phone] • Fax: [phone] • [e-mail]
North America
Elmo Motion Control Inc.
42 Technology Way, Nashua, NH 03060
USA
Tel: [phone] • Fax: [phone] • [e-mail]
Europe
Elmo Motion Control GmbH
Hermann-Schwer-Strasse 3, 78048 VS-Villingen
Germany
Tel: [phone] • Fax: [phone] • [e-mail]
China
Elmo Motion Control Technology (Shanghai) Co. Ltd.
Room 1414, Huawen Plaza, No. 999 Zhongshan West Road, Shanghai (200051)
China
Tel: [phone] • Fax: [phone] • info-[email protected]
Asia Pacific
Elmo Motion Control
#807, Kofomo Tower, 16-3, Sunae-dong, Bundang-gu, Seongnam-si, Gyeonggi-do,
South Korea
Tel: [phone] • Fax: [phone] • info-[email protected]

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Table of Contents
Chapter 1: Safety Information ...................................................................................... 7
1.1. Warnings.....................................................................................................................8
1.2. Cautions......................................................................................................................8
1.3. Directives and Standards............................................................................................9
1.4. CE Marking Conformance...........................................................................................9
1.5. Warranty Information ................................................................................................9
Chapter 2: Introduction ............................................................................................. 10
2.1. Drive Description ..................................................................................................... 10
2.2. Product Features ..................................................................................................... 10
2.2.1. Current Control......................................................................................... 10
2.2.2. Velocity Control ........................................................................................ 11
2.2.3. Position Control ........................................................................................ 11
2.2.4. Advanced Position Control (Advanced model only) ................................. 11
2.2.5. Communication Options........................................................................... 11
2.2.6. Feedback Options ..................................................................................... 12
2.2.7. Fault Protection ........................................................................................ 12
2.3. System Architecture ................................................................................................ 13
2.4. How to Use this Guide............................................................................................. 13
Chapter 3: Installation ............................................................................................... 15
3.1. Before You Begin ..................................................................................................... 15
3.1.1. Site Requirements .................................................................................... 15
3.1.2. Hardware Requirements .......................................................................... 15
3.2. Unpacking the Drive Components........................................................................... 17
3.3. Mounting the Cello.................................................................................................. 18
3.4. Connecting the Cables............................................................................................. 19
3.4.1. Wiring the Cello ........................................................................................ 19
3.4.2. Connecting the Power Cables................................................................... 22
3.4.2.1. Connecting the Motor Cable ................................................... 22
3.4.2.2. Connecting the Main Power Cable .......................................... 23
3.4.3. Connecting the Optional Backup Supply Cable (24v) ............................... 24
3.4.4. Feedback and Control Cable Assemblies.................................................. 25
3.4.5. Main Feedback Cable (FEEDBACK A) ........................................................ 25
3.4.6. Main and Auxiliary Feedback Combinations ............................................ 34
3.4.7. Auxiliary Feedback (FEEDBACK B)............................................................. 35
3.4.7.1. Main Encoder Buffered Outputs or Emulated Encoder Outputs
Option on FEEDBACK B (YA[4]=4) ............................................ 35
3.4.7.2. Differential Auxiliary Encoder Input Option on FEEDBACK B
(YA[4]=2) .................................................................................. 38
3.4.7.3. Single-Ended Auxiliary Input Option on FEEDBACK B (YA[4]=2)40
3.4.7.4. Pulse-and-Direction Input Option on FEEDBACK B (YA[4]=0).. 42

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3.4.8. I/O Cables ................................................................................................. 46
3.4.8.1. General I/O Port (J1)................................................................ 46
3.4.8.2. General Input Port (J2) ............................................................ 48
3.4.9. Communication Cables............................................................................. 50
3.4.9.1. RS-232 Communication ........................................................... 50
3.4.9.2. CANopen Communication ....................................................... 51
3.5. Powering Up ............................................................................................................ 53
3.6. Initializing the System.............................................................................................. 53
Chapter 4: Technical Specifications ............................................................................ 54
4.1. Features................................................................................................................... 54
4.1.1. Motion Control Modes ............................................................................. 54
4.1.2. Advanced Positioning Motion Control Modes ......................................... 54
4.1.3. Advanced Filters and Gain Scheduling...................................................... 54
4.1.4. Fully Programmable.................................................................................. 54
4.1.5. Feedback Options ..................................................................................... 55
4.1.6. Input/Output ............................................................................................ 55
4.1.7. Built-In Protection .................................................................................... 56
4.2. Cello Dimensions ..................................................................................................... 57
4.3. Power Ratings.......................................................................................................... 58
4.4. Environmental Conditions....................................................................................... 58
4.5. Cello Connections.................................................................................................... 59
4.5.1. Backup Supply (Optional) ......................................................................... 60
4.6. Control Specifications.............................................................................................. 60
4.6.1. Current Loop............................................................................................. 60
4.6.2. Velocity Loop ............................................................................................ 61
4.6.3. Position Loop ............................................................................................ 61
4.7. Feedbacks ................................................................................................................ 62
4.7.1. Feedback Supply Voltage.......................................................................... 62
4.7.2. Incremental Encoder Input....................................................................... 62
4.7.3. Digital Halls ............................................................................................... 63
4.7.4. Interpolated Analog (Sine/Cosine) Encoder ............................................. 63
4.7.5. Resolver .................................................................................................... 64
4.7.6. Tachometer............................................................................................... 64
4.7.7. Potentiometer .......................................................................................... 65
4.7.8. Encoder Outputs....................................................................................... 65
4.8. I/Os .......................................................................................................................... 65
4.8.1. Digital Input Interfaces ............................................................................. 66
4.8.2. Digital Output Interface............................................................................ 67
4.8.3. Analog Input ............................................................................................. 68
4.9. Communications...................................................................................................... 68
4.10. Pulse-Width Modulation (PWM)............................................................................. 68
4.11. Mechanical Specifications ....................................................................................... 68
4.12. Compliance with Standards..................................................................................... 69

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Chapter 1:
Safety Information
In order to achieve the optimum, safe operation of the Cello servo drive, it is imperative that
you implement the safety procedures included in this installation guide. This information is
provided to protect you and to keep your work area safe when operating the Cello and
accompanying equipment.
Please read this chapter carefully before you begin the installation process.
Before you start, ensure that all system components are connected to earth ground. Electrical
safety is provided through a low-resistance earth connection.
Only qualified personnel may install, adjust, maintain and repair the servo drive. A qualified
person has the knowledge and authorization to perform tasks such as transporting, assembling,
installing, commissioning and operating motors.
The Cello servo drive contains electrostatic-sensitive components that can be damaged if
handled incorrectly. To prevent any electrostatic damage, avoid contact with highly insulating
materials, such as plastic film and synthetic fabrics. Place the product on a conductive surface
and ground yourself in order to discharge any possible static electricity build-up.
To avoid any potential hazards that may cause severe personal injury or damage to the product
during operation, keep all covers and cabinet doors shut.
The following safety symbols are used in this manual:
Warning:
This information is needed to avoid a safety hazard, which might cause
bodily injury.
Caution:
This information is necessary for preventing damage to the product or to
other equipment.

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1.1. Warnings
•To avoid electric arcing and hazards to personnel and electrical contacts, never
connect/disconnect the servo drive while the power source is on.
•Power cables can carry a high voltage, even when the motor is not in motion.
Disconnect the Cello from all voltage sources before it is opened for servicing.
•After shutting off the power and removing the power source from your equipment,
wait at least 1 minute before touching or disconnecting parts of the equipment that are
normally loaded with electrical charges (such as capacitors or contacts). Measuring the
electrical contact points with a meter, before touching the equipment, is
recommended.
1.2. Cautions
•The Cello servo drive contains hot surfaces and electrically-charged components during
operation.
•The maximum DC power supply connected to the instrument must comply with the
parameters outlined in this guide.
•The Cello can operate only through an isolated power source, using an isolated
transformer and a rectifier circuit. Power to this device must be supplied by DC voltage,
within the boundaries specified for the Cello. High voltages may damage the drive.
The DC power supply voltage range is defined in the table in Section 4.3.
Safety margins must be considered in order to avoid activating the under- or over-voltage
protection against line variations and/or voltage drop under load. The transformer should
be able to deliver the required power to the drive (including peak power) without
significant voltage drops (10% maximum). While driving high-inertia loads, the power
supply circuit must be equipped with a shunt regulator; otherwise, the drive will be
disabled whenever the capacitors are charged above the maximum voltage.
•Before switching on the Cello, verify that all safety precautions have been observed
and that the installation procedures in this manual have been followed.

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1.3. Directives and Standards
The Cello conforms to the following industry safety standards:
Safety Standard Item
Approved IEC/EN 61800-5-1, Safety Adjustable speed electrical power drive systems
Recognized UL 508C Power Conversion Equipment
In compliance with UL 840 Insulation Coordination Including Clearances and
Creepage Distances for Electrical Equipment
In compliance with UL 60950-1
(formerly UL 1950)
Safety of Information Technology Equipment
Including Electrical Business Equipment
In compliance with EN 60204-1 Low Voltage Directive 73/23/EEC
The Cello servo drive has been developed, produced, tested and documented in accordance
with the relevant standards. Elmo Motion Control is not responsible for any deviation from the
configuration and installation described in this documentation. Furthermore, Elmo is not
responsible for the performance of new measurements or ensuring that regulatory
requirements are met.
1.4. CE Marking Conformance
The Cello servo drive is intended for incorporation in a machine or end product. The actual end
product must comply with all safety aspects of the relevant requirements of the European
Safety of Machinery Directive 98/37/EC as amended, and with those of the most recent
versions of standards EN 60204-1 and EN 292-2 at the least.
According to Annex III of Article 13 of Council Directive 93/68/EEC, amending Council Directive
73/23/EEC concerning electrical equipment designed for use within certain voltage limits, the
Cello meets the provisions outlined in Council Directive 73/23/EEC. The party responsible for
ensuring that the equipment meets the limits required by EMC regulations is the manufacturer
of the end product.
1.5. Warranty Information
The products covered in this manual are warranted to be free of defects in material and
workmanship and conform to the specifications stated either within this document or in the
product catalog description. All Elmo drives are warranted for a period of 12 months from the
time of installation, or 18 months from time of shipment, whichever comes first. No other
warranties, expressed or implied — and including a warranty of merchantability and fitness for
a particular purpose — extend beyond this warranty.

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Chapter 2:
Introduction
This installation guide describes the Cello servo drive and the steps for its wiring, installation
and powering up. Following these guidelines ensures maximum functionality of the drive and
the system to which it is connected.
2.1. Drive Description
The Cello is a powerful servo drive that operates in digital current, velocity, position and
advanced position modes, in conjunction with a permanent-magnet synchronous brushless
motor or DC brush motor. The Cello features flexible sinusoidal and trapezoidal commutation,
with vector control. The Cello can operate as a stand-alone device or as part of a multi-axis
network in a distributed configuration.
The Cello drive is set up and tuned using Elmo’s Composer software. This Windows-based
application enables users to quickly and simply configure the servo drive for optimal use with
their motor.
Power to the Cello is provided by a 10 to 195 VDC source. A “smart” control-supply algorithm
enables the Cello to operate with the power supply only, with no need for an auxiliary 24 Volt
supply. If backup functionality is required for storing control parameters in case of power-outs,
an external 24 VDC power supply can be connected, providing maximum flexibility and optional
backup functionality when needed.
Two variations of the Cello are available: the Standard version and the Advanced version, which
features advanced positioning capabilities. Both versions operate with RS-232 and/or CANopen
communication.
2.2. Product Features
2.2.1. Current Control
•Fully digital
•Sinusoidal commutation with vector control or trapezoidal commutation with encoder
and/or digital Hall sensors
•12-bit current loop resolution
•Automatic gain scheduling, to compensate for variations in the DC bus power supply

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2.2.2. Velocity Control
•Fully digital
•Programmable PI and FFW (feed forward) control filters
•Sample rate two times current loop sample time
•“On-the-fly” gain scheduling
•Automatic, manual and advanced manual tuning and determination of optimal gain
and phase margins
2.2.3. Position Control
•Programmable PIP control filter
•Programmable notch and low-pass filters
•Position follower mode for monitoring the motion of the slave axis relative to a master
axis, via an auxiliary encoder input
•Pulse-and-direction inputs
•Sample time: four times that of current loop
•Fast event capturing inputs
2.2.4. Advanced Position Control (Advanced model only)
•Position-based and time-based ECAM mode that supports a non-linear follower mode,
in which the motor tracks the master motion using an ECAM table stored in flash
memory
•PT and PVT motion modes
•Dual (position/velocity) loop
•Fast output compare (OC)
2.2.5. Communication Options
Depending on the application, Cello users can select from two communication options:
•RS-232 serial communication
•CANopen for fast communication in a multi-axis distributed environment

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2.2.6. Feedback Options
•Incremental Encoder – up to 20 Mega-Counts (5 Mega-Pulse) per second
•Digital Halls – up to 2 kHz
•Incremental Encoder with Digital Halls for commutation – up to 20 Mega-Counts per
second for encoder
•Absolute Encoder
•Interpolated Analog (Sine/Cosine) Encoder – up to 250 kHz (analog signal)
Internal Interpolation – programmable up to x4096
Automatic Correction of:
•amplitude mismatch
•phase mismatch
•signals offset
Encoder outputs, buffered, differential.
•Resolver
Programmable 10 to 15 bit resolution
Up to 512 Revolutions Per Second (RPS)
Encoder outputs, buffered, differential
•Tachometer and Potentiometer
•Two inputs for Tachometer Feedback:
Up to ±50 VDC
Up to ±20 VDC
•Potentiometer Feedback:
0 to 5 V voltage range
Resistance: 100 Ω to 1000 Ω
•Elmo drives provide supply voltage for all the feedback options
2.2.7. Fault Protection
The Cello includes built-in protection against possible fault conditions, including:
•Software error handling
•Status reporting for a large number of possible fault conditions
•Protection against conditions such as excessive temperature, under/over voltage, loss
of commutation signal, short circuits between the motor power outputs and between
each output and power input/return
•Recovery from loss of commutation signals and from communication errors

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2.3. System Architecture
Auxiliary
Power
Supply
PWM
Controller
Power Stage
Protection Current
Feedback
Incremental
Encoder
24 VDC
I/Os
Incremental Encoder
Buffered Output
or
Emulated Output
Resolver
Analog
Encoder
Auxiliary
Encoder
or
or
Potentiometer
Tachometer
or
or
Communication
RS 232 and CANopen
Figure 1: Cello System Block Diagram
2.4. How to Use this Guide
In order to install and operate your Elmo Cello servo drive, you will use this manual in
conjunction with a set of Elmo documentation. Installation is your first step; after carefully
reading the safety instructions in the first chapter, the following chapters provide you with
installation instructions as follows:
•Chapter 3, Installation, provides step-by-step instructions for unpacking, mounting,
connecting and powering up the Cello.
•Chapter 4, Technical Specifications,lists all the drive ratings and specifications.
Upon completing the instructions in this guide, your Cello servo drive should be successfully
mounted and installed. From this stage, you need to consult higher-level Elmo documentation
in order to set up and fine-tune the system for optimal operation. The following figure
describes the accompanying documentation that you will require.

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SimplIQ Command Reference Manual
Cello Installation Guide
SimplIQ Software Manual
Programming
Setup
Installation
Composer User Manual
CANopen Implementation Guide
Figure 2: Elmo Documentation Hierarchy
As depicted in the previous figure, this installation guide is an integral part of the Cello
documentation set, comprising:
•The Composer Software Manual, which includes explanations of all the software tools
that are part of Elmo’s Composer software environment.
•The SimplIQ Command Reference Manual, which describes, in detail, each software
command used to manipulate the Cello motion controller.
•The SimplIQ Software Manual, which describes the comprehensive software used with
the Cello.

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Chapter 3:
Installation
The Cello must be installed in a suitable environment and properly connected to its voltage
supplies and the motor.
3.1. Before You Begin
3.1.1. Site Requirements
You can guarantee the safe operation of the Cello by ensuring that it is installed in an
appropriate environment.
Feature Value
Ambient operating temperature 0 °C to 40 °C (32 °F to 104 °F)
Maximum operating altitude 10,000 m (30,000 ft)
Maximum non-condensing humidity 90%
Operating area atmosphere No flammable gases or vapors permitted in area
Models for extended environmental conditions are available.
Caution: The Cello dissipates its heat by convection. The maximum operating ambient
temperature of 0 °C to 40 °C (32 °F to 104 °F) must not be exceeded.
3.1.2. Hardware Requirements
The components that you will need to install your Cello are:
Component Connector Described in Section Drawing
Main Power Cable VP+ PR 3.4.2.2
Motor Cable M1 M2 M3 3.4.2.1
Backup Supply Cable
(if needed)
24v 3.4.3

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Component Connector Described in Section Drawing
Main Feedback Cable FEEDBACK A 3.4.5
Auxiliary Feedback
Cable
(if needed)
FEEDBACK B 3.4.70
Digital I/O Cable
(if needed)
GENERAL I/O
J1
3.4.8.1
Digital Inputs and
Analog Inputs Cable
(if needed)
GENERAL I/O
J2
3.4.8.2
RS232
Communication
Cable
RS232 3.4.9.1
CANopen
Communication
cable(s) (if needed)
CAN (in)
CAN (out)
3.4.9.2
PC for drive setup
and tuning
Motor data sheet or
manual

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3.2. Unpacking the Drive Components
Before you begin working with the Cello system, verify that you have all of its components, as
follows:
•The Cello servo drive
•The Composer software and software manual
The Cello is shipped in a cardboard box with Styrofoam protection.
To unpack the Cello:
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 Cello you have unpacked is the appropriate type for your requirements,
locate the part number sticker on the side of the Cello. It looks like this:
The P/N number at the top gives the type designation as follows:
4. Verify that the Cello type is the one that you ordered, and ensure that the voltage meets
your specific requirements.

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3.3. Mounting the Cello
The Cello 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 Cello
(see the diagram below).
Figure 3: Mounting the Cello

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3.4. Connecting the Cables
The Cello has ten connectors.
3.4.1. Wiring the Cello
Once the Cello is mounted, you are ready to wire the device. Proper wiring, grounding and
shielding are essential for ensuring safe, immune and optimal servo performance of the Cello.
Caution: Follow these instructions to ensure safe and proper wiring:
•Use twisted pair shielded cables for control, feedback and communication connections.
For best results, the cable should have an aluminum foil shield covered by copper
braid, and should contain a drain wire.
The drain wire is a non-insulated wire that is in contact with parts of the cable, usually
the shield. It is used to terminate the shield and as a grounding connection.
•The impedance of the wire must be as low as possible. The size of the wire must be
thicker than actually required by the carrying current. A 24, 26 or 28 AWG wire for
control and feedback cables is satisfactory although 24 AWG is recommended.
•Use shielded wires for motor connections as well. If the wires are long, ensure that the
capacitance between the wires is not too high: C < 30 nF is satisfactory for most
applications.
•Keep all wires and cables as short as possible.
•Keep the motor wires as far away as possible from the feedback, control and
communication cables.
•Ensure that in normal operating conditions, the shielded wires and drain carry no
current. The only time these conductors carry current is under abnormal conditions,
when electrical equipment has become a potential shock or fire hazard while
conducting external EMI interferences directly to ground, in order to prevent them
from affecting the drive. Failing to meet this requirement can result in
drive/controller/host failure.
•After completing the wiring, carefully inspect all wires to ensure tightness, good solder
joints and general safety.

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The following connectors are used for wiring the Cello.
Type Function Port Connector Location
5-Pin Phoenix
(1st two pins)
(provided)
Power VP+, PR
5-Pin Phoenix
(last 3 pins)
(provided)
Motor M1, M2, M3
3 ground
screws
Ground PE, PE, PE
2-Pin Phoenix
(provided)
Optional
Backup Supply
24 VDC
Table 1: Connectors on the “Bottom” of the Cello
Type Function Port Connector Location
15-Pin D-Sub Feedback A Feedback A
15-Pin D-Sub
(high-density)
General I/O J1
15-Pin D-Sub
(high-density)
General I/O J2
Table 2: Connectors on the “Front” of the Cello
Type Function Port Connector Location
8-Pin RJ-45 CANopen CAN
8-Pin RJ-45 CANopen CAN
15-Pin D-Sub
(high-density)
Feedback B Feedback B
8-Pin RJ-45 RS-232 RS-232
Table 3: Connectors on the “Top” of the Cello
Optional
Backup Supply
Ground
Power & Motor
CANopen
Feedback B
RS-232
J2: I/O
J1: I/O
Feedback A