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Whistle Installation Guide (Ver 1.2

1. 3 32 3 15 1 Whistle Thermal doter mere RE RH ERE ees 3 32 3 15 24 Heat Dissipation Daftar oti ere tO e oce te Ye dotted a 3 32 3 15 3 How to Use the Charts ariii a ian enemies 3 33 3 16 Evaluation Board and Cable 3 34 Appendix Whistle Technical 1 Ac T t b btt Gu eee qaya gaa 1 A 1 1 Motion Control 1 A 1 2 Advanced Positioning Control Modes sese 1 A 1 3 Advanced Filters and Gain Scheduling sess 1 A 1 4 Fully nennen 1 AMS Feedback Options ere etr 1 1 6 Input Output ener enne enne 2 AJ Built In Protection ecce de rtt etes EE Eee curd A 2 ATS ACCESSOTIES Suus teer ede eder de RE eed 3 A19 Status Indication iae d teta eri m eie Utt Ies e ives ee deed A 3 A 1 10 Automatic Procedures ener nnne nnns A 3 AO Whistle Dimensions eode petere bbb taste 3 3 RERO ERR RED RR RD A 4 4 Environmental 8 4112 22
2. 5 Whistle 2 CAN Interface J1 Whistle n CAN Interface J1 Note If cable is long 5M it is WHI0043A recommended to ground at both ends Figure 3 28 CANopen Network Diagram Caution When installing CANopen communication ensure that each servo drive is allocated a unique ID Otherwise the CANopen network may hang Whistle Installation Guide Installation MAN WHISIG Ver 1 0 3 32 3 13 Powering Up After the Whistle is connected to its devices the Whistle is ready to be powered up Caution Before applying power ensure that the DC supply is within the specified range and that the proper plus minus connections are in order 3 14 Initializing the System After the Whistle has been connected and mounted the system must be set up and initialized This is accomplished using the Composer Elmo s Windows based software application Install the application and then perform setup and initialization according to the directions in the Composer Software Manual 3 15 Heat Dissipation The best way to dissipate heat from the Whistle is to mount it so that its heatsink faces up For best results leave approximately 10 mm of space between the Whistle s heatsink and any other assembly 3 15 1 Whistle Thermal Data e Hea
3. 4242 tod ME 2 fi T JaM ot Lo A M N E 3 um qi Lg 6 ME NE A m J ot bog 5v Suppl A E N f v Supply EE E 1 pos x m SUPRET J22 N i i pog age Return 2 a T plc ces cc WHI0033A Figure 3 13 Main Feedback Potentiometer Feedback with Digital Hall Sensor Connection Diagram for Brushless Motors p Integration Board Whistle J2 pr CER E S mm h Potentiometer Main Feedback 9 J29 5 1 1 a POT NI J2 1 5v Supply 51 Poy U l a 422 SUPRET f U tage Return V 0034 Figure 3 14 Main Feedback Potentiometer Feedback Connection Diagram for Brush Motors and Voice Coils 3 16 Whistle Installation Guide Installation 3 17 MAN WHISIG Ver 1 0 3 10 Auxiliary Feedback For auxiliary feedback select one of the following options a Single ended emulated encoder outputs used to provide emulated encoder signals to another controller or drive The Emulated Encoder Output Option is only available when using a Resolver or Analog Encoder as the main feedback device This option can be used when Whistle is used as a current amplifier to provide position data to the position c
4. Table 3 10 RS 232 Pin Assignments Whistle Installation Guide MAN WHISIG Ver 1 0 Integration Board Whistle RS232 Communication J1 Tx Installation 3 30 PC RS232 COMRET V WHI0049A Figure 3 27 RS 232 Connection Diagram 3 12 2 CANopen Communication amp Notes for connecting the CANopen communication cable Connect the shield to the ground of the host PC Usually this connection is soldered internally inside the connector at the PC end You can use the drain wire to facilitate connection Ensure that the shield of the cable is connected to the shield of the connector used for communications The drain wire can be used to facilitate the connection Make sure to have a 120 ohm resistor termination at each of the two ends of the network cable The Whistle s CAN ports are non isolated Pin Position Pin Signal Function J1 20 CAN ground 1 21 CAN busline dominant low 1 22 CAN CAN H busline dominant high EX EX EX DN 1 HH Bc lt N Table 3 11 CANopen Pin Assignments Whistle Installation Guide Installation MAN WHISIG Ver 1 0 Integration Board Whistle 1 CAN Interface J1 CAN Controller 3 31 8
5. ANLRET I WHI0041A Figure 3 26 Analog Input with Single ended Source Whistle Installation Guide Installation MAN WHISIG Ver 1 0 3 29 3 12 Communications The communication interface may differ according to the user s hardware The Whistle can communicate using the following options a RS 222 full duplex b CANopen RS 232 communication requires a standard commercial 3 core null modem cable connected from the Whistle to a serial interface on the PC The interface is selected and set up in the Composer software In order to benefit from CANopen communication the user must have an understanding of the basic programming and timing issues of a CANopen network For ease of setup and diagnostics of CAN communication RS 232 and CANopen can be used simultaneously 3 12 1 RS 232 Communication lt Notes for connecting the RS 232 communication cable Connect the shield to the ground of the host PC Usually this connection is soldered internally inside the connector at the PC end You can use the drain wire to facilitate connection RS 232 communication port is non isolated Ensure that the shield of the cable is connected to the shield of the connector used for RS 232 communications The drain wire can be used to facilitate the connection Pin Signal Function Pin Location JA 1 RS232 Rx RS 232 receive JA 2 RS232 RS 232 transmit J1 3 RS232_COMRET Communication return
6. Aux Feedback Analog Encoder position data emulated in single ended unbuffered Incremental Encoder format Incremental Encoder or Analog Encoder or Resolver or Tachometer or Potentiometer Input Incremental Encoder or Analog Encoder or Resolver or Tachometer or Potentiometer Input Resolver Input Potentiometer Tachometer Input Typical Applications Main Feedback Resolver Main Feedback Potentiometer or Tachometer Aux Feedback Resolver position data emulated in single ended unbuffered Incremental Encoder format Aux Feedback There is no Aux Feedback output option whena Potentiometer or Tachometer is the main feedback device Any application where the main encoder is used not only for the drive but also for other purposes such as position controllers and or other drives Analog Encoder applications where position data is required in the Encoder s quadrature format Resolver applications where position data is required in the Encoder s quadrature format Aux Feedback Singe ended Pulse amp Direction Commands Input Aux Feedback Singe ended Incremental Encoder Input Any application where two feedbacks are used by the drive The Auxilliary Feedback port serves as an input for the auxiliary incremental encoder For applications such as Follower ECAM or Dual Loop Any application where two feedbacks are used by
7. 3 4 Mounting the Whistle The Whistle was designed for mounting on a printed circuit board It is connected by 2mm pitch 0 51 mm square pins When designing the Whistle into a device be sure to leave about 1 cm 0 4 outward from the heatsink to enable free air convection around the Whistle We recommend that the Whistle be soldered directly to the board Alternatively the Whistle can be attached to socket connectors mounted on the PCB If the PCB is enclosed in a metal chasis we recommend that the Whistle be screw mounted to it as well to help with heat dissipation The Whistle has screw mount holes on each corner of the heatsink for this purpose woe O n 0 51 mm SQ Pin x50 40 50 eg 00 Ons O footprint Figure 3 1 Whistle Footprint Whistle Installation Guide Installation MAN WHISIG Ver 1 0 3 5 Integrating the Whistle on a PCB The Whistle is designed to be mounted on a PCB either by soldering its pins directly to the PCB or by using suitable socket connectors In both cases the following rules apply 3 5 1 Traces 1 The size of the traces on the PCB thickness and width is determined by the current carrying capacity required by the application The rated continuous current limit Ic of the Whistle is the current used for sizing the motor traces M1 M2 M3 and PE and power traces VP PR and PE For control feedbacks and Inputs outputs conductors the actual curr
8. JA 9 IN1 Programmable input 1 general purpose RLS FLS INH J1 10 IN2 Programmable input 2 general purpose RLS FLS INH 1 2 n n n JA 11 IN3 Programmable input 3 general purpose RLS FLS INH 1 12 INA Programmable input 4 general purpose RLS FLS INH J1 13 5 Hi Speed Programmable input 5 event capture Main Home general purpose RLS FLS INH E E o S Ap EH x 1 14 IN6 Hi Speed Programmable input 6 event capture Auxiliary Home general purpose RLS FLS INH x N J1 15 INRET Programmable input return Table 3 7 Digital Input Pin Assignments 3 26 Installation Whistle Installation Guide MAN WHISIG Ver 1 0 Rin 1 43K Rin 1 43K Rin 1 43K 5 5 5 x x c c 7 55 22 6 53 35 E 2 a Rin 1 43K WHIO0039A Figure 3 24 Digital Input Connection Diagram Whistle Installation Guide MAN WHISIG Ver 1
9. MAN WHISIG Ver 1 2 A 1 8 Accessories e Heat sinks TBD e Evaluation Board Cable Kit A 1 9 Status Indication e Output for a bi color LED A 1 10 Automatic Procedures e Commutation alignment e Phase sequencing e Current loop offset adjustment e Current loop gain tuning e Current gain scheduling e Velocity loop offset adjustment e Velocity gain tuning e Velocity gain scheduling e Position gain tuning A 2 Whistle Dimensions 55 00 49 00 Whistle Technical Specifications 9 70x4 46 50 40 50 55 00 0 51 mm SQ pin x50 WHI0007A A 3 Whistle Installation Guide MAN WHISIG Ver 1 2 A 3 Power Ratings Whistle Technical Specifications Feature Unit 1 60 2 5060 5 60 10 60 1 100 25 100 5 100 Minimum supply voltage VDC 7 5 12 Nominal supply voltage VDC 48 85 Maximum supply voltage VDC 59 95 power gus Soe Babe 23802 eee gt 3380 154 the drive without heatsink Efficiency at rate power gt 99 Output Voltage gt 95 of supply VDC at f 22 KHz DC and Trapezoidal Commutation Continuous 1 29 5 10 1 2 5 Current Limit Ic Sinusoidal Commutation Continuous 5 Current A 0 7 1 8 3 6 7 0 7 1 8 3 6 Limit Ic Peak current limit RMS A 2 Switching 22 5 default on the motor requency Swit
10. 3 8 Auxiliary Supply for dive 3 9 3 8 Supply e pere DET Ree 3 10 3 8 2 Separate Auxiliary Supply 3 10 3 8 3 Shared Supply yau aqnu yq S hu kaqtuy tate 3 11 3 9 Main Feedback nnne rennen nenne 3 12 3 10 Auxiliary eee re ee er eet a te eee eges 3 17 3 10 1 Main and Auxiliary Feedback Combinations 3 18 3 10 2 Auxiliary Feedback Emulated Encoder Output Option Y A 4 4 3 19 3 10 3 Auxiliary Feedback Single Ended Encoder Input Option Y A 4 2 3 21 3 10 4 Auxiliary Feedback Pulse and Direction Input Option Y A 4 0 3 23 Whistle Installation Guide Contents MAN WHISIG Ver 1 2 3 11I O s 3 25 JILI Digital ett tee teet tre pen ten 3 25 3 11 2 Digital Output gus Rei eee e meer 3 27 3 11 3 Analog ete 3 28 3 12 Communications eo teet rtt eor atu 3 29 3 12 1 RS 232 Communication sa neiaa iaten inane eerte enne nennen nnne 3 29 3 12 2 CANopen Communication n asas 3 30 3 13 POWerlng PEE 3 32 3 14 Initializing the System 3 32 3 15 Heat 1881
11. A 9 Pulse Width Modulation 2 1 0004 1 2060000003 0000000 14 Whistle Installation Guide MAN WHISIG Ver 1 2 10 Standards Compliance 10 1 Quality Assurance A 10 2 Design 10 3 Safety A 10 4 EMC A 10 5 Workmanship A 10 6 A 10 7 Packing 10 8 WEEE 10 9 RoHS Contents EN Whistle Installation Guide Contents MAN WHISIG Ver 1 2 This page was left blank intentionally Whistle Installation Guide MAN WHISIG Ver 1 2 Chapter 1 Safety Information In order to achieve the optimum safe operation of the Whistle 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 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 Whistle servo drive contains electrostatic sensitive components that can be damaged if handled incorrectly To prevent any electrost
12. rating de rating stress etc IPC D 275 Reliability prediction of electronic equipment PC SM 782 rating de rating stress etc IPC CM 770 Printed wiring for electronic equipment 5 UL508c clearance creepage spacing conductors 01840 sizing etc In compliance with VDE0160 7 IEC68 Type testing Whistle Installation Guide Whistle Technical Specifications MAN WHISIG Ver 1 2 A 10 3 Safety Specification Description In compliance with UL508c Power conversion equipment In compliance with UL840 Insulation coordination including clearance and creepage distances of electrical equipment In compliance with UL60950 Safety of information technology equipment including electrical business equipment In compliance with EN60204 1 Low voltage directive 72 23 EEC A 10 4 EMC Specification Description In compliance with EN55011 and Limits and methods of measurement of radio EN61000 disturbance characteristics of industrial scientific and medical ISM radio frequency equipment Electromagnetic compatibility EMC A 10 5 Workmanship In compliance with IPC A 610 level 3 Acceptability of electronic assemblies A 10 6 PCB In compliance with IPC A 600 level 2 Acceptability of printed circuit boards A 10 7 Packing Specification Description In compliance with EN100015 Protection of electrostatic sensitive devices 10 8 WEEE Speci
13. 0 Installation 3 27 Pin Position 0 0 0 0 0 A o 3 11 2 Digital Output Pin Signal Function 1 7 High Speed Programmable digital output 1 J1 17 OUTRET1 Programmable digital output return 1 J1 8 OUT2 Programmable digital output 2 J1 16 OUTRET2 Programmable digital output return 2 Table 3 8 Digital Output Pin Assignment Integration Board 1 1 1 Whistle J1 1 Controller Digital Outputs I um E E OUTRET1 f T E I a I mm 1 WHIO0040A Figure 3 25 Digital Output Connection Diagram Whistle Installation Guide Installation 3 28 MAN WHISIG Ver 1 0 3 11 3 Analog Input Pin Signal Function Pin Position J2 3 ANLIN1 Analog input 1 J2 4 ANLIN1 Analog input 1 J2 2 ANLRET Analog ground a a a a a a a a a 1 Om c N gt Table 3 9 Analog Input Pin Assignments Integration Board Whistle J2 Analog Inputs Single Ended Source ANLIN1 3 74 KO ANLIN1
14. A 1 4 A 1 5 Motion Control Modes e Current Torque up to 14 KHz sampling rate e Velocity up to 7 KHz sampling rate Position up to 3 5 KHz sampling rate Advanced Positioning Control Modes e PT PVT ECAM Follower Dual Loop Current Follower e Fast event capturing inputs e Fast output compare OC Motion Commands Analog current and velocity PWM current and velocity digital SW and Pulse and Direction Advanced Filters and Gain Scheduling e On the Fly gain scheduling of current and velocity e Velocity and position with 1 2 4 PIP controllers e Automatic commutation alignment Automatic motor phase sequencing Fully Programmable e Third generation programming structure with motion commands Metronome e Event capturing interrupts e Event triggered programming Feedback Options e Incremental Encoder up to 20 Mega Counts 5 Mega Pulse per second e Digital Halls up to 2 KHz Incremental Encoder with Digital Halls for commutation up to 20 Mega Counts per second for encoder Interpolated Analog Encoder up to 250 KHz analog signal Internal Interpolation up to x4096 Automatic Correction of amplitude mismatch phase mismatch signal offset Emulated encoder outputs single ended unbuffered of the Analog encoder e Analog Hall Sensor e Resolver Programmable 10 15 bit resolution Up to 512 Revolution Per Second RPS Emulated encoder outputs si
15. conditions e 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 e Recovery from loss of commutation signals and from communication errors 2 3 System Architecture Communication RS 232 and CANopen Controller PWM Current Feedback Figure 2 1 Whistle System Block Diagram Analog Encoder or Resolver Main 12 95 VDC Power Supply Incrementa Encoder Optional 12 95 VDC Auxiliary Supply Auxiliary Encoder Whistle Installation Guide Introduction MAN WHISIG Ver 1 2 2 4 How to Use this Guide In order to install and operate your Elmo Whistle 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 Whistle The Appendix Technical Specifications lists all the drive ratings and specifications Upon completing the instructions in this guide your Whistle servo drive should be successfully mounted and installed From this stage you need to consult higher level Elmo documentation in order to set up a
16. 0 000001200000000000000000000500 000 4 AE SAuxiliary Supply ede het e et I He RE cei A 5 A 5 Control Specifications ianua dude nna nee reed 5 AL Current LOO pin ette te deeper eie h hu eo e A 5 ASA Melocity L00Duix i eR iem et ete ede E Inde 6 AS Position ERE Ie 6 6 ananas 7 A 6 1 Feedback Supply Voltage 7 6 2 Main Feedback Options l nn sas A 7 A 6 2 1 Incremental Encoder A 7 6 2 2 Digital Halls rre P PB au A 8 4 6 2 3 Interpolated Analog Encoder Sine Cosine A 8 6 2 4 EE EE EE u q 9 A 6 2 5 Tachometer 9 6 2 6 Potenti omete oen e EER A 10 A 6 3 Auxiliary Feedback Port output mode YA 4 4 A 10 A 6 4 Auxiliary Feedback Port input mode 4 2 0 A 11 7 A 12 A 7 1 Digital Input Interfaces eene nnns A 12 A 7 2 Digital Output Interface esses eene ener A 13 177 3 Analog Inp t 4 3 uay Eee Ue gU te ONT ei e HER Ee A 13 A 6 Communications iie E doe uae und 14
17. 0Vmax Feedback Voltage m Tacho Up to 50Vmax A Feedback Voltage Tacho Encoder Hall 5 Supply Hall Encoder Supply Voltage Return WHI0031A Only one tachometer port is available at a time Figure 3 11 Main Feedback Tachometer Feedback with Digital Hall Sensor Connection Diagram for Brushless Motors 3 14 Whistle Installation Guide Installation 3 15 MAN WHISIG Ver 1 0 Integration Board Whistle J2 abba ss Tachometer Main Feedback e 225215 o x 1 um Up to 20v max feedback voltage m I use with applications having a Tact 23216 Va Tacho tacho voltage below 20v s Jum 1 ae l 0 f 2 mz z acho Up to 20v max feedback voltage 12 8 E use with applications having a Tac2 Tacho tacho voltage above 20v and below 50v le bee ee WHI0032A Only one tachometer port is available at a time Figure 3 12 Main Feedback Tachometer Feedback Connection Diagram for Brush Motors Whistle Installation Guide MAN WHISIG Ver 1 0 Installation Integration Board l Whistle J2 Potentiometer with l Main Feedback pR Hall Sensor 2 je
18. 2 226 ones de e e edet Eg Peyton Tet 2 3 227 hkata 2 3 2 3 System Architecture enn HF HE Sabena ceed aa a 2 3 2 4 How to Use this Guide 2 4 Chapter 3 Installatiori uon HRoRRHORHEGRE RR Pie b ai RR c RD P OI PEG 3 3 1 Site Requirements 0 9 n edu Ne ec eeu ERR Us 3 3 2 Unpacking the Drive 3 3 3 PIDOULS eie tee asus aaa sha S e ate ted uten io die deiade 3 2 3 331 3 Connector Types d ccn ede dort ua sat 3 2 3 32 Connector le TERCER EE ab ua 3 3 3 3 3 Connector JZ onre edere riot e re DO Ee Dive 3 4 3 4 Mounting the Whistle 3 4 3 5 Integrating the Whistle on a 3 5 credi iter Cette eae etel tubes ie aae quai ev ds 3 5 3 5 12 Grounds and s dep eee e nece e ERR Ee E eere 3 5 3 6 The Whistle Connection 3 7 3 7 Main Power and Motor 3 8 3 7 1 Connecting Motor 2 1 2 ener 3 8 3 7 2 Connecting Main Power eene 3 9
19. I0022A Figure 3 17 Emulated Encoder Differential Output Highly Recommended Connection Diagram Whistle Installation Guide MAN WHISIG Ver 1 0 Installation 3 21 3 10 3 Auxiliary Feedback Single Ended Encoder Input Option YA 4 2 Pin Signal J1 4 SUPRET Function Supply return J1 19 INDEX Auxiliary index input J1 18 CHB Auxiliary channel B input 1 5 CHA Auxiliary channel A input Note The Whistle s Auxiliary Feedback is single ended When mounted on an integration board circuitry can be added to make it differential With or Without Integration Board Whistle J1 Auxiliary Feedback Pin Position 1 2 E E D c N Table 3 5 Single Ended Auxiliary Encoder Pin Assignment Single Ended Encoder INDEX COMMON WHI0024A Figure 3 18 Single ended Auxiliary Encoder Input Acceptable Connection Diagram Whistle Installation Guide Installation 3 22 MAN WHISIG Ver 1 0 Whistle J1 Single Ended Auxiliary Feedback Encoder J1 19 ik INDEX m INDEX 1nF J1 18 mm q 1nF J1 5 1K mm q e 1nF 18 COMMON um WHI0020A Figu
20. Whistle Digital Servo Drive Installation Guide ER TR T j i nm 4 September 2005 Ver 1 2 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 Whistle servo drive in its installation 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 WHISIG Copyright 2005 Elmo Motion Control Ltd rights reserved Whistle Catalog Number Sank Feedback Standar A Advanced Blank a Continuous Current and or Halls Amps R Resolver Interpolated Analog Encoder T Tachometer amp Potentiometer Maximum DC Operating Voltage Related Products Evaluation Board Catalog Number Evaluation Board User Manual WHI EVLBRD 1 available upon request MAN EVLBRD WHI available on our web site Revision History Ver 1 2 September 2005 Elmo Motion Control Inc 1 Park Drive Suite 12 Westford MA 01886 USA T
21. YYY Feedback andar Blank tal A Advanced a and or Halls Amps R Resolver Maximum DC Interpolated Analog Encoder T Tachometer amp Potentiometer Verify that the Whistle type is the one that you ordered and ensure that the voltage meets your specific requirements 3 3 Pinouts 3 3 1 2 mm Pitch 0 51 mm SQ Connector Types Function 1 0 COMM Auxiliary Feedback 2 mm Pitch 0 51 mm SQ Main Feedback Analog Input LED 2 mm Pitch 0 51 mm SQ Motor power output 1 Motor power output 2 Motor power output 3 Protective earth Power input return Positive power input Auxiliary power input Connector Location MAN WHISIG Ver 1 0 Whistle Installation Guide Installation 3 3 2 Connector J1 SUPRET oun ovr IN IN J1 14 I Programmable Digital input 6 1 15 INRET Programmable Digital input return J1 16 OUTRET2 Programmable Digital output 2 return OUTRETI AUX PORT CHB AUX PORT INDEX COMRET JA 13 I Programmable Digital input 5 Whistle Installation Guide Installation MAN WHISIG Ver 1 0 3 3 3 Connector J2 ummumus _ Maximum current 200mA Sup 000000002 5 72 10 INDEX Index input pay HA HalemorAiput ________ Lane m beer sa 2 13 2 14 LED 2 OUT Bi color indication output 2 Cathode 2 15 LED 1 OUT Bi color indication output 1 Anode
22. and tuned using Elmo s Composer software tools This Windows based application enables users to quickly and simply configure the servo drive for optimal use with their motor The Whistle as part of the SimplIQ product line is fully programmable with Elmo Metronome motion control language Power to the Whistle is provided by a 12 95 isolated DC power source not included with the Whistle A smart control supply algorithm enables the Whistle to operate with only one power supply with no need for an auxiliary power supply for the logic If back up functionality is required for storing control parameters in case of power loss an external 12 95 VDC supply should be connected via the VL terminal on the Whistle providing maximum flexibility and backup functionality when needed Note This back up power supply can operate from any voltage source within the 12 95 VDC range This is much more flexible than a standard 24 power supply requirement If back up power is not needed two terminals VP and VL are shorted so that the main power supply will also power the control logic supply In this way there is no need for a separate control logic supply The Whistle is a PCB mounted device which enables efficient and cost saving implementation The Whistle is available in two models The Standard Whistle is a basic servo drive which operates in current velocity and position modes includes PT amp PVT It operates simultaneo
23. ased 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 Whistle users can select from two communication options RS232 serial communication CANopen for fast communication in a multi axis distributed environment Whistle Installation Guide Introduction MAN WHISIG Ver 1 2 2 2 6 Feedback Options e Incremental Encoder up to 20 Mega Counts 5 Mega Pulse per second e Digital Halls up to 2 KHz e Incremental Encoder with Digital Halls for commutation up to 20 Mega Counts per second for encoder e Interpolated Analog Cosine Encoder up to 250 KHz analog signal Internal Interpolation up to x4096 Automatic Correction of amplitude mismatch phase mismatch signals offset Auxiliary emulated unbuffered single ended encoder output e Resolver Programmable 10 15 bit resolution Up to 512 Revolution Per Second RPS Auxiliary emulated unbuffered single ended encoder output e Tachometer Potentiometer e Elmo drives provide supply voltage for all the feedback options 2 2 7 Fault Protection The Whistle includes built in protection against possible fault conditions including e Software error handling e Status reporting for a large number of possible fault
24. atic 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 Note This is auxiliary information that ensures the correct operation of the equipment Whistle Installation Guide Safety Information MAN WHISIG Ver 1 2 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 Whistle from all voltage sources before it is opened for servicing The Whistle servo drive contains 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 disconn
25. ation 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 Whistle Installation Guide Safety Information MAN WHISIG Ver 1 2 This page was left blank intentionally Whistle Installation Guide Introduction MAN WHISIG Ver 1 2 Chapter 2 Introduction This installation guide describes the Whistle servo drive and the steps for its wiring installation and power up Following these guidelines ensures maximum functionality of the drive and the system to which it is connected 2 1 Drive Description The Whistle series of digital servo drives was designed to deliver the highest density of power and intelligence The Whistle can deliver up to 500 W of continuous power or 1000 W of peak power in a 2 in 55 X 15 x 46 5 mm or 2 x 0 6 x 1 8 38cc package The Whistle is designed for OEM s It operates 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 The Whistle is designed for use with any type of sinusoidal and trapezoidal commutation with vector control The 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 Whistle drive is easily set up
26. ce current 1 5 ma designed to also support open collector Halls Maximum frequency fmax 2 KHz A 6 2 3 Interpolated Analog Encoder Sine Cosine Feature Analog encoder format Analog input signal level Input resistance Maximum analog signal frequency Interpolation multipliers Maximum counts frequency Details Sine and Cosine signals Offset voltage 2 2 V 2 8 V Differential 1 V peak to peak Differential 120 Q fmax 250 kHz Programmable x4 to x4096 80 mega counts sec internally Automatic errors correction Signal amplitudes mismatch Signal phase shift Signal offsets Encoder outputs See Auxiliary Encoder Outputs specifications A 6 3 A 8 Whistle Installation Guide MAN WHISIG Ver 1 2 A 6 2 4 Resolver Whistle Technical Specifications Feature Details Resolver format Sine Cosine Differential Input resistance Differential 2 49 KO Resolution Programmable 10 15 bits Maximum electrical frequency RPS 512 revolutions sec Resolver transfer ratio 0 5 Reference frequency 1 Ts Is sample time in seconds Reference voltage Supplied by the Whistle Reference current up to 50 mA Encoder outputs See Auxiliary Encoder Output specifications A 9 A 6 3 6 2 5 Tachometer Maximum operating differential 20V voltage for 1 1 Maximum absolute differential input voltage for 1 1 Maximum operatin
27. ching Method Advanced Unipolar PWM Weight 50 grams 1 8 ounces Dimensions 55 x 15 x 46 5 mm 2 x 0 6 x 1 8 Digital In Digital Out Analog In OL Mounting Method PCB Mount or soldered pins A 4 Environmental Conditions Feature Details Operating ambient temperature 0 40 C 32 104 F Storage temperature 20 85 C 4 185 F Humidity 90 maximum non condensing Maximum Operating Altitude Unlimited above 10 000m 30 000 feet Protection level IP20 Whistle Installation Guide Whistle Technical Specifications 5 MAN WHISIG Ver 1 2 A 4 1 Auxiliary Supply Feature Details Auxiliary power supply Isolated DC source only Auxiliary supply input voltage 12 VDC 95 VDC Auxiliary supply input power lt 2 5 this includes the 5V 200mA load for the encoder A 5 Control Specifications A 5 1 Current Loop Feature Details Controller type Vector digital Compensation for bus voltage On the fly automatic gain scheduling variations Motor types AC brushless sinusoidal DC brushless trapezoidal DC brush Linear motors a Voice coils Current control Fully digital Sinusoidal with vector control Programmable PI control filter based on pair of PI controls of AC current signals and constant power at high speed Current loop bandwidth gt 2 5 KHz Current sampling time Programmable 70 100 usec Current sa
28. ctions Connect the VL and PR pins on the Whistle in the manner described in section 3 5 Integrating the Whistle on a Pin Function Pin Positions VL Auxiliary Supply Input PR Supply Input Return Caution Power from the Whistle to the motor must come from the Main Supply and NOT from the Auxiliary Supply WHI0045A Table 3 2 Auxiliary Supply Pins Whistle Installation Guide Installation 3 10 MAN WHISIG Ver 1 0 3 8 1 Single Supply A single isolated DC power supply can provide power for both the main power and the Auxiliary Drive Logic Supply The drawing below shows how a single supply is connected 12 95 Isolated DC Power Supply WHI0026B Figure 3 5 Single Supply for both the Main Power Supply and the Auxiliary Supply 3 8 2 Separate Auxiliary Supply Power to the Auxiliary Supply can be provided by a separate Auxiliary Supply Integration Board Whistle 12 95v Isolated Auxiliary Backup e Supply o L 5 WHI0027A Figure 3 6 Separate Auxiliary Supply Connection Diagram Whistle Installation Guide Installation 3 11 MAN WHISIG Ver 1 0 3 8 3 Shared Supply A Main DC Power Supply can be designed to supply power to the Whistle s Logic as well as to the Whistle s Main Pow
29. der abnormal 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 Failure to meet any of the above mentioned requirements can result in drive controller host failure Follow these instructions to ensure safe and proper implementation Whistle Installation Guide MAN WHISIG Ver 1 0 3 6 Whistle CAN N Controller _ CAN L COMRET The Whistle Connection Diagram Installation PC RS232 RS232 COMRET 17 Main Feedback Isolated Transformer Figure 3 2 Aux Feedback Main Feedback Power Connector IN1 IN2 IN3 INA INS ING INRET OUT1 OUTRET1 OUT2 OUTRET2 ANALIN1 ANALIN1 Circuit lt eue Drain Wire NES MEE Li HEY em ER TN EX ANALIN1 M P U ANALIN1 Circuit Common V LED 1 OUT LED 2 OUT Y BI COLOR LED Whistle Connection Diagram Common Controller WHI0002A Whistle Installation Guide MAN WHISIG Ver 1 0 3 7 Main Power and Motor Power Pin Function Cable VP Pos Power input Pow
30. ecting 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 P P P P 1 2 Cautions The Whistle 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 When connecting the Whistle to an approved 11 95V VDC 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 Whistle verify that all safety precautions have been observed and that the installation procedures in this manual have been followed gt Whistle Installation Guide Safety Information MAN WHISIG Ver 1 2 1 3 Directives and Standards The Whistle conforms to the following industry safety standards Safety Standard Item In compliance with UL508c Power Conversion Equipment In compliance with UL840 Insulation Coordination Including Clearance and Creepage Distances of Electrical Equipment In compliance with UL60950 1 Safety of Information Technology Equipment formerly UL1950 Including Electrical Business Equipment In compliance with EN60204 1 Low Voltage Direc
31. el 1 978 399 0034 Fax 1 978 399 0035 info us elmomc com Germany Tel 49 07720 8577 60 Fax 49 07720 8577 70 info de elmomc com MAN WHISIG PDF Elmo Motion Control GmbH Steinbeisstrasse 41 D 78056 Villingen Schwenningen d Elmo Motion Control www elmomc com Whistle Installation Guide MAN WHISIG Ver 1 2 Contents Chapter 1 Safety Information ERE 1 1 1 2 2 amp 1 2 1 3 Directives and 1 3 4 Mark a as 1 3 1 5 Warranty Information 1 3 Chapter 2 Introduction 2 4 102 44 1000010000000000000000000000000 nennen erre 2 1 2 1 Drive 2 1 2 2 Product Features 2 2 2 2 1 Current Control u eR pretii eerie Rea 2 2 2 22 Velocity 2 2 2 2 3 Position Control eee mter er mie eire eed 2 2 2 24 Advanced Position Control in Advanced model only 2 2 2 2 5 Communication Options sse nennen nnne nnne 2 2
32. ent is very small but generous thickness and width of the conductors will contribute to a better performance and lower interferences 2 The traces should be as short as possible to minimize EMI and to minimize the heat generated by the conductors 3 The spacing between the high voltage conductors PR M1 M2 VL must be at least Surface layer 15 mm Internal layer 0 10 mm Complying with the rules above will help satisfy UL safety standards MIL STD 275 and the IPC D 275 standard for non coated conductors operating at voltages lower than 100VDC and at unlimited altitudes above 10 000 meters 30 000 feet 3 5 2 Grounds and Returns The Returns of the Whistle are structured internally in a star configuration The returns in each functional block are listed below Functional Block Return Pin Power PR Power Return Internal Switch Mode P S PR Power Return RS232 Communications RS232_COMRET J1 3 CAN Communications CAN COMRET J1 20 Control section Internal not accessible Main Feedback SUPRET J2 2 Aux Feedback SUPRET J1 4 Analog input ANLRET 2 2 The returns above are all shorted within the Whistle in a topology that results in optimum performance 4 When wiring the traces of the above functions on the Integration Board the Returns of each function must be wired separately to its designated terminal on the Whistle DO NOT USE A COMMON GROUND PLANE S
33. er PR Power return Power PE Protective earth Power AC Motor DC Motor PE Protective earth Motor Motor M1 Motor phase Motor N C M2 Motor phase Motor Motor Motor phase Motor Motor Installation Pin Positions When connecting several whistles to several motors all should be wired in an identical manner This will enable the same SimplIO program to run on all drives 3 7 1 Table 3 1 Connector for Main Power and Motor Connecting Motor Power Connect the M1 2 and PE pins on the Whistle in the manner described in section 3 5 Integrating the Whistle on a PCB The phase connection is arbitrary as the Composer will establish the proper commutation automatically during setup However if you plan to copy the setup to other drives then the phase order on all copy drives must be the same Whistle k WHI0025A Figure 3 3 AC Motor Power Connection Diagram Whistle Installation Guide Installation MAN WHISIG Ver 1 0 3 7 2 Connecting Main Power Connect the VP PR and PE pins on the Whistle in the manner described in section 3 5 Integrating the Whistle on a PCB Whistle 12 95 e Isolated DC Power Supply VI WHI0026A Figure 3 4 Main Power Supply Connection Diagram no Auxiliary Supply 3 8 Auxiliary Supply for drive logic 2 Notes for 12 95 VDC auxiliary supply conne
34. er see Figure 3 5 and the upper portion of Figure 3 7 If backup functionality is required for storing control parameters in case of power outs a backup supply can be connected see the Aux Backup Supply in Figure 3 7 Integration Board Main 12 95v Isolated JJ Nee Whistle mm VP PR fi mm e PE Transformer _ 18 95 VDC AUX BACKUP SUPPLY for Logic Y x e PE Isolated ME e 2 e mm I OPTIONAL The Whistle Can Operate Isolated Without the Aux Backup Supply Transformer Due to the Diode Coupling WHI0044A Figure 3 7 Shared Supply Connection Diagram Whistle Installation Guide Installation 3 12 MAN WHISIG Ver 1 0 3 9 Main Feedback The Main Feedback port is used to transfer feedback data from the motor to the drive The Whistle can accept any one the following devices as a main feedback mechanism Incremental encoder only Incremental encoder with digital Hall sensors Digital Hall sensors only Incremental Analog Sine Cosine encoder option Resolver option Tachometer option Potentiometer option Incremental I
35. fication Description In compliance with 2002 96 EC Waste Electrical and Electronic Equipment regulations Please send out of service Elmo drives to the nearest Elmo sales office A 10 9 RoHS In compliance with 2002 95 EC Restrictions on Application of Hazardous effective July 2006 Substances in Electric and Electronic Equipment Whistle Installation Guide Whistle Technical Specifications MAN WHISIG Ver 1 2 This page was left blank intentionally
36. g differential 50V voltage for TAC2 TAC2 Maximum absolute differential input 60V voltage for TAC2 TAC2 Input resistance for TAC2 TAC2 100 KQ Only one Tachometer port can be used at a time either TAC1 TACI or TAC2 TAC2 TAC1 TAC1 is used in applications with having a Tachometer of less than 20V TAC2 TAC2 is used in applications with having a Tachometer of between 20V and 50V Whistle Installation Guide Whistle Technical Specifications MAN WHISIG Ver 1 2 6 2 6 Potentiometer Operating Voltage Range 0 5V supplied by the Whistle Potentiometer Resistance 1000 1 above this range linearity is affected detrimentally A 6 3 Auxiliary Feedback Port output mode YA 4 4 Emulated output A B Index Single ended Output current capability Maximum output current max 2 mA High level output voltage Vou gt 3 0 V Minimum output current 2 mA Low level output voltage Vor lt 0 4 V Available as options Emulated encoder outputs of analog encoder Emulated encoder outputs of the resolver Maximum frequency fmax 5 MHz pulses output Edge separation between A amp B Programmable number of clocks to allow adequate noise filtering at remote receiver of emulated encoder signals Index marker Length of pulse is one quadrature one quarter of an encoder cycle and synchronized to A amp B Peo Pru Pph Phase A input Phase B inp
37. h or Without Integration Board Whistle J1 Auxiliary Feedback Controller DIR CHB PULS CHA COMMON 1 0038 Figure 3 21 Pulse and Direction Auxiliary Encoder Input Direct Connection Diagram Whistle Installation Guide Installation 3 24 MAN WHISIG Ver 1 0 Integration Board Whistle J1 Auxiliary Feedback 1K Controllers DIR CHB r e I I l l l l l 1 29 V i 1K 1 1K PULS l 1 1nF V COMMON I BOARD I PE WHIO0O046A Figure 3 22 Pulse and Direction Auxiliary Encoder Input Buffered Connection Diagram Whistle J1 Auxiliary Feedback Controller DIR CHB PULS CHA SUPRET WHIO0047A Figure 3 23 Pulse and Direction Auxiliary Encoder Input Differential Connection Diagram Whistle Installation Guide Installation MAN WHISIG Ver 1 0 3 25 3 11 I O s The Whistle has 6 Digital Inputs 2 Digital Outputs and 1 Analog Input IO n Total Digital Input 6 6 Digital Output 2 2 Analog Input 1 1 3 11 1 Digital Input Each of the pins below can function as an independent input Pin Signal Function Pin Position
38. he Whistle has two feedback ports Main and Auxiliary The Whistle supplies voltage only to the main feedback device The user must provide a separate power supply for auxiliary feedback devices if needed Main encoder supply voltage 5 V 5 200 mA maximum A 6 2 Main Feedback Options A 6 2 1 Incremental Encoder Input Feature Details Encoder format A Band Index Differential Quadrature Interface RS 422 Input resistance Differential 120 Q TBD Maximum incremental encoder frequency Maximum absolute 5 MHz pulses Minimum quadrature input period PIN 112 nsec Minimum quadrature input high low period PHL 56 nsec Minimum quadrature phase period PPH 28 ns Maximum encoder input voltage range Common mode 7V Differential mode 57V PPH Phase input Phase B input Figure 1 Main Feedback Encoder Phase Diagram Whistle Installation Guide MAN WHISIG Ver 1 2 A 6 2 2 Digital Halls Feature Halls inputs Whistle Technical Specifications Details Hc Single ended inputs Built in hysteresis of 1V for noise immunity Input voltage Nominal operating range lt Vi lt 5V Maximum absolute 1V lt Vi lt 15 High level input voltage V tnigh gt 2 5V Low level input voltage V lt 1V Input current Sink current when input pulled to the common 3ma Sour
39. horting the commons on the Integration Board may cause performance degradation ground loops etc Whistle Installation Guide Installation MAN WHISIG Ver 1 0 5 Inputs The 6 inputs are optically isolated from the other parts of the Whistle 6 inputs share a single common Return INRET J1 15 To retain isolation the Input Return pin as well as other conductors on the input circuit must be laid out separately 6 Outputs The 2 outputs are optically isolated from the other parts of the Whistle Each output has a separate floating return OUTRETI J1 17 for output 1 and OUTRET2 J1 16 for output 2 To retain isolation the Output Return pins as well as other conductors on the output circuit must laid out separately 7 Return Traces The return traces should be as large as possible but without shorting each other and with minimal cross overs 8 Main Power Supply and Motor Traces The power traces must be kept as far away as possible from the feedback control and communication traces 9 Terminal terminal is connected directly to the heat sink of the Whistle The heat sink serves as an EMI common plane The PE terminal should be connected to the system s Protective Earth Any other metallic parts such as the chassis of the assembly should be connected to the Protective Earth as well 10 Under normal operating conditions the PE trace carries no current The only time these traces carry current is un
40. ignments Whistle Installation Guide Installation 3 13 MAN WHISIG Ver 1 0 Integration Board Whistle J2 Main Feedback HC Incremental Encoder with Hall Sensor Hall C HB I Hall B CHB INDEX INDEX HA mam Haia 5v r Encoder Hall 5v Supply SUPRET Hall Encoder Supply Voltage Return SH V WHI0028A Figure 3 8 Main Feedback Incremental Encoder Connection Diagram Integration Board Whistle J2 Main Feedback EIN SR OPEN Sine Cosine Encoder Encoder 5v Supply Encoder Return WHI0029A Figure 3 9 Main Feedback Interpolated Analog Encoder Connection Diagram Whistle Installation Guide MAN WHISIG Ver 1 0 Integration Board Whistle J2 Main Feedback Installation Figure 3 10 Main Feedback Resolver Connection Diagram Whistle J2 Main Feedback Resolver gt 1 j T i a n L3 m c Drain MEN Wire NW The shield is not connected to the ground or motor chassis WHI0030A Tachometer with Hall Sensor HC HB HA 5V SUPRET im Up to 2
41. max Executable time If output is set to one of the built in functions Home flag Brake or AOK execution is immediate upon detection 0 lt lt 4 5 indi no indi no If output is set to General output and is executed from a program the typical time is approximately 0 5 msec Digital Output Schematic A 7 3 Analog Input Feature Details Maximum operating differential voltage 10 V Maximum absolute differential input voltage 16V Differential input resistance 3 74 Analog input command resolution 14 bit Whistle Installation Guide Whistle Technical Specifications MAN WHISIG Ver 1 2 A 8 Communications Specification Details RS22 Signals RxD TxD Gnd Full duplex serial communication for setup and control Baud Rate of 9 600 57 600 bit sec CANopen CANbus Signals CAN L Maximum Baud Rate of 1 Mbit sec Version DS301 V4 01 Layer Setting Service and Protocol Support DSP305 Device Profile drive and motion control DSP 402 A 9 Pulse Width Modulation PWM PWM resolution 12 bit PWM switching frequency on the load 2 Ts factory default 22 kHz on the motor A 10 Standards Compliance A 10 1 Quality Assurance Specification Description ISO 9001 2000 Quality Management A 10 2 Design Specification Description Reliability prediction of electronic equipment MIL HDBK 217F
42. mpling rate up to 16 KHz Whistle Installation Guide MAN WHISIG Ver 1 2 A 5 2 Velocity Loop Feature Controller type Whistle Technical Specifications Details PI Velocity control Fully digital Programmable PI and FFW control filters On the fly gain scheduling Automatic manual and advanced manual tuning Velocity and position feedback options Velocity loop bandwidth Velocity sampling time Incremental Encoder Digital Halls Interpolated Analog sin cos Encoder optional Resolver optional Tachometer and Potentiometer optional Note With all feedback options 1 T with automatic mode switching is activated gap frequency and derivative gt 350 Hz 140 200 usec x2 current loop sample time Velocity sampling Rate up to 8 KHz Velocity command options Analog Internally calculated by either jogging or step Note software calculated profiles support on the fly changes A 5 3 Position Loop Controller type Position command options 1 2 4 PIP Software Pulse and Direction Analog Potentiometer Position loop bandwidth Position sampling time 280 400 usec x 4 current loop sample time Position sampling rate up to 4 KHz A 6 Whistle Installation Guide Whistle Technical Specifications A 7 MAN WHISIG Ver 1 2 A 6 Feedbacks A 6 1 Feedback Supply Voltage T
43. nd fine tune the system for optimal operation The following figure describes the accompanying documentation that you will require Maestro Software Manual s Maestro Installation Guide Networking CANopen Implementation Guide SimplIQ Software Manual SimplIQ Command Reference Manual Composer User Manual Setup Whistle Installation Guide Whistle Eval Board User Guide Figure 2 2 Elmo Digital Servo Drive Documentation Hierarchy MAN WHISIG Ver 1 2 Whistle Installation Guide Introduction As depicted in the previous figure this installation guide is an integral part of the Whistle documentation set comprising The Whistle Evaluation Board User Guide contains information about how to use the Whistle Evaluation Board and Cable Kit The Composer Software Manual which includes explanations of all the software tools that part of Elmo s Composer software environment SimpliQ Command Reference Manual which describes in detail each software command used to manipulate the Whistle motion controller The SimplIQ Software Manual which describes the comprehensive software used with the Whistle MAN WHISIG Ver 1 2 Whistle Installation Guide Introduction This page was left blank intentionally Whistle Installation Guide 3 1 MAN WHISIG Ver 1 0 Chapter 3 Installation 3 1 Site Requirements You can guarantee the safe operation of the Whistle by ensuring that it is installed in an appro
44. ngle ended unbuffered of the Resolver Auxiliary Encoder inputs ECAM follower etc single ended unbuffered Tachometer amp Potentiometer The Whistle can provide power 5V 200mA max for one Encoder Resolver or Hall Whistle Installation Guide Whistle Technical Specifications 2 MAN WHISIG Ver 1 2 1 6 Input Output e One Analog Input up to 14 bit resolution e Six programmable Digital Inputs optically isolated two of which are fast event capture inputs Inhibit Enable motion Software and analog reference stop Motion limit switches Begin on input Abort motion Homing General purpose e Two programmable Digital Outputs optically isolated open collector one with fast output compare OC Brake Control Amplifier fault indication General purpose Servo enable indication e Pulse and Direction inputs single ended PWM current command output for torque and velocity A 1 7 Built In Protection e Software error handling Abort hard stops and soft stops e Status reporting e Protection against Shorts between motor power outputs Shorts between motor power output and power input Failure of internal power supplies Over temperature Cont temperature measurement Temp can be read on the fly Warning can be initiated X degrees before temp disable is activated Over Under voltage Loss of feedback Following error Current limits Whistle Installation Guide
45. nterpolated Analog Tachometer and Encoder Encoder Resolver Potentiometer WHI XX YYY_ WHI XX YYYI WHI XX YYYR WHI XX YYYT Pin Signal Function Signal Function Signal Function Signal Function J2 13 HC Hall sensor NC NC HC Hall sensor C input input J2 11 Hall sensor NC NC HA Hall sensor A A input input J2 2 SUPRET Supply SUPRET Supply return SUPRET Supply return SUPRET Supply return return 2 1 5 Encoder Hal 5V Encoder Hall 5V Encoder Hall 5V Encoder Hall 1 5V supply 5V supply 5V supply 5V supply 2 6 CHA Channel A 53 Sine A 1 TachoInput1 complement complement complement Neg 20V max 2 5 Channel A 51 Sine A 1 Tacho Input 1 Pos 20V max J2 10 INDEX Index R Reference R2 Vref complmnt NC complement complement f 1 TS 50mA Maximum J2 9 INDEX Index Reference R1 Vref f 1 TS POT Potentiometer 50mA Max Input Max J2 12 HB Hallsensor NC NC HB Hall sensor B B input input 2 8 Channel Cosine B 54 Cosine B Tac2 Input 2 complement complement complement Neg 50V max J2 7 CHB Channel B Cosine 52 2 Tacho Input 2 Pos 50V max 2 3 ANALIN is used for Analog Input 2 4 ANALIN is used for Analog Input J2 14 LED 2 OUT AOKLED cathode is used for LED indication J2 15 LED 1 OUT AOKLED anode is used for LED indication Table 3 3 Main Feedback Pin Ass
46. ontroller Whistle is used in velocity mode to provide position data to the position controller The Whistle is used as a master in follower or ECAM mode b Single ended auxiliary encoder input for the input of position data of the master encoder in follower or ECAM mode c Pulse and direction input for single ended input of pulse and direction position commands When using one of the auxiliary feedback options the relevant functionality is software selected for that option Refer to the SimplIQ Command Reference Manual for detailed setup information Whistle Installation Guide MAN WHISIG Ver 1 0 Installation 3 18 3 10 1 Main and Auxiliary Feedback Combinations The Main Feedback is always used in motion control devices whereas Auxiliary Feedback is often but not always used The Auxiliary Feedback connector on the Whistle has three bi directional pins CHA CHB and INDEX When used in combination with Main Feedback the Auxiliary Feedback can be set by software as follows Auxiliary Feedback YA 4 4 Aux Feedback output YAJ 4 2 Aux Feedback input YA 4 0 Aux Feedback input Incremental Encoder Input Main Feedback Incremental dii Aux Feedback There is no Auxiliary Feedback 27 output option when an Incremental Encoder is the main feedback device Main Feedback Main Feedback Interpolated Analog Sin Cos Encoder Input Feedback
47. priate environment Feature Value Ambient operating temperature 0 to 40 C 32 to 104 F Maximum relative humidity 9076 non condensing Operating area atmosphere No flammable gases or vapors permitted in area Models for extended environmental conditions are available The Whistle dissipates its heat by convection The maximum operating ambient temperature of 0 to 40 C 32 to 104 must not be exceeded 3 2 Unpacking the Drive Components Before you begin working with the Whistle verify that you have all of its components as follows Whistle servo drive Composer software and software manual The Whistle is shipped in a cardboard box with styrofoam protection To unpack the Whistle 1 Carefully remove the servo drive from the box and the Styrofoam 2 Check he 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 Toensure that the Whistle you have unpacked is the appropriate type for your requirements locate the part number sticker on the side of the Whistle It looks like this P N WHI 5 100 E l Imo __ SIN WHI2055003 Motion Control www elmomc com WHIO08A Whistle Installation Guide MAN WHISIG Ver 1 0 Installation The part number at the top gives the type designation as follows Blank Continuous Current Operating Voltage WHI AXX
48. re 3 19 Single ended Auxiliary Encoder Input Recommended Connection Diagram Integration Board COMMON i I Whistle J1 bey Encoder Auxiliary Feedback prod lt Li 1 1 INDEX prod lt 12001 1 i ry lt 1 d BENI I ui 12001 21 e Es PY X i 1 1 t 1 lt 1 1 1 i q CHA I 1200 pod H 1 1 H 1 CHA 1 1 1 1 1 i 1 l 1 1 1 1 IN 1 1 1 1 BOARD m PE p 1 WHI0042A Figure 3 20 Differential Auxiliary Encoder Input Highly Recommended Connection Diagram Whistle Installation Guide Installation 3 23 MAN WHISIG Ver 1 0 3 10 4 Auxiliary Feedback Pulse and Direction Input Option YA 4 0 Pin Signal Function Pin Position J1 4 SUPRET Supply return J1 18 DIR CHB Direction input push pull 5 V or open collector 1 2 u u n n J1 5 PULS CHA Pulse input push pull 5 V or open collector Note The Whistle s Auxiliary Feedback is single ended When mounted on an integration board circuitry can be added to make it differential 0 0 D A H y c N Table 3 6 Pulse and Direction Pin Assignments Wit
49. sults show 30 5076 better power dissipation To determine if your application needs a heatsink 1 2 3 Note Allow maximum heatsink temperature to be 80 or less Determine the ambient operating temperature of the Whistle Calculate the allowable temperature increase as follows foranambient temperature of 40 AT 80 C 40 40 Use the chart to find the actual dissipation power of the drive Follow the voltage curve to the desired output current and then find the dissipated power If the dissipated power is below 4W the Whistle will need no additional cooling The chart above shows that no heatsink is needed when the heatsink temperature is 80 ambient temperature is 40 and heat dissipated is 4 Watts 3 33 Whistle Installation Guide Installation 3 34 MAN WHISIG Ver 1 0 3 16 Evaluation Board and Cable Kit A circuit board is available for evaluating the Whistle It comes with standards terminal blocks for power connections and D sub plugs sockets for signals connections The Evaluation Board is provided with a cable kit Figure 3 29 The Whistle Mounted on an Evaluation Board available upon request Evaluation Board Catalog Number WHI EVLBRD 1 Evaluation Board User Manual MAN EVLBRD WHI available on our web site Whistle Installation Guide MAN WHISIG Ver 1 2 Appendix Whistle Technical Specifications A 1 Features A 1 1 A 1 2 A 1 3
50. t dissipation capability Approximately 10 C W e Thermal time constant Approximately 240 seconds thermal time constant means that the Whistle will reach 2 3 of its final temperature after 4 minutes e Shut off temperature 86 C 88 C measured on the heatsink 3 15 2 Heat Dissipation Data Heat Dissipation is shown in graphically below Whistle 60 Series Power Dissipation 50V 10 0 40V 30V 20V g 8 0 70 c g 60 Heatsink 50 Required a Standard 40 C Ambient Temp 4 a 4 0 WEEEREEREEREREERREREERRERERREREREREREERREERERREERREERRERREREESAMunES EREREEREREERRRERRERREREERREERRRERRRERREEEEERSEEREEERHEREREEHERNEERE Heatsink amp 3 0 not 20 Required 1 0 0 0 T T T T T T T T T T T f T T T T t T T T T T T T T T T T T T T T t T fa Ra 9 Be Oy O Cy 0 e 95 ww e 95 lt e 9 e Peak Current A Whistle Installation Guide Installation MAN WHISIG Ver 1 0 1 Power Dissipation W Whistle 100 Series Power Dissipation 6 0 5 0 Heatsink m Standard 40 Ambient Temp Required Heatsink 2 0 not Required 1 0 0 0 9 9 NOP 7 49 gt 9 85 Peak TOVDC eak Current A 50 3 15 3 How to Use the Charts The charts above are based upon theoretical worst case conditions Actual test re
51. the drive The Auxilliary Feedback port serves as an input for Pulse amp Direction Commands Whistle Installation Guide MAN WHISIG Ver 1 0 Installation Pin Position 1 E 3 10 2 Auxiliary Feedback Emulated Encoder Output Option YA 4 4 Pin Signal Function J1 4 SUPRET Supply return J1 19 INDEX Index output J1 18 CHBO Channel B output 1 5 CHAO Channel A output Note The Emulated Encoder Output Option is only available when using a Resolver or Analog Encoder as the main feedback device Note The Whistle s Auxiliary Feedback is single ended When mounted on an integration board circuitry can be added to make it differential 2 EIS Table 3 4 Emulated Single Ended Encoder Output Pin Assignments With or Without Integration Board Whistle J1 Auxiliary Feedback INDEX mm Controller WHI0048A Figure 3 15 Emulated Encoder Direct Output Acceptable Connection Diagram 3 19 Whistle Installation Guide Installation 3 20 MAN WHISIG Ver 1 0 Whistle J1 Auxiliary Feedback Controller INDEX COMMON WHI0023A Integration Board Whistle J1 Auxiliary Feedback Controller INDEX COMMON WH
52. tive 73 23 EEC The Whistle 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 Mark Conformance The Whistle 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 EN60204 1 and EN292 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 Whistle meets the provisions outlined in Council Directive 73 23 EEC The party responsible for ensuring that the equipment meet 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 install
53. ts the time from application of If input is set to one of the built in functions Home Inhibit Hard Stop Soft Stop Hard and Soft Stop Forward Limit Reverse Limit or Begin execution is immediate upon detection 0 lt T lt 4xTS n If input is set to General input execution depends input until vd on program Typical execution time 0 5 msec execution 15 complete High speed T lt 5 psec inputs 5 amp 6 Notes minimum pulse width in high speed mode Home mode is high speed mode and be used for fast capture and precise homing High speed input has a digital filter set to same value as digital filter EF of main encoder Highest speed is achieved when turning on optocouplers Whistle Technical Specifications 1 Analog Input Connector Location jeseues o H yer ula 1 Digital Input Schematic Whistle Installation Guide Whistle Technical Specifications MAN WHISIG Ver 1 2 A 7 2 Digital Output Interface Feature Details Connector Location Type of output Optically isolated Open collector and open emitter Maximum supply output 30V Max output current Iout max 10 mA Iout max Vout Low VOL at maximum output Vout 0 3 V voltage low level RL External resistor RL must be selected to limit output current to no more than 10 mA _ Vec VOL o
54. usly via RS 232 and CANopen DS 301 DSP 305 DSP 402 communications and features a third generation programming environment Whistle Installation Guide Introduction MAN WHISIG Ver 1 2 Advanced Whistle includes all the motion capabilities and communication options included in the Standard model as well as advanced positioning capabilities ECAM Follower and Dual Loop and increased program size Both versions operate with RS 232 and 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 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 rate four times current loop sample time Fast event capturing inputs 2 2 4 Advanced Position Control in Advanced model only Position b
55. ut Figure 2 Auxiliary Feedback Encoder Phase Diagram Whistle Installation Guide Whistle Technical Specifications MAN WHISIG Ver 1 2 A 6 4 Auxiliary Feedback Port input mode YA 4 2 O Encoder input A B Index pulse and direction input Single ended Output current capability Vin Low OV lt Viz lt 0 8V Vin High 2V lt Vin lt 5V Maximum absolute voltage 0 lt Vin lt 5 5V Input current 1A Available as options Single ended Encoder inputs Pulse and Direction inputs Edge separation between A amp B Programmable number of clocks to allow adequate noise filtering at remote receiver of emulated encoder signals Index marker Length of pulse is one quadrature one quarter of an encoder cycle and synchronized to A amp B PPH Phase input Phase B input Figure 3 Auxiliary Feedback Encoder Phase Diagram Whistle Installation Guide MAN WHISIG Ver 1 2 A 7 I O s The Whistle has 6 Digital Inputs 2 Digital Outputs A 7 1 Digital Input Interfaces Feature Type of input Details Optically isolated All six inputs share one signal return line Input current for all inputs lin 2 4 mA Vin 5 V High level 25 lt Vin lt 10 V 5V typical input voltage lt Vin 1V input voltage Minimum gt 4x TS where TS is sampling time pulse width ii Execution time all inpu

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