Gold Whistle Servo Drive Complete Guide

4.1 Port A support

Incremental encoder: A, B, Z differential input (see Figure 12). Suitable for mainstream orthogonal encoders.

Hall sensor: Three single ended Hall signals (HA, HB, HC) used for initial commutation of brushless motors (Figure 13).

Absolute serial encoder: supports Endat 2.2, BiSS C/B, Panasonic, Tamagawa, Sanyo Denki, SSI. The clock and data are differential signals (Figure 14, 15). Pay attention to clock frequency and cable length when wiring.

Hiperface: requires a dedicated interface, at which point RS-232 is occupied (Figure 16).

4.2 Port B support

Incremental encoder (same as port A).

Sine/Cosine Encoder (Sin/Cos): 1 Vpp differential signal, capable of achieving high-resolution interpolation (Figure 18).

Rotary transformer: requires specific hardware options, excitation output, and sine/cosine feedback (Figure 19).

4.3 Port C - Simulated Encoder Output

Port C converts feedback signals from port A or B, or internal position/velocity variables, into differential incremental encoder outputs (A, B, Z signals). Can be used to transmit the driver position signal to the upper controller (Figure 20).

4.4 Feedback troubleshooting

Encoder communication error (absolute): Check if the clock frequency matches (Endat maximum 2 MHz, BiSS maximum 10 MHz); Measure differential voltage (usually 2-5 V); Ensure that the shielding layer is grounded at one end.

Hall signal incorrect: The motor cannot start smoothly and shakes. Use the Hall test function of EASII software to check the phase sequence and level of three signals.

Rotating transformer has no signal: check the excitation frequency (default 10   kHz) and amplitude; Measure the resistance of Sin/Cos to ground.

Communication interface and networking

5.1 USB 2.0

Used for debugging and configuration, connect to PC via Mini USB and use Elmo Application Studio (EASII) software. Note that the USB shielding layer must be connected to COMRET (Figure 24).

5.2 RS-232 TTL level

Standard asynchronous serial communication, with a logic level of 3.3V TTL, cannot be directly connected to the PC's RS-232 (requires an external level conversion chip, see Figure 23). Suitable for simple point-to-point communication.

5.3 CAN bus

Supports CAN 2.0B with a maximum baud rate of 1 Mbps. Both ends of the network must be connected to a 120 Ω terminal resistor (Figure 26). CAN-H and CAN_L are twisted pair cables. Common faults: No communication on the bus → Check for terminal resistance, node address conflicts, and common mode voltage exceeding the range (CAN-H/L ground voltage should be around 2-3 V).

5.4 EtherCAT / Ethernet

Gold Whistle can serve as an EtherCAT slave with IN and OUT ports, and supports LED status indication (RUN, ERR, LINK/ACT, SPEED). The EtherCAT-IN port can also be configured as a regular Ethernet (requiring corresponding firmware support). When connecting, use a standard CAT5e or higher Ethernet cable, and be careful not to form a loop between the two ports (Figure 25).

Troubleshooting: EtherCAT scan cannot reach slave station → Check IN/OUT wiring direction; Confirm the slave address (configured through EASII or SDO); Observe the status of the RUN LED (green flashing indicates PRE-OP, green constant light indicates OP). If the ERR LED lights up, it indicates a synchronization error or watchdog timeout, and the main station cycle and DC synchronization settings need to be checked.

Safety Function: STO (Safe Torque Off)

Gold Whistle has built-in dual channel STO inputs (STO1 and STO2) that comply with IEC 61800-5-2 SIL3 and ISO 13849-1 PL e/Cat. 3. When any channel is disconnected or the signals of two channels are inconsistent, the driver immediately cuts off the motor power output (no torque state).

6.1 Wiring (TTL mode)

STO1 and STO2 are 3.3V logic inputs and can accept signals ranging from 3.3V to 5V. Two normally open contacts of the safety relay need to be connected, or the 24V output of the safety PLC (requires external level conversion). Figure 29 shows the TTL connection method. STO-RET is the common return terminal (should be connected to COMRET).

6.2 Common STO Issues

Drive unable to enable (Status LED orange): STO not released. Measure the STO-RET voltage of STO1 and STO2, which should be at a high level (>2V). If it is a low level, check if the safety circuit is closed.

Unable to recover after STO triggering: The safety channel may malfunction (such as two channels with inconsistent levels for more than 1 second). The 24V safety power supply needs to be cut off and reconnected. If it repeatedly occurs, check if the safety relay contacts are stuck.

Key points of PCB integration and layout

7.1 Welding and Mechanical Installation

Gold Whistle is designed to be directly soldered onto PCBs. Pin spacing of 1.27mm (J2) and 2mm (power end). Before welding, ensure that the PCB pads are flat to avoid virtual soldering. You can also use a socket, but it is not recommended as it will increase inductance and reduce heat dissipation performance.

There are four screw mounting holes at the bottom of the heat sink, which can fix the drive to the metal chassis to assist in heat dissipation. If relying solely on air convection, it is necessary to ensure a minimum gap of 10mm above and below the radiator.