AWG 64 MB MEMORY CARD FOR WII Product manual

SERVOSTAR® 300
Digital Servo Amplifier
Product Manual
Edition 09/2006
Valid for Hardware Revision 02.01
Keep all manuals as a product component
during the life span of the servo amplifier.
Pass all manuals to future users / owners
of the servo amplifier.
File sr300_e.xxx
Record of Document Revisions:
Revision
06/04
04/05
04/05a
11/05
12/05
02/06
05/06
09/06
Remarks
First edition
Restart lock -AS-, UL-listing, new pinning for X8, several corrections
order numbers 400V types for NA updated
Chapter 1 updated, ComCoder wiring corrected, Acuro(BISS)-Interface new, max. station address changed to 127, motor choke changed, SynqNet and EtherCat expansion cards added,
chapter 6 restructured, order codes restructured
Feedback section, termination resistors X1/X5, CE section
Error messages and warnings updated, additional information (SERCOS), AWG cross-sections
added, inch dimensions added, analog-in circuit updated, cross section (awg)
CAN baud rate coding updated, LED display structure updated, input analog-in updated, BISS
interface updated, hardware revision added, Errors/Warnings updated
New document structure, new cover design, warning n24, Quickstart integrated
Hardware Revision (HR) History
Hardware Rev.
00.00
01.00
01.01
02.01
usable
Firmware Rev.
<= 2.0
<= 2.0
<= 2.0
<= 2.0
usable
DRIVEGUI.EXE Rev.
<= 1.30 Build 0054
<= 1.30 Build 0054
<= 1.30 Build 0054
<= 1.30 Build 0054
Remarks
First version
Housing improved, shield assembly improved
AS completed, pinning X8 changed
UL approv., X3 divided to two connectors
WINDOWS is a registered trademark of Microsoft Corp.
HIPERFACE is a registered trademark of Max Stegmann GmbH
EnDat is a registered trademark of Dr. Johannes Heidenhain GmbH
SERVOSTAR is a registered trademark of Danaher Motion
Technical changes which improve the performance of the equipment may be made without prior notice!
Printed in the Federal Republic of Germany
All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm
or any other method) or stored, processed, copied or distributed by electronic means without the written permission of Danaher Motion.
Kollmorgen
09/2006
Contents
page
1
General
1.1
1.2
1.3
1.4
2
About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hints for the online edition (PDF format) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
7
8
Safety
2.1
2.2
3
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Standards
3.1
3.2
3.3
3.4
4
European Directives and Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
American Directives and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Asian Directives and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.1
CE conformance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.2
Conformance with UL and cUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
11
12
12
12
Handling
4.1
4.2
4.3
4.4
4.5
5
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
13
13
13
Package
5.1
5.2
6
Package supplied. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Technical description
6.1
6.2
6.3
6.4
The SERVOSTAR 300 family of digital servo amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection to various electrical supply networks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Components of a servo system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.1
Technical data for 110/230 V (types S3_ _6_) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.2
Technical data for 400/480 V (types S3_ _0_) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.3
Inputs / outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.4
Recommended tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.5
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.6
Permissible ambient conditions, ventilation, mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.7
Conductor cross-sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5
LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6
Control circuit for motor-holding brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7
Grounding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8
Regen circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9
Switch-on and switch-off behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9.1
Stop function as per EN 60204 (VDE 0113). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9.2
Emergency Stop strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
15
17
18
19
19
20
21
21
21
22
22
22
23
24
24
26
26
27
Mechanical Installation
7.1
7.2
7.3
7.4
8
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guide to mechanical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
28
29
30
Electrical installation
8.1
8.2
8.3
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guide to electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.1
Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.2
Shielding connection to the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.3
Technical data for connecting cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5
Connector assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6
Connection diagram (Overview). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7
Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.1
Mains electrical supply connection (X0). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.1.1
Three phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.1.2
Two phase without neutral. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.1.3
Single phase with neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.2
24V auxiliary supply (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.3
DC bus link (X8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8
Motor connection with brake (X9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9
External regen resistor (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVOSTAR ® 300 Product Manual
31
32
33
33
34
35
36
37
38
39
39
39
39
39
40
40
41
41
3
Contents
09/2006
Kollmorgen
page
8.10 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.1
Resolver (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.2
ComCoder (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.3
Incremental or Sine Encoder with hall sensors (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.4
Sine Encoder with EnDat 2.1 or HIPERFACE (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.5
ACURO encoder, BISS interface (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.6
Incremental Encoder (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10.7
Sine Encoder without data channel (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11 Digital and analog inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.1
Analog inputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.2
Digital inputs (X3/X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.3
Digital outputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12 Encoder emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.1
Incremental encoder output - A quad B (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.2
SSI output (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.13 Master-slave operation, encoder master control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.13.1
Connection to a SERVOSTAR master, 5 V signal level (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.13.2
Connection to incremental encoder master with 24 V signal level (X3) . . . . . . . . . . . . . . . . . . . . . . . . .
8.13.3
Connection to a sine encoder master (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.14 Interface for stepper motor controllers (step and direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.14.1
Connection to a stepper controller with 5 V signal level (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.14.2
Connection to a stepper controller with 24 V signal level (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.15 RS232 interface, PC connection (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.16 CANopen interface (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17 Personnel safe restart lock -AS-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.1
Technical data and pinning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.2
Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.3
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.4
Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.4.1 Signal diagram (sequence) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.4.2 Control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.4.3 Functional test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.4.4 Mains supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
42
42
43
44
45
46
47
48
49
49
50
51
52
52
53
54
54
55
55
56
57
57
58
59
60
60
60
60
61
62
63
64
64
Setup
9.1
9.2
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Setup software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.2.1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.2.1.1
Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.2.1.2
Software description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.2.1.3
Hardware requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.2.1.4
Operating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.2.2
Installation under WINDOWS 2000 / XP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.3
Quickstart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.3.1
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.3.1.1
Unpacking, Mounting and Wiring the Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.3.1.2
Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.3.1.3
Minimum Wiring for Drive Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9.3.2
Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.3.3
Important Screen Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.3.4
Setup Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.3.4.1
Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.3.4.2
Units/Mechanical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.3.4.3
Motor (rotary) / Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9.3.4.4
Motor (linear) / Feedback (Encoder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9.3.4.5
Save Parameters and Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.3.5
Motion Service (Jog Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.3.6
More Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9.4
Multi-axis systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.4.1
Station address for CAN-bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.4.2
Baud rate for CAN-bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.5
Keypad operation / LED display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.5.1
Keypad operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.5.2
Status display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.5.3
Standard menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.5.4
Advanced menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
9.6
Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
9.7
Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9.8
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4
SERVOSTAR ® 300 Product Manual
Kollmorgen
09/2006
Contents
page
10
Expansions and Accessories
10.1 Expansion Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
10.1.1
Guide to installation of expansion cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
10.1.2
Expansion card -I/O-14/08- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10.1.2.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10.1.2.2 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10.1.2.3 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10.1.2.4 Entering a motion block number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10.1.2.5 Connector assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10.1.2.6 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
10.1.3
Expansion card -PROFIBUS-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.1.3.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.1.3.2 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.1.3.3 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.1.4
Expansion card -SERCOS- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.1.4.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.1.4.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.1.4.3 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.1.4.4 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.1.4.5 Modifying the station address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.1.4.6 Modifying the baud rate and optical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.1.5
Expansion card -DEVICENET- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.1.5.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.1.5.2 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.1.5.3 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.1.5.4 Combined module/network status-LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.1.5.5 Setting the station address (device address) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.1.5.6 Setting the transmission speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.1.5.7 Bus cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
10.1.6
Expansion card -ETHERCAT- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10.1.6.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10.1.6.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10.1.6.3 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10.1.7
Expansion card -SYNQNET- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.1.7.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.1.7.2 NODE ID Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.1.7.3 Node LED table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.1.7.4 SynqNet Connection, Connector X21B/C (RJ-45). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.1.7.5 Digital inputs/outputs, connector X21A (SubD 15-pin, socket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.1.7.6 Connection diagram digital inputs/outputs, connector X21A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.1.8
Expansion module -2CAN-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.1.8.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.1.8.2 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.1.8.3 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.1.8.4 Connector assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.1.8.5 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10.2.1
External power supply 24 V DC / 5 A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10.2.2
External power supply 24 V DC / 20 A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10.2.3
External regen resistor BAR(U) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.2.4
Motor chokes 3YLN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
11
Appendix
11.1 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2 Order codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.1
Servo amplifier, expansion cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.2
Mating connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.3
Motor cables with connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.4
Feedback cables with connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.5
Power supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.6
Regen resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.7
Motor chokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6
SERVOSTAR ® 300 Product Manual
Kollmorgen
General
09/2006
1
General
1.1
About this manual
This manual describes the SERVOSTAR® 300 series of digital servo amplifiers
(standard version: 1.5A ...10A rated current).
A more detailed description of the expansion cards that are currently available and the
digital connection to automation systems can be found, together with our applications
notes, in Acrobat-Reader format on the accompanying CD-ROM (system requirements:
WINDOWS, Internet Browser, Acrobat Reader) in different languages.
You can print out this documentation on any standard commercial printer. A printed copy
of the documentation is available from us at extra cost.
This manual addresses personnel with the following qualifications:
Transport :
only by personnel with knowledge of handling electrostatically
sensitive components.
Unpacking:
only by electrically qualified personnel.
Installation :
only by electrically qualified personnel.
Setup :
only by qualified personnel with extensive knowledge of
electrical engineering and drive technology
1.2
Hints for the online edition (PDF format)
Bookmarks:
Table of contents and index are active bookmarks.
Table of contents and index in the text:
The lines are active cross references. Click on the desired line and the appropriate page
is indicated.
Page/chapter numbers in the text:
Page/chapter numbers with cross references are active. Click at the page/chapter number to reach the indicated target.
1.3
Symbols used
Danger to personnel
from electricity and its
effects effects
ð p.
see page
SERVOSTAR ® 300 Product Manual
Danger to maschinery,
general warning
l
Important
notes
special emphasis
7
General
1.4
Kollmorgen
09/2006
Abbreviations used
The abbreviations used in this manual are explained in the table below.
Abbrev.
AGND
AS
BTB/RTO
CAN
CE
CLK
COM
DGND
DIN
Disk
EEPROM
EMC
EMI
EN
ESD
F-SMA
IEC
IGBT
INC
ISO
LED
MB
NI
PC
PELV
PLC
PWM
RAM
RBallast / RBR
RBext
RBint
RES
ROD
S1
S3
SRAM
SSI
UL
V AC
V DC
VDE
8
Meaning
Analog ground
Restart lock, option
Ready to operate
Fieldbus (CANopen)
Communité Europeenne
Clock signal
Serial interface for a PC-AT
Digital ground (for 24V and digital I/O)
German Institute for Industrial Standards
Magnetic storage (diskette, hard disk)
Electrically erasable programmable memory
Electromagnetic compatibility
Electromagnetic interference
European Standard
Electrostatic discharge
Fiber Optic Cable connector according to IEC 60874-2
International Electrotechnical Commission
Insulated-gate bipolar transistor
Incremental interface
International Organization for Standardization
Light-emitting diode
Megabyte
Zero pulse
Personal computer
Protected low voltage
Programmable logic controller
Pulse-width modulation
Volatile memory
Ballast resistor (= regen resistor)
External regen resistor
Internal regen resistor
Resolver
digital encoder
continuous operation
Intermittent operation
Static RAM
Synchronous serial interface
Underwriters Laboratories
Alternating voltage
DC voltage
Society of German Electrical Technicians
SERVOSTAR ® 300 Product Manual
Kollmorgen
09/2006
2
Safety
2.1
Safety Instructions
Safety
l
Only properly qualified personnel are permitted to carry out activities such as
transport, installation, commissioning and maintenance. Properly qualified persons are those who are familiar with the transport, assembly, installation, commissioning and operation of the product, and who have the appropriate qualifications for their job. The qualified personnel must know and observe the
following standards and regulations:
IEC 364 and CENELEC HD 384 or DIN VDE 0100
IEC Report 664 or DIN VDE 0110
national accident prevention regulations or BGV A3
l
Check the Hardware Revision Number of the product (see product label). This
revision number must match the Hardware Revision Number on the cover page
of the manual.
l
Read this documentation before carrying out the installation and commissioning. Incorrect handling of the servo amplifier can lead to personal injury or
material damage. It is vital that you keep to the technical data and information
on connection requirements (nameplate and documentation).
l
Discharge your body before touching the servo amplifier. The servo amplifiers
contain electrostatically sensitive components which may be damaged by incorrect handling. Avoid contact with highly insulating materials (artificial fabrics, plastic film etc.). Place the servo amplifier on a conductive surface.
l
The manufacturer of the machine must produce a hazard analysis for the machine and take appropriate measures to ensure that unforeseen movements do
not result in personal injury or material damage.
l
Do not open or touch the equipment during operation. Keep all covers and cabinet doors closed during operation. Touching the equipment is allowed during installation and commissioning for properly qualified persons only. Otherwise, there are deadly hazards, with the possibility of death, severe injury or
material damage.
—
During operation, servo amplifiers may have uncovered live
components, depending on their level of enclosure protection.
—
Control and power connections may be live, even though the
motor is not rotating.
—
Servo amplifiers may have hot surfaces during operation.
Surface can reach temperatures above 80°C.
l
Never undo any electrical connections to the servo amplifier while it is live.
There is a danger of electrical arcing with damage to contacts and personal injury.
Wait at least five minutes after disconnecting the servo amplifier from the main
supply power before touching potentially live sections of the equipment (e.g.
contacts) or undoing any connections. Capacitors can still have dangerous
voltages present up to five minutes after switching off the supply power. To be
sure, measure the voltage in the DC Bus link and wait until it has fallen below
40V.
SERVOSTAR ® 300 Product Manual
9
Safety
2.2
09/2006
Kollmorgen
Use as directed
Servo amplifiers are components that are built into electrical plant or machines, and can
only be operated as integral components of such plant or machines.
The manufacturer of the machine must generate a hazard analysis for the machine, and
take appropriate measures to ensure that unforeseen movements cannot cause injury or
damage to any person or property.
Servo amplifiers in the SERVOSTAR 300 series can be supplied from 3-phase grounded
(earthed) industrial supply networks (TN-system, TT-system with grounded neutral point,
no more than 5000A symmetrical rated current at 230V or 480V+10%).
The servo amplifiers must not be operated directly on non-grounded supply networks or
on asymmetrically grounded supplies with a voltage >230V. Connection to other types of
supply networks (with an additional isolating transformer) is described on p. 17.
Periodic overvoltages between phases (L1, L2, L3) and the housing of the servo amplifier
must not exceed 1000V crest.
In accordance with EN 61800, voltage spikes (< 50µs) between phases must not exceed
1000V. Voltage spikes (< 50µs) between a phase and the housing must not exceed
2000V.
If the servo amplifiers are used in residential areas, in business/commercial areas, or in
small industrial operations, then additional filter measures must be implemented by the
user.
The SERVOSTAR 300 family of servo amplifiers is exclusively intended for driving suitable brushless synchronous servomotors and asynchronous motors with closed-loop control of torque, speed and/or position. The rated voltage of the motors must be at least as
high as the DC bus link voltage produced by the servo amplifier.
The servo amplifiers must only be operated in a closed control cabinet, taking into
account the ambient conditions defined on page 22. Ventilation or cooling may be necessary to keep the temperature within the cabinet below 40°C.
Use only copper conductors for wiring. The conductor cross-sections can be derived from
the standard EN 60204 (alternatively for AWG cross-sections: NEC Table 310-16, 60°C
or 75°C column).
We only guarantee the conformance of the servo system with the standards cited on p.11
if the components (servo amplifier, motor, cables etc.) are those supplied by us.
Restart lock for personnel safety
The servo amplifier has an integrated personnel safe restart lock, which meets the requirements of safety category 3 according to EN 954-1.
The conceptual examination of the function "safe stop" (called restart lock AS in the following) was accomplished by the BG-Institute for Occupational Safety and Health and the
classification in category 3 according to EN 954-1 was confirmed.
Please consider the specifications on page 60 when you use this function
10
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3
Standards
3.1
European Directives and Standards
Standards
Servo amplifiers are components that are intended to be incorporated into electrical plant
and machines for industrial use. When the servo amplifiers are built into machines or
plant, the amplifier must not be used until it has been established that the machine or
equipment fulfills the requirements of the EC Machinery Directive (98/37/EC), the EC
EMC Directive (89/336/EEC) and the EC Low Voltage Directive 73/23/EEC.
Standards to be applied for conformance with the EC Machinery Directive (98/37/EC):
EN 60204-1 (Safety and Electrical Equipment in Machines)
EN 12100 (Safety of Machines)
The manufacturer of the machine must generate a hazard analysis for the machine,
and must implement appropriate measures to ensure that unforeseen movements
cannot cause injury or damage to any person or property.
Standards to be applied for conformance with the EC Low Voltage Directive (73/23/EEC):
EN 60204-1 (Safety and Electrical Equipment in Machines)
EN 50178 (Electronic Equipment in Power Installations)
EN 60439-1 (Low Voltage Switchgear Combinations)
Standards to be applied for conformance with the EC EMC Directive (89/336/EEC):
EN 61000-6-1 / EN 61000-6-2 (Interference Immunity in Residential & Industrial Areas)
EN 61000-6-3 / EN 61000-6-4 (Interference Generation in Residential & Industrial Areas)
The manufacturer of the machine/plant is responsible for ensuring that it meets the limits
required by the EMC regulations. Advice on the correct installation for EMC (such as
shielding, grounding, treatment of connectors and cable layout) can be found in this documentation.
The machine/plant manufacturer must check whether other standards or EC
Directives must be applied to the machine/plant.
3.2
American Directives and Standards
Chapter in process
3.3
Asian Directives and Standards
Chapter in process
SERVOSTAR ® 300 Product Manual
11
Standards
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09/2006
3.4
Approvals
3.4.1
CE conformance
Conformance with the EC EMC Directive 89/336/EEC and the Low Voltage Directive
73/23/EEC is mandatory for the supply of servo amplifiers within the European Community. Product standard EN 61800-3 is applied to ensure conformance with the EMC Directive. The Declaration of Conformity form can be found on our website (download area).
Concerning noise immunity the servo amplifier meets the requirements to the 2nd environmental category (industrial environment). For noise emission the amplifier meets the
requirement to a product of the category C2 (motor cable £ 10m).
Warning!
This product can cause high-frequency interferences in non industrial
environments which can require measures for interference suppression.
With a motor cable length from 10m onwards, the servo amplifier meets the requirement
to the category C3.
The servo amplifiers have been tested by an authorized testing laboratory in a defined
configuration, using the system components that are described in this documentation.
Any divergence from the configuration and installation described in this documentation
means that you will be responsible for carrying out new measurements to ensure conformance with regulatory requirements. The standard EN 50178 is applied to ensure conformance with the Low Voltage Directive.
3.4.2
Conformance with UL and cUL
This servo amplifier is listed under UL file number E217428.
UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S.
and Canadian standard (in this case UL 840 and UL 508C).
This standard describes the fulfilment by design of minimum requirements for electrically
operated power conversion equipment, such as frequency converters and servo amplifiers, which is intended to eliminate the risk of fire, electric shock, or injury to persons,
being caused by such equipment. The technical conformance with the U.S. and Canadian
standard is determined by an independent UL (cUL) inspector through the type testing
and regular checkups.
Apart from the notes on installation and safety in the documentation, the customer does
not have to observe any other points in direct connection with the UL (cUL)-certification of
the equipment.
UL 508C
UL 508C describes the fulfilment by design of minimum requirements for electrically operated power conversion equipment, such as frequency converters and servo amplifiers,
which is intended to eliminate the risk of fire being caused by such equipment.
UL 840
UL 840 describes the fulfilment by design of air and insulation creepage spacings for
electrical equipment and printed circuit boards.
12
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4
Handling
4.1
Transport
4.2
4.3
4.4
Handling
l
Transport by qualified personnel in the manufacturer’s original recyclable packaging
l
Avoid shocks while transporting
l
Transport temperature:
-25 to +70°C, max. rate of change 20°C / hour
l
Transport humidity:
max. 95% relative humidity, no condensation
l
The servo amplifiers contain electrostatically sensitive components, that can
be damaged by incorrect handling. Discharge yourself before touching the servo amplifier. Avoid contact with highly insulating materials, such as artificial
fabrics and plastic films. Place the servo amplifier on a conductive surface.
l
If the packaging is damaged, check the unit for visible damage. In such an event, inform the shipper and the manufacturer.
Packaging
l
Recyclable cardboard with inserts
l
Dimensions:
(HxWxD) 115x365x275mm
l
Labeling:
instrument label on outside of box
Storage
l
Storage only in the manufacturer’s original recyclable packaging
l
Max. stacking height
8 cartons
l
Storage temperature
-25 to +55°C, max. rate of change 20°C / hour
l
Storage humidity
5 ... 95% relative humidity, no condensation
l
Storage duration:
Less than 1 year: without restriction.
More than 1 year: capacitors must be re-formed before setting up and operating the
servo amplifier. To do this, remove all electrical connections and apply single-phase
230V AC for about 30 minutes to the terminals L1 / L2.
Maintenance, Cleaning
The instruments do not require any maintenance, opening the instruments invalidates the
warranty.
Cleaning : — if the casing is dirty: clean with Isopropanol or similar
do not immerse or spray
— if there is dirt inside the unit: must be cleaned by the manufacturer
— dirty protective grill on fan: clean with a dry brush
4.5
Disposal
In accordance to the WEEE-2002/96/EG-Guidelines we take old devices and accessories
back for professional disposal, if the transport costs are taken over by the sender. Send
the devices to:
Danaher Motion GmbH
Wacholderstr. 40-42
D-40489 Düsseldorf
SERVOSTAR ® 300 Product Manual
13
Package
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09/2006
5
Package
5.1
Package supplied
When you order an amplifier from the SERVOSTAR 300 series (order numbers ð p.106),
you will receive:
—
—
SERVOSTAR 3xx
mating connectors X0, X3, X4, X8, X9 only with SERVOSTAR 303-310 (S3xx6)
The mating SubD connectors are not part of the package!
—
—
—
Assembly, Installation and Setup instructions (product manual)
Online documentation on CD-ROM
Setup software DRIVEGUI.EXE on CD-ROM
Accessories : (must be ordered separately, if required)
—
—
—
—
—
—
—
5.2
synchronous servomotor (linear or rotary)
motor cable (prefabricated), or both power connectors separately,
with the motor cable as a cut-off length
feedback cable (prefabricated)
or both feedback connectors separately, with the feedback cable as a cut-off length
motor choke 3YLN (ð p.103), for motor cables longer than 25 meters
external regen resistor BAR(U) (ð p.102)
communication cable to the PC (ð p.58) for setting parameters from a PC
power cable, control cables, fieldbus cables (as cut-off lengths)
Nameplate
The nameplate depicted below is attached to the side of the servo amplifier.
The information described below is printed in the individual fields.
Servo amplifier type
Danaher Motion GmbH
Wacholderstr. 40-42
D-40489 Düsseldorf
www.DanaherMotion.com
Serial number
Comments
Customer Support
Europe
Tel. +49 (0)203 / 99790
Italy
Tel. +39 (0)362 / 594260
North America Tel. +1 540 633 3400
Typenbezeichnung
Model Number Ser. Nr
Spannungsversorgung
Power Supply Nennstrom
E217428
UL
®
US
LISTED
IND. CONT. EQ.
1VD4
Nom. Current Schutzart
Comment
Encl.Rating
Hardware
Revision
example
example
14
C
Ser. No. Bemerkung
Umgebungstemp.
Ambient temp.
max. ambient
temperature
Enclosure Rating
Electrical supply
Installed load
Output current
in S1 operation
Hardware
Revision
SERVOSTAR ® 300 Product Manual
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Technical description
6
Technical description
6.1
The SERVOSTAR 300 family of digital servo amplifiers
Standard version
l
Two voltage classes with large nominal voltage range
1 x 110V-10% ... 3 x 230V+10% (SERVOSTAR 303-310, S3xx6)
3 x 208V-10% ... 3 x 480V+ 10% (SERVOSTAR 341-346, S3xx0)
l
Instrument width 70 mm
l
Shielding connection directly on the servo amplifier
l
Two analog inputs
l
Integrated CANopen (default: 500 kBaud), for integration in CAN-bus systems and
for setting parameters for several drives via the PC interface of one of the amplifiers
l
Slot for an expansion card
l
Integrated RS232, integrated pulse direction interface
l
Integrated restart lock -AS- for personnel safety, ð p. 60
Power section
l
Directly on grounded 3-phase supply, 110V-10% or 230V-10% up to 480V+10%
TN-network or TT-network with grounded neutral point, 5000 A max. symmetrical
current rating, connection to other supply types only via isolating transformer,
ð p. 17
l
B6 bridge rectifier, integral supply filter and soft-start circuit
l
Single-phase supply operation possible (e.g. for setup)
l
Fusing
(e.g. fusible cutout) to be provided by the user
l
Shielding
All shielding connections are made directly on the amplifier
l
Output stage IGBT module with floating current measurement
l
Regen circuit with dynamic distribution of the regenerated power between
several amplifiers on the same DC bus link circuit. Internal
regen resistor as standard, external regen resistors if required.
l
DC bus link voltage 135 … 450 V DC or 260 … 900 V DC,
can be connected in parallel.
l
Interference suppression filters are integrated for the electrical supply feed and the
24V auxiliary supply voltage (with motor cable £ 10m for general availability as per
EN 61800-3, with motor cable < 10m for 2nd environmental category as per EN
61800-3).
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15
Technical description
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09/2006
Integrated safety
l
Appropriate insulation/creepage distances and electrical isolation ensure safe electrical separation, as per EN 50178, between the power input / motor connections and
the signal electronics.
l
Soft-start, overvoltage detection, short-circuit protection, phase-failure monitoring.
l
Temperature monitoring of the servo amplifier and motor (if our motors and prefabricated cables are used).
Auxiliary supply voltage 24V DC
l
Electrically isolated, internal fusing, from an external 24V DC power supply unit with,
for instance, isolating transformer or uninterruptible power supply.
Operation and parameter setting
l
With our user-friendly setup software, for setup via the serial interface of a PC.
l
If no PC is available: direct operation by two keys on the servo amplifier and a 3-character LED display.
l
Fully programmable via RS232 interface.
Completely digital control
l
Digital current controller (space vector, pulse-width modulation, 62.5 µs)
l
Adjustable digital speed controller (62.5 µs)
l
Integrated position controller, with adaptation possibilities for all applications (250 µs)
l
Integrated step/direction interface for connecting a servomotor to a stepper controller
l
Evaluation of resolver signals and sine-cosine signals of high-resolution encoders
l
Encoder emulation (incremental, compatible with A quad B or SSI)
Comfort functions
l
2 programmable analog inputs
l
4 programmable digital inputs
l
2 programmable digital outputs
l
programmable logical combinations of digital signals
Expansions
16
l
I/O-14/08 expansion card, ð p.86
l
PROFIBUS DP expansion card, ð p.89
l
SERCOS expansion card, ð p.90
l
DeviceNet expansion card, ð p.92
l
EtherCat expansion card, ð p. 95
l
SynqNet expansion card, ð p. 96
l
-2CAN- expansion module, separated connectors for CAN-bus and RS232, ð p.98
l
For third-party expansion cards (ModBus, LightBus, FIP-IO etc.) please contact the
manufacturer for further information
SERVOSTAR ® 300 Product Manual
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6.2
09/2006
Technical description
Connection to various electrical supply networks
This page illustrates all the possible connection variations for different electrical supply
networks.
An isolating transformer is always required for 400 … 480V networks that are
asymmetrically grounded or not grounded.
110V : SERVOSTAR 303-310*
230V : all types
400V / 480V : SERVOSTAR 341-346*
* Order code reference see p. 106
SERVOSTAR ® 300 Product Manual
17
Technical description
6.3
Kollmorgen
09/2006
Components of a servo system
WINDOWS® PC
Controls / PLC
SERVOSTAR
24V PSU
Fuses
Drive cut-out
Terminals
18
Motor
SERVOSTAR ® 300 Product Manual
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Technical description
09/2006
6.4
Technical data
6.4.1
Technical data for 110/230 V (types S3_ _6_)
Rated data
Order Code
DIM
—
Rated supply voltage
(grounded supply, phase to phase)
V~
SERVOSTAR
303
306
310
S30361
S30661
S31061
1 x 110V-10% … 1 x 230V+10%
3 x 110V-10% … 3 x 230V+10%
50/60 Hz
1.1
2,4
4
450
Rated input power for S1 operation
kVA
Max. DC bus link voltage
V=
Rated output current (rms value, ± 3%)
at 1x110V
Arms
3
3
3
at 3x115V
Arms
3,5
8
10
at 3x230V
Arms
3
6
10
at 1x230/240V
Arms
3
4
4
Peak output current (rated current x 2 for approx. 5s, ± 3%)
at 1x110V
Arms
5
5
5
at 3x115V
Arms
9
15
20
at 3x230V
Arms
9
15
20
at 1x230/240V
Arms
9
9
9
Switching frequency of the output stage
kHz
8 (16*)
Technical data for regen circuit
—
ð p.24
Threshold for overvoltage switch-off
VDC
235 / 455
Motor inductance min.
at 1x110V
mH
3,7
3,7
3,7
at 3x115V
mH
2,1
1,3
1,0
at 3x230V
mH
4,3
2,6
1,9
at 1x230/240V
mH
4,3
4,3
4,3
Motor inductance max.
mH
Consult our customer support
Form factor of the output current
—
1.01
(rated conditions, min. load inductance)
Bandwidth of current controller
kHz
> 1.2
Residual voltage drop at rated current
V
4
Thermal dissipation, output stage disabled
W
12
Thermal dissipation at rated current
W
35
60
90
(incl. PSU losses, without regen dissipation)
Mechanical
Weight
kg
approx. 2,6
Height, without connectors
mm
275
279
Width
mm
70
Depth, without connectors
mm
171
Depth, with connectors
mm
< 200
* at reduced current
SERVOSTAR ® 300 Product Manual
19
Technical description
6.4.2
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09/2006
Technical data for 400/480 V (types S3_ _0_)
Rated data
Order Code
Rated supply voltage
(grounded supply, phase to phase)
Rated input power for S1 operation
Max. DC bus link voltage
Rated output current (rms value, ± 3%)
at 3x208V
at 3x230V
at 3x400V
at 3x480V
Peak output current (max. approx. 5s, ± 3%)
at 3x208V
at 3x230V
at 3x400V
at 3x480V
Switching frequency of the output stage
Technical data for regen circuit
Threshold for overvoltage switch-off
Motor inductance min.
at 3x208V
at 3x230V
at 3x400V
at 3x480V
Motor inductance max.
Form factor of the output current
(rated conditions, min. load inductance)
Bandwidth of subordinate current controller
Residual voltage drop at rated current
Thermal dissipation, output stage disabled
Thermal dissipation at rated current
(incl. PSU losses, without regen dissipation)
Mechanical
Weight
Height, without connectors
Width
Depth, without connectors
Depth, with connectors
* at reduced current
20
DIM
—
SERVOSTAR
341
343
346
S30101
S30301
S30601
V~
3 x 208V-10% … 480V+10%, 50/60 Hz
kVA
V=
1.2
2,5
900
5
Arms
Arms
Arms
Arms
2
2
1,5
1,5
5
5
4
3
6
6
6
6
Arms
Arms
Arms
Arms
kHz
—
VDC
4,5
4,5
4,5
4,5
7,5
7,5
7,5
7,5
8 (16*)
ð p.24
455 / 800 / 900
12
12
12
12
mH
mH
mH
mH
mH
7,7
4,6
2,9
8,5
5,1
3,2
14,8
8,9
5,6
17,8
10,7
6,7
Consult our customer support
—
1.01
kHz
V
W
> 1.2
5
12
W
kg
mm
mm
mm
mm
40
275
60
90
approx. 2,7
278
70
171
< 235
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6.4.3
09/2006
Technical description
Inputs / outputs
V
±10
V
±10
V as per EN 61131-2 Type 1, max. 30VDC
V
open Emitter, max. 30VDC, 10mA
V
DC max. 30, AC max 42
BTB/RTO output, relay contacts
mA
500
Auxiliary supply voltage, electrically isoV
20 - 30
A
1
lated, without brake/fan
V
24 (-0% +15%)
Auxiliary supply voltage, electrically iso2.5
lated, with brake/fan (check voltage drop !) A
Max. output current to brake
A
1.5
Connection technology
Control signals
—
Combicon connector
Power signals
—
Combicon connector
Resolver input
—
SubD 9-pin (socket)
Incremental encoder input
—
SubD 15-pin. (socket)
PC interface, CAN
—
SubD 9-pin (plug)
Encoder emulation, ROD/SSI
—
SubD 9-pin (plug)
Analog inputs 1, 2 (resolution 14/12 bit)
Max. common-mode voltage
Digital control inputs
Digital control outputs, active high
6.4.4
Recommended tightening torques
Connector
X0, X8, X9
Grounding bolt
6.4.5
Tightening torque
0,5..0,6 Nm
3.5 Nm
Fusing
Internal fusing
Circuit
Auxiliary voltage 24V
Regen resistor
Internal fuse
3.15 A (slow)
electronic
External fusing
Wire fuses or similar
AC supply feed FN1/2/3 (X0/1; 2; 3)
24V feed
FH1/2
Regen resistor FB1/2 (X8/2; 4)
SERVOSTAR
SERVOSTAR
303*, 341*, 343*
306*, 310*, 346*
6 AT (FRx-6)
10 AT (FRx-10)
max. 8 AF (FRx-12)
6 AT (FRS-6)
6 AT (FRS-6)
x = S or S-R for 480V applications
x = N or N-R for 230V applications
* order code reference see p. 106
SERVOSTAR ® 300 Product Manual
21
Technical description
6.4.6
Kollmorgen
09/2006
Permissible ambient conditions, ventilation, mounting position
Storage hints
Transport hints
Supply voltage
ð p.13
ð p.13
303-310*:
341-346*:
1x110V-10% …1x230V+10%, 50/60 Hz
3x110V-10% …3x230V+10%, 50/60 Hz
3x208V-10% - 3x 480V+10%, 50/60 Hz
Auxiliary voltage
without brake and fan
with brake or fan
20 V DC ... 30 V DC
24 V DC (-0% +15%), check voltage drop !
0...+40°C under rated conditions
Ambient temperature in operation
+40...+55°C with power derating 2.5% / °C
rel. humidity 85%, no condensation
Humidity in operation
up to 1000 meters a.m.s.l. without restriction
1000…2500 meters a.m.s.l. with power derating
Site altitude
1.5% / 100meters
Pollution level
Pollution level 2 as per IEC 60664-1, 2.5.1
Enclosure protection
IP 20
vertical ð p.29
Mounting position
Ventilation 1 A and 3 A types
natural convection
built-on fan
all other types
Make sure that there is sufficient forced ventilation within the control cabinet.
* order code reference see p. 106
6.4.7
Conductor cross-sections
Following EN 60204, we recommend for single-axis systems:
AC connection
1.5 mm² (14awg)
600V,105°C
1000V, 105°C,
DC bus link
1.5 mm² (14awg)
shielded for lengths
Regen resistor
>20cm
600V, 105°C, shielded,
Motor cables up to 25 m
1 - 1.5 mm² (14awg)
capacitance <150pF/m
600V,105°C, shielded,
Motor cables 25m to 50 m,
1 mm² (14awg)
with motor choke 3YLN
capacitance <150pF/m
4x2x0,25 mm² (22awg),
twisted pairs, shielded,
Resolver, motor thermostat
max. 100m
capacitance <120pF/m
Encoder, motor thermostat 7x2x0,25 mm² (22awg), max.50m twisted pairs, shielded
ComCoder, Thermoschutz 8x2x0,25 mm² (22awg), max.25m twisted pairs, shielded
Setpoints, AGND
0.25 mm² (22awg)
twisted pairs, shielded
Control signals, BTB, DGND 0.5 mm² (20awg)
600V, 105°C, shielded,
Holding brake (motor)
min. 0.75 mm² (18awg)
check voltage drop
+24 V / DGND
max. 2,5 mm² (12awg)
check voltage drop
For multi-axis systems, observe the specific operating conditions for your system.
To reach the max. permitted cable length, observe cable requirements ð p. 35.
* Danaher Motion North America supplies cables up to 39 meters
* Danaher Motion Europe supplies cables up to max. length
6.5
LED display
A 3-character LED display indicates the status of the amplifier after switching on the 24V
supply (ð p.79). When the keys on the front panel are used, the parameter and function
numbers are shown, as well as the numbers for any errors that may occur (ð p.80).
22
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6.6
09/2006
Technical description
Control circuit for motor-holding brake
A 24V / max.1.5A holding brake in the motor can be controlled directly by the amplifier.
Check voltage drop, measure the voltage at brake input and check brake function
(brake and no brake).
This function does not ensure personnel safety!
The brake function must be enabled through the BRAKE parameter (screen page: Motor,
setting: WITH). In the diagram below you can see the timing and functional relationships
between the ENABLE signal, speed setpoint, speed and braking force.
During the internal ENABLE delay time of 100ms, the speed setpoint of the servo amplifier is internally driven down an adjustable ramp to 0V. The output for the brake is switched on when the speed has fallen to 3% of the preset final speed, at the latest after 1
second.
The rise (fbrH) and fall (fbrL) times of the holding brake that is built into the motor are different for the various types of motor (see motor manual). A description of the interface can
be found on page 41. Operation of the brake in a manner that provides personnel safety
requires an additional “make” contact in the brake circuit, and a suppressor device, such
as a varistor, for the brake circuit.
Recommended circuit:
SERVOSTAR
SERVOSTAR ® 300 Product Manual
23
Technical description
6.7
Kollmorgen
09/2006
Grounding system
AGND — analog inputs, internal analog ground, encoder emulation, RS232, CAN
DGND — digital inputs/outputs and the 24V supply, optically isolated.
6.8
Regen circuit
During braking with the aid of the motor, energy is fed back into the servo amplifier. This
regenerative energy (hence the term “regen” circuit) is dissipated as heat in the regen
resistor. The regen resistor is switched in by the regen circuit.
The setup software can be used to adapt the regen circuit (thresholds) according to the
electrical supply voltage.
Our customer service can help you with the calculation of the regen power that is necessary for your system.
A description of the interface can be found on page 41.
Functional description:
1.- Individual amplifiers, not coupled through the DC bus link circuit (DC+, DC-)
If the energy fed back from the motor has an average or peak power that exceeds the
preset level for the regen power rating, then the servo amplifier generates the warning
“n02 regen power exceeded” and the regen circuit is switched off.
The next internal check of the DC bus link voltage (after a few milliseconds) detects an
overvoltage and the servo amplifier is switched off, with the error message “Overvoltage
F02” (ð p.80).
The BTB/RTO contact (terminals X3/2,3) will be opened at the same time (ðp.51)
2.- Several servo amplifiers coupled through the DC bus link (DC+, DC-)
Thanks to the built-in regen circuit, several amplifiers (even with different current ratings)
can be operated off a common DC bus link, without requiring any additional measures.
The combined (peak and continuos) power of all amplifiers is always available. The
switch-off on overvoltage takes place as described under 1. (above) for the amplifier that
has the lowest switch-off threshold (resulting from tolerances).
Technical data of the regen circuits dependent on the amplifiers type and the mains voltage situation see table on the next page.
24
SERVOSTAR ® 300 Product Manual
Kollmorgen
09/2006
Technical description
Technical Data:
343 / 346
(S30301/S30601)
341
(S30101)
306 / 310
(S30661/S31061)
303
(S30361)
Regen circuit
Rated data
Switch-on (upper) threshold of regen circuit
Overvoltage F02
Regen resistor (internal)
Continuous power in regen circuit (RBint)
Pulse power in regen circuit (RBint max. 1s)
Regen resistor (external)*
Continuous power in regen circuit (RBext) max.
Pulse power in regen circuit (RBext max. 1s)
Switch-on (upper) threshold of regen circuit
Overvoltage F02
Regen resistor (internal)
Continuous power in regen circuit (RBint)
Pulse power in regen circuit (RBint max. 1s)
Regen resistor (external)*
Continuous power in regen circuit (RBext) max.
Pulse power in regen circuit (RBext max. 1s)
Switch-on (upper) threshold of regen circuit
Overvoltage F02
Regen resistor (internal)
Continuous power in regen circuit (RBint)
Pulse power in regen circuit (RBint max. 1s)
Regen resistor (external)*
Continuous power in regen circuit (RBext) max.
Pulse power in regen circuit (RBext max. 1s)
Switch-on (upper) threshold of regen circuit
Overvoltage F02
Regen resistor (internal)
Continuous power in regen circuit (RBint)
Pulse power in regen circuit (RBint max. 1s)
Regen resistor (external)*
Continuous power in regen circuit (RBext) max.
Pulse power in regen circuit (RBext max. 1s)
*
Dim.
V
V
Ohm
W
kW
Ohm
kW
kW
V
V
Ohm
W
kW
Ohm
kW
kW
V
V
Ohm
W
kW
Ohm
kW
kW
V
V
Ohm
W
kW
Ohm
kW
kW
Supply voltage
110 V 230 V 400 V 480 V
200 400
235 455
66
66
20
20
—
0,75
3
66
66
0,3
0,3
0,75
3
200 400
235 455
66
66
50
50
—
0,75
3
66
66
1
1
0,75
3
400 720 840
455 800 900
91
91
91
20
20
20
—
2,1
7
9
91
91
91
0,3
0,3
0,3
2,1
7
9
400 720 840
455 800 900
91
91
91
50
50
50
—
2,1
7
9
91
91
91
1,0
1,0
1,0
2,1
7
9
Partially other resistance values are possible. Please ask our customer support.
SERVOSTAR ® 300 Product Manual
25
Technical description
6.9
Kollmorgen
09/2006
Switch-on and switch-off behavior
The diagram below illustrates the correct functional sequence for switching the servo
amplifier on and off.
DC bus link
6.9.1
Stop function as per EN 60204 (VDE 0113)
If a fault occurs (ð p.80) then the output stage of the servo amplifier is switched off and
the BTB/RTO contact is opened. In addition, a global error signal can be generated at
one of the digital outputs (terminals X3/16 and X3/17) – see online help for the setup software. These signals can be used by the higher-level control system to finish the current
PLC cycle or to shut down the drive (with additional brake or similar).
Devices with activated (holding-)“Brake” function use a special sequence for switching off
the output stage (ð p.23).
The “Stop” functions are defined in EN 60204 (VDE 0113), Paras. 9.2.2, 9.2.5.3.
There are three categories of stop functions:
Category 0: Shutdown by an immediate switch-off of the energy supply to the
drive machinery (i.e an uncontrolled shutdown);
Category 1: A controlled shutdown, during which the supply of energy to the drive
machinery is maintained as long as shutdown is being carried out, and
only interrupted when standstill has been reached;
Category 2: A controlled shutdown, during which the supply of energy to the drive
machinery is maintained.
Every machine must be equipped with a Category 0 stop function. Stop functions to Categories 1 and/or 2 must be provided if the safety of functional requirements of the machine
make them necessary.
You can find further information and implementation examples in the Application Note
“Stop and Emergency Stop Functions”.
26
SERVOSTAR ® 300 Product Manual
Kollmorgen
6.9.2
09/2006
Technical description
Emergency Stop strategies
The Emergency Stop function is defined in EN 60204 (VDE 0113), Para. 9.2.5.4.
Implementation of the Emergency Stop function :
Wiring recommendation can be found in the Application Note “Stop and Emergency Stop
Functions".
Category 0:
The controller enable is switched to “disable”, the electrical supply is disconnected.
The drive must be held by an electromechanical holding device (brake).
In multi-axis systems with a coupled DC bus link, the motor cable must also be
disconnected by a changeover switch (a contactor, such as the Siemens
3RT1516-1BB40) and short-circuited by resistors connected in a star configuration.
Category 1:
If hazardous conditions can result from an Emergency Stop switch-off with an
uncontrolled run-down, the drive can be switched off after a controlled shutdown.
Stop Category 1 permits electromotoric (i.e. regenerative) braking with a switch-off
when zero speed has been reached. Safe shutdown can be achieved if the loss of
the electrical supply is not evaluated as a fault and the control system takes over
the disabling of the servo amplifier.
In normal circumstances, only the supply power is switched off in a safe manner.
The 24V auxiliary supply remains switched on.
SERVOSTAR ® 300 Product Manual
27
Mechanical Installation
7
Mechanical Installation
7.1
Important notes
7.2
Kollmorgen
09/2006
l
Protect the servo amplifier from impermissible stresses. In particular, do not let any
components become bent or any insulation distances altered during transport and
handling. Avoid contact with electronic components and contacts.
l
Ensure that there is an adequate flow of cool, filtered air into the bottom of the control
cabinet, or use a heat exchanger. Please refer to page 22.
l
Take care that the servo amplifier and motor are properly grounded.
Do not use painted (i.e. non-conductive) mounting plates.
l
Don't mount devices, which produce magnetic fields, directly beside the servo amplifier. Strong magnetic fields could directly affect internal components. Install devices
which produce magnetic field with distance to the servo amplifiers and/or shield the
magnetic fields.
Guide to mechanical installation
The following notes should help you to carry out the mechanical installation in a sensible
sequence, without overlooking anything important.
Site
28
In a closed control cabinet. Please refer to page 22.
The site must be free from conductive or corrosive materials.
For the mounting position in the cabinet ð p.29.
Ventilation
Check that the ventilation of the servo amplifier is unimpeded, and
keep within the permitted ambient temperature ð p.22. Keep the required space clear above and below the servo amplifier ð p.29.
Assembly
Assemble the servo amplifier and power supply close together, on the
conductive, grounded mounting plate in the cabinet.
Grounding
Shielding
For EMC-compliant shielding and grounding ð p.38.
Ground the mounting plate, motor housing and CNC-GND of the
control system. Notes on connection techniques ð p.34.
SERVOSTAR ® 300 Product Manual
Kollmorgen
7.3
09/2006
Mechanical Installation
Assembly
Material: 3 x M5 hexagon socket screws to DIN 912
Tool required : 4 mm Allen key
SERVOSTAR
SERVOSTAR ® 300 Product Manual
29
Mechanical Installation
7.4
Kollmorgen
09/2006
Dimensions
n
Fa
.
nly
so
e
typ
1
0A
1
xx6
nd
S3 x01
a
A
x
S3
h6
wit
0
.31
3..
0
46
R3
...3
1
A
34
ST
VO
AR
T
R
S
SE
O
RV
SE
30
SERVOSTAR ® 300 Product Manual
Kollmorgen
09/2006
8
Electrical installation
8.1
Important notes
Electrical installation
l
Check the combination of servo amplifier and motor. Compare the rated voltage and
current of the units. Implement the wiring according to the connection diagram on
page 33.
l
Make sure that the maximum permissible rated voltage at the terminals L1, L2, L3 or
+DC, –DC is not exceeded by more than 10% even in the most unfavorable circumstances (see EN 60204-1 Section 4.3.1). An excessive voltage on these terminals can
lead to destruction of the regen circuit and the servo amplifier.
l
The fusing of the AC supply input and 24V supply must be installed by the
user (ð p.21).
l
Route power and control cables separately. We recommend a distance of at least
200mm. This improves the interference immunity required by EMC regulations.
If a motor power cable is used that includes cores for brake control, the brake control cores must be separately shielded.
Ground the shielding at both ends (ð p.38).
l
Ground all shielding with large areas (low impedance), with metalized connector housings or shield connection clamps wherever possible. Notes on connection techniques can be found on page 34.
l
Feedback lines may not be extended, since thereby the shielding would be interrupted and the signal processing could be disturbed.
l
Lines between amplifiers and external regen resistor must be shielded.
l
Install all power cables with an adequate cross-section, as per EN 60204 (ð p.22)
and use the requested cable material (ð p. 35) to reach max. cable length.
l
Wire the BTB/RTO contact in series into the safety circuit of the installation. The safety circuit must operate the supply contactor. This is the only way to ensure monitoring of the servo amplifier.
l
It is permissible to use the setup software to alter the settings of the servo amplifier.
Any other alterations will invalidate the warranty.
Never disconnect the electrical connections to the servo amplifier while it is live.
In unfavorable circumstances this could cause destruction of the electronics.
Residual charges in the capacitors can have dangerous levels up to 300 seconds
after switching off the electrical supply. Measure the bus voltage on the DC bus
link (+DC/-DC) and wait until the voltage has fallen below 40V.
Control and power connections can still be live, even if the motor is not rotating.
SERVOSTAR ® 300 Product Manual
31
Electrical installation
8.2
Kollmorgen
09/2006
Guide to electrical installation
The following notes should help you to carry out the electrical installation in a sensible
sequence, without overlooking anything important.
Cable selection Select cables in accordance with EN 60204 ð p.22.
Grounding
Shielding
Wiring
Final check
32
For EMC-compliant shielding and grounding ð p.38.
Ground the mounting plate, motor housing and CNC-GND of the
control system. Notes on connection techniques ð p.34.
Route power leads and control cables separately.
Wire the BTB/RTO contact in series into the safety circuit of the
system.
— Connect the digital control inputs and outputs.
— Connect up AGND (also if fieldbuses are used).
— Connect the analog input source, if required.
— Connect the feedback device.
— Connect the encoder emulation, if required.
— Connect the expansion card
— (see corresponding notes from page 85 on).
— Connect the motor cable
— Connect shielding to EMC connectors (shield connection) at both
— ends. Use the motor choke (3YLN) if cable > 25 meters.
— Connect motor-holding brake, connect shielding to EMC
— connector/shield connection at both ends.
— If required, connect the external regen resistor (with fusing).
— Connect the auxiliary supply
— (maximum permissible voltage values ð p.22).
— Connect the main electrical supply
— (maximum permissible voltage values ð p.22).
— Connect the PC (ð p.58).
— Final check of the implementation of the wiring against the
— wiring diagrams that have been used.
SERVOSTAR ® 300 Product Manual
Kollmorgen
Electrical installation
09/2006
8.3
Wiring
8.3.1
Important Notes
Only professional staff who are qualified in electrical engineering are allowed to
install the servo amplifier.
The installation procedure is described as an example. A different procedure may be
appropriate or necessary, depending on the application of the equipments.
We provide further know-how through training courses (on request).
Warning !
Only install and wire up the equipment when it is not live, i.e. when neither the
electrical supply nor the 24 V auxiliary voltage nor the supply voltages of any other
connected equipment is switched on.
Take care that the cabinet is safely disconnected (with a lock-out, warning signs
etc.). The individual voltages will be switched on for the first time during setup.
X
The ground symbol
, which you will find in all the wiring diagrams, indicates
that you must take care to provide an electrically conductive connection with the
largest feasible surface area between the unit indicated and the mounting plate in
the control cabinet. This connection is for the effective grounding of HF
interference, and must not be confused with the PE-symbol W
(PE = protective earth, safety measure as per EN 60204).
Use the following connection diagrams :
Overview
Mains
Motor
Feedback
Resolver
ComCoder / Encoder with Hall
Incr. or Sine Encoder with Hall
Encoder with EnDat/HIPERFACE
Acuro (BISS)
Incremental encoder (AqB)
Encoder without data channel
Encoder Emulation
Encoder emulation ROD
Encoder emulation SSI
Master-slave interface
Pulse direction interface
RS232 / PC
CAN interface
Restart lock -ASExpansion cards
I/O-14/08
PROFIBUS
SERCOS
DeviceNet
EtherCat
SynqNet
2CAN
SERVOSTAR ® 300 Product Manual
: page 38
: page 39
: page 41
: page 42
: page 43
: page 44
: page 45
: page 46
: page 47
: page 48
: page 52
: page 53
: page 54
: page 56
: page 58
: page 59
: page 63
: page 88
: page 89
: page 91
: page 92
: page 95
: page 97
: page 99
33
Electrical installation
8.3.2
Kollmorgen
09/2006
Shielding connection to the front panel
Remove the outside shroud of the
cable and the shielding braid on the
desired core length. Secure the cores with a cable tie.
Remove the outside shroud of the
line on a length from for instance
30mm without damaging the shielding braid.
Pull a cable tie by the slot in the
shielding rail on the front panel of
the servo amplifier.
Press the shielding of the cable
firmly against the front panel with
the cable tie.
34
SERVOSTAR ® 300 Product Manual
Kollmorgen
8.3.3
09/2006
Electrical installation
Technical data for connecting cables
Further information on the chemical, mechanical and electrical characteristics of the
cables can be obtained from our customer service.
Observe the rules in the section "Conductor cross-sections" on page 22. To reach
the max. permitted cable length, you must use cable material that matches the
capacitance requirements listed below.
Insulation material
Sheathing
Core insulation
PUR (polyurethane, code 11Y)
PETP (polyesteraphthalate, code 12Y)
Capacitance
Motor cable
less than 150 pF/m
Resolver/Encoder cable less than 120 pF/m
Technical data
—
—
—
—
The brackets in the core definition indicate the shielding.
All cables are suitable for use as trailing cables.
The technical data refer to use as moveable cables.
Operating life : 1 million bending cycles
Cores
[mm²]
(4x1.0)
(4x1.5)
(4x1.0+(2x0.75))
(4x1.5+(2x0.75))
(4x(2x0.25))
(7x(2x0.25))
max.
length
[m]
50*
50*
50*
50*
100*
50*
Use for
motor / power
motor / power
motor incl. brake
motor incl. brake
Resolver
Encoder
Operating
Outside Bending
temp. range diameter radius
[°C]
[mm]
[mm]
-30 / +80
10
100
-30 / +80
10.5
105
-30 / +80
10.5
105
-30 / +80
11.5
120
-30 / +80
6.9
70
-30 / +80
7.7
90
* Danaher Motion North America supplies cables up to 39 meters
* Danaher Motion Europe supplies cables up to max. length.
Motor cables longer than 25m require the use of a motor choke 3YLN (see p.103).
SERVOSTAR ® 300 Product Manual
35
Electrical installation
8.4
Kollmorgen
09/2006
Block diagram
The block diagram below just provides an overview.
36
SERVOSTAR ® 300 Product Manual
Kollmorgen
8.5
09/2006
Electrical installation
Connector assignments
Þ p. 42
Þ p. 43
Þ p. 45
Þ p. 45
Þ p. 46
The connectors of the expansion
card depend on used expansion
card (see pages 86 ff).
SERVOSTAR ® 300 Product Manual
37
Electrical installation
8.6
Kollmorgen
09/2006
Connection diagram (Overview)
Refer to the Safety Instructions (ð p.9)
and Use as Directed (ð p.10) !
SERVOSTAR 300
ð p.43
ð p.45
ð p.49
ð p.45
ð p.46
ð p.42
ð p.50
ð p.41
ð p.41
ð p.39
ð p.51
ð p.50
ð p.60
ð p.52
ð p.53
ð p.54
ð p.56
ð p.59
ð p.40
ð p.58
ð p.86
ð p.89
ð p.90
ð p.92
ð p.95
ð p.97
38
SERVOSTAR ® 300 Product Manual
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09/2006
8.7
Electrical supply
8.7.1
Mains electrical supply connection (X0)
8.7.1.1
Three phase
—
—
Electrical installation
Directly to 3-phase supply network, filter is integrated
Fusing (e.g. fusible cut-outs) to be provided by the user ð p.21
SERVOSTAR 300
8.7.1.2
Two phase without neutral
SERVOSTAR 300
8.7.1.3
Single phase with neutral
SERVOSTAR 300
SERVOSTAR ® 300 Product Manual
39
Electrical installation
8.7.2
Kollmorgen
09/2006
24V auxiliary supply (X4)
— External 24V DC power supply, electrically isolated, e.g. via an isolating transformer
— Required current rating ð p.19
— Integrated EMC filter for the 24V auxiliary supply
SERVOSTAR 300
8.7.3
DC bus link (X8)
Terminals X8/1 (-DC) and X8/3 (+RBext). Can be connected in parallel, whereby the
regen power is divided between all the amplifiers that are connected to the same DC bus
link circuit.
SERVOSTAR 300
SERVOSTAR 300
Only servo amplifiers with mains supply from the same mains (identical mains
supply voltage) may be connected by the DC bus link.
40
SERVOSTAR ® 300 Product Manual
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8.8
09/2006
Electrical installation
Motor connection with brake (X9)
Cable length £ 25 meters
SERVOSTAR 300
Cable length >25 meters
For cable lengths above 25m up to max. 50m, the motor choke 3YLN
(ð S.103) must be wired into the motor cable, close to the amplifier.
SERVOSTAR 300
8.9
External regen resistor (X8)
Remove the plug-in link between the terminals X8/5 (-RB) and X8/4 (+Rbint).
SERVOSTAR 300
SERVOSTAR ® 300 Product Manual
41
Electrical installation
8.10
Kollmorgen
09/2006
Feedback
Feedback system
Resolver
ComCoder
8.10.1
Conn.
X2
X1
See
p. 42
p. 43
Incremental or Sine Encoder with Hall
X1
p. 44
Sine Encoder with EnDat/HIPERFACE
ACURO Encoder
Incremental Encoder (A quad B)
Sine Encoder without Data channel
X1
X1
X5
X1
p. 45
p. 46
p. 47
p. 48
Remarks
2 to 36 poles
A, B, zero, Hall
A, B, zero, Hall or
Sine, Cosine, zero, Hall
Sine, cosine, clock, data
Data (BISS)
A, B, zero
Sine, cosine, zero
Resolver (X2)
Our rotatory servomotors are fitted as standard with 2-pole hollow-shaft resolvers. It is
possible to connect resolvers with 2 to 36 poles to SERVOSTAR 300. The thermostat
contact in the motor is connected via the resolver cable to X2 and evaluated there.
If cable lengths of more than 100 meters are planned, please contact our customer service.
SERVOSTAR 300
42
SubD 9
round 12-pin
SERVOSTAR ® 300 Product Manual
Kollmorgen
8.10.2
09/2006
Electrical installation
ComCoder (X1)
As an option our motors can be equipped with a ComCoder as feedback unit. For the
commutation hall sensors are used and for the resolution an incremental encoder.
The thermostat contact in the motor is connected via the ComCoder cable to X1 and
evaluated there.
If cable lengths of more than 25m are planned, please consult our customer service.
Frequency limit (A,B): 350 kHz
SERVOSTAR 300
SERVOSTAR ® 300 Product Manual
SubD15
round, 17 pin
43
Electrical installation
8.10.3
Kollmorgen
09/2006
Incremental or Sine Encoder with hall sensors (X1)
Feedback devices (incremental or sine-cosine), which don't deliver an absolute information for commutation, can be used as complete feedback system combined with an additional Hall encoder. All signals are connected to X1.
If cable lengths of more than 25m are planned, please consult our customer service.
Frequency limit (A,B): 350 kHz
SERVOSTAR 300
44
SubD15
SERVOSTAR ® 300 Product Manual
Kollmorgen
8.10.4
Electrical installation
09/2006
Sine Encoder with EnDat 2.1 or HIPERFACE (X1)
As an option, our servomotors can be fitted with a single-turn or multi-turn sine-cosine
encoder. Preferred types are the ECN1313 and EQN1325 encoders.
The encoder is used by the SERVOSTAR 300 as a feedback device for drive tasks that
require highly precise positioning or extremely smooth running.
The thermostat contact in the motor is connected via the encoder cable to X1 and
evaluated there.
If cable lengths of more than 50m are planned, please consult our customer service.
Frequency limit (A,B): 350 kHz
SERVOSTAR 300
SERVOSTAR ® 300 Product Manual
SubD 15
round, 17-pin
45
Electrical installation
8.10.5
Kollmorgen
09/2006
ACURO encoder, BISS interface (X1)
As an option, our servomotors can be fitted with a single-turn or multi-turn ACURO encoder with BISS interface.
The encoder is used by the SERVOSTAR 300 as a feedback device for drive tasks that
require highly precise positioning or extremely smooth running.
The thermostat contact in the motor is connected via the encoder cable to X1 and evaluated there.
If lead lengths of more than 50m are planned, please consult our customer service.
SERVOSTAR 300
46
SubD 15
round, 17-pin
SERVOSTAR ® 300 Product Manual
Kollmorgen
8.10.6
09/2006
Electrical installation
Incremental Encoder (X5)
An incremental encoder can be used as standard motor feedback.
Select feedback type 19 "ROD 5V with W&S". Drive executes wake&shake to calculate
the necessary start-up information for the position controller every time the 24V auxiliary
voltage is switched on.
If lead lengths of more than 50m are planned and for questions concerning the power
supply of the encoder, please consult our customer service.
The thermostat contact in the motor is connected to X1 (see p.45) or X2 (see p.42).
Frequency limit: 1.5 MHz
Don't use this feedback type with vertical load (hanging load).
SERVOSTAR 300
SERVOSTAR ® 300 Product Manual
47
Electrical installation
8.10.7
Kollmorgen
09/2006
Sine Encoder without data channel (X1)
An sine-cosine encoder without data channel can be used as standard motor feedback.
Select feedback type 7 "SinCos 5V with W&S". Drive executes wake&shake to calculate
the necessary start-up information for the position controller every time the 24V auxiliary
voltage is switched on.
The thermostat contact in the motor is connected via the encoder cable to X1 and evaluated there.
If lead lengths of more than 50m are planned, please consult our customer service.
Frequency limit: 350 kHz
Don't use this feedback type with vertical load (hanging load).
SERVOSTAR 300
48
SERVOSTAR ® 300 Product Manual
Kollmorgen
09/2006
8.11
Digital and analog inputs and outputs
8.11.1
Analog inputs (X3)
Electrical installation
The servo amplifier is fitted with two programmable differential inputs for analog setpoints. AGND (X3/7) must always be joined to the GND of the controls as a ground
reference.
Technical characteristics
—
—
—
—
—
Differential-input voltage max. ± 10 V
Ground reference AGND, terminal X3/7
Input resistance 2.4 kW
Common-mode voltage range for both inputs ± 10 V
Update rate 62,5 µs
SERVOSTAR 300
Analog-In 1 input (terminals X3/3-4)
Differential input voltage max. ± 10 V, resolution 14-bit, scalable.
Standard setting : speed setpoint
Analog-In 2 input (terminals X3/5-6)
Differential input voltage max. ± 10 V, resolution 12-bit, scalable.
Standard setting : torque setpoint
Application examples for setpoint input Analog-In 2:
—
adjustable external current limit
—
reduced-sensitivity input for setting-up/jog operation
—
pre-control / override
Defining the direction of rotation
Standard setting : clockwise rotation of the motor shaft (looking at the shaft end)
—
Positive voltage between terminal X3/3 (+ ) and terminal X3/4 ( - ) or
—
Positive voltage between terminal X3/5 (+ ) and terminal X3/6 ( - )
To reverse the direction of rotation, swap the connections to terminals X3/3-4 or X3/5-6
respectively, or change the ROTATION DIRECTION parameter in the “Speed controller”
screen page.
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8.11.2
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Digital inputs (X3/X4)
All digital inputs are electrically isolated via optocouplers.
Technical characteristics
—
—
—
Ground reference is Digital-GND (DGND, terminals X4/3 and X4/4)
The inputs at X3 are PLC-compatible (IEC 61131-2 Type 1)
High: 11...30 V / 2...11 mA , Low: -3...5 V / <1 mA
Update rate Software:250 µs / Hardware: 2 µs
SERVOSTAR 300
ENABLE input
The output stage of the servo amplifier is enabled by applying the ENABLE signal
(terminal X3/12, 24 V input, active high). Enable is possible only if input AS-Enable has a
24 V signal (see page 60ff).
In the disabled state (low signal) the connected motor has no torque.
AS-ENABLE input
An additional digital input (AS-Enable) releases the power output stage of the amplifier as
long as a 24 V signal is applied to this input. If the AS-Enable input goes open-circuit,
then power will no longer be supplied to the motor, the drive will lose all torque and coast
down to a stop. A fail-safe brake function for the drive, if one is required, must be ensured
through a mechanical brake since electrical braking with the aid of the drive is no longer
possible.
You can thus achieve a restart lock-out for personnel safety by using the AS-enable input
in conjunction with an external safety circuit.
You can find further information and connection examples on page 60.
This input is not compatible with IEC 61131-2.
Programmable digital inputs
You can use the DIGITAL-IN1 to DIGITAL-IN4 digital inputs to initiate pre-programmed
functions that are stored in the servo amplifier. A list of these pre-programmed functions
can be found on the “Digital I/O” screen page of our setup software.
If an input was freshly assigned to a pre-programmed function, then the data set must be
saved in the EEPROM of the servo amplifier and a reset has to be carried out (with the
amplifier setup software for example).
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Electrical installation
Digital outputs (X3)
Technical characteristics
—
—
—
—
Ground reference is Digital-GND (DGND, terminals X4/3 and X4/4)
All digital outputs are floating
DIGITAL-OUT1 and 2
: Open Emitter, max. 30 V DC, 10 mA
BTB/RTO
: Relay output, max. 30 V DC or 42 V AC, 0.5 A
Update rate 250 µs
SERVOSTAR 300
Ready-to-operate contact BTB/RTO
Operational readiness (terminals X3/1 and X3/2 ) is signaled by a floating relay contact.
The contact is closed when the servo amplifier is ready for operation, and the signal is
not influenced by the enable signal, the I²t-limit, or the regen threshold.
All faults cause the BTB/RTO contact to open and the output stage to be switched
off (if the BTB/RTO contact is open, the output stage is inhibited -> no power
output). A list of the error messages can be found on page 80.
Programmable digital outputs DIGITAL-OUT 1 / 2:
You can use the digital outputs DIGITAL-OUT1 (terminal X3/13) and DIGITAL-OUT2 (terminal X3/14) to output messages from pre-programmed functions that are stored in the
servo amplifier.
A list of these pre-programmed functions can be found on the “I/O digital” screen page of
our setup software.
If an input is to be freshly assigned to a pre-programmed function, then the parameter set
must be saved in the EEPROM of the servo amplifier and a reset has to be carried out
(with the amplifier setup software for example).
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8.12
Encoder emulation
8.12.1
Incremental encoder output - A quad B (X5)
The incremental-encoder interface is part of the standard package. Select encoder
function ROD (A Quad B) Encoder (“Encoder Emulation” screen page). The servo amplifier calculates the motor shaft position from the cyclic- absolute signals of the resolver or
encoder, generating incremental-encoder compatible pulses from this information. Pulse
outputs on the SubD connector X5 are 2 signals, A and B, with 90° phase difference (i.e.
in quadrature, hence the alternative term “A quad B” output), with a zero pulse.
The resolution (before multiplication) can be set by the RESOLUTION function:
Enc. function (ENCMODE) Feedback system
Resolver
ROD (1)
Resolution (lines)
16 … 1024
16 … 4096 and
8192…524288 (2n)
22 … 27 (multiplicaIncremental encoder
tion) TTL line x enwithout data channel
coder resolution
EnDat/HIPERFACE
ROD interpolation (3)
Zero pulse (NI)
once per turn
(only at A=B=1)
once per turn
(only at A=B=1)
encoder signal
passed through
from X1 to X5
Use the NI-OFFSET parameter to adjust + save the zero pulse position within one
mechanical turn. The drivers operate off an internal supply voltage.
The maximum permissible cable length is 100 meters.
Connections and signals for the incremental encoder interface :
Default count direction: UP when the motor shaft is rotating clockwise (looking at the
shaft's end)
SERVOSTAR 300
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8.12.2
Electrical installation
09/2006
SSI output (X5)
The SSI interface (synchronous serial absolute-encoder emulation) is part of the standard
package. Select encoder function SSI (“Encoder Emulation” screen page). The servo
amplifier calculates the motor shaft position from the cyclic-absolute signals of the resolver or encoder. From this information a SSI date (Stegmann patent specification DE
3445617C2) is provided. Max 32 bits are transferred. The leading data bit contains the
number of revolutions and are selectable from 12 to 16 bits. The following max. 16 bits
contain the resolution and are not variable.
The following table shows the allocation of the SSI date depending upon selected number
of revolutions:
Revolution
Resolution (variable)
Bit
SSIREVOL
15 14 13 12 11 10 9 8
14 13 12 11 10 9 8
13
12 11 10 9 8
12
11 10 9 8
11
10 9 8
7
7
7
7
7
6
6
6
6
6
5
5
5
5
5
4
4
4
4
4
3
3
3
3
3
2
2
2
2
2
1
1
1
1
1
0
0
0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
0
0
The signal sequence can be output in Gray code or in Binary (standard) code.
The servo amplifier can be adjusted to the clock frequency of your SSI-evaluation with the
setup software (cycle time 1,3 µs or 10 µs).
The drivers operate off an internal supply voltage.
Connection and signals for the SSI interface :
Default count direction: UP when the motor shaft is rotating clockwise (looking at the end
of the motor shaft)
SERVOSTAR
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Electrical installation
8.13
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09/2006
Master-slave operation, encoder master control
This interface can be used to link several SERVOSTAR 300 amplifiers together in master-slave operation.
Parameter setting for the slave amplifier is carried out with the aid of the setup software
(electrical gearing). The resolution (no. of pulses/turn) can be adjusted, and the analog
setpoint inputs are out of action.
Signal diagram (for encoders with RS422 or 24 V output)
8.13.1
Connection to a SERVOSTAR master, 5 V signal level (X5)
This interface can be used to link several SERVOSTAR 300 amplifiers together in master-slave operation. Up to 16 slave amplifiers can be controlled by the master, via the
encoder output. The SubD connector X5 is used for this purpose.
Frequency limit: 1.5 MHz, transition time tv £ 0.1 µs
SERVOSTAR 300
54
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8.13.2
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Electrical installation
Connection to incremental encoder master with 24 V signal level (X3)
This interface can be used to operate the SERVOSTAR as a slave, mastered by an encoder with a 24 V signal level (master-slave operation).
This uses the digital inputs DIGITAL-IN 1 and 2 on connector X3.
Frequency limit: 100 kHz, transition time tv £ 0.1 µs
SERVOSTAR 300
8.13.3
Connection to a sine encoder master (X1)
This interface can be used to operate the SERVOSTAR as a slave, mastered by a
sine-cosine encoder (master-slave operation). This uses the SubD connector X1.
Frequency limit (A, B): 350 kHz
SERVOSTAR 300
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Electrical installation
8.14
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09/2006
Interface for stepper motor controllers (step and direction)
This interface can be used to connect the servo amplifier to a third-party stepper-motor
controller. Parameter setting for the slave amplifier is carried out with the aid of the setup
software (electrical gearing). The number of steps can be adjusted, so that the servo
amplifier can be adapted to match the step-direction signals of any stepper controller.
Various monitoring signals can be generated.
The analog inputs are out of action.
Speed profile and signal diagram
Note:
Using an A quad B encoder provides better EMC noise immunity.
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Electrical installation
Connection to a stepper controller with 5 V signal level (X5)
This interface can be used to connect the servo amplifier to a stepper-motor controller
with a 5 V signal level. It uses the SubD connector X5.
Frequency limit: 1.5 MHz
SERVOSTAR 300
8.14.2
Connection to a stepper controller with 24 V signal level (X3)
This interface can be used to connect the servo amplifier to a stepper-motor controller
with a 24 V signal level. It uses the digital inputs DIGITAL-IN 1 and 2 on connector X3.
Frequency limit: 100 kHz
SERVOSTAR 300
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Electrical installation
8.15
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09/2006
RS232 interface, PC connection (X6)
Operating, position control, and motion-block parameters can be set up by using the
setup software on an ordinary commercial PC.
Connect the PC interface (X6) of the servo amplifier to a serial interface on the PC via a
null-modem cable, while the supply to the equipment is switched off.
Do not use a null-modem power link cable!
This interface has the same electrical potential as the CANopen interface.
The interface is selected and set up in the setup software. Further notes on page 66.
With the optional -2CAN- expansion card, the two interfaces for RS232 and CAN, which
would otherwise use the same connector X6, are separated out onto three connectors
(ð p.98).
SERVOSTAR 300
Interface cable between the PC and servo amplifiers of the SERVOSTAR 300 series:
(View : looking at the solder side of the SubD sockets on the cable)
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8.16
09/2006
Electrical installation
CANopen interface (X6)
The interface for connection to the CAN-bus (default : 500 kBaud). The integrated profile
is based on the CANopen DS301 communication profile and the DS402 drive profile.
The following functions are available in connection with the position controller:
Jogging with variable speed, homing run (zeroing to reference), start motion task, start
direct task, digital setpoint provision, data transmission functions and many others.
Detailed information can be found in the CANopen manual. The interface is at the same
electrical potential as the RS232 interface. The analog setpoint inputs can still be used.
With the optional -2CAN- expansion card, the two interfaces for RS232 and CAN, which
otherwise use the same connector X6, are separated out onto three connectors (with termination, ð p.98).
SERVOSTAR 300
CAN-bus cable
To meet ISO 11898, a bus cable with a characteristic impedance of 120 W should be
used. The maximum usable cable length for reliable communication decreases with
increasing transmission speed. As a guide, you can use the following values which we
have measured, but they are not to be taken as assured limits:
Cable data:
Characteristic impedance
100-120 W
Cable capacitance
max. 60 nF/km
Lead loop resistance
159.8 W/km
Cable length, depending on the transmission rate
Transmission rate (kBaud)
1000
500
250
max. cable length (m)
10
70
115
Lower cable capacitance (max. 30 nF/km) and lower lead resistance
(loop resistance, 115 W/km) make it possible to achieve greater distances.
(Characteristic impedance 150 ± 5 W Þ terminating resistor 150 ± 5 W).
For EMC reasons, the SubD connector housing must fulfill the following requirements:
— metal or metalized housing
— provision for cable shielding connection on the housing, large-area connection
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Electrical installation
8.17
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Personnel safe restart lock -ASA frequently required application task is the protection of personnel against the restarting
of drives. This can be achieved by an electronic inhibit or with mechanical elements (positively driven relay contacts).
When positively driven relay contacts where used, either the net contactor in the mains
supply circuit switched off or the motor was disconnected from the servo amplifier by an
additional contactor.
The disadvantages of this method are :
— the DC bus link has to be charged up again at restart
— wear on the contacts of the contactors, caused by switching under load
— extensive wiring required, with additional switching components
The restart lock -AS- avoids these disadvantages.
The conceptual examination of the function "safe stop" (called restart lock AS in the following) was accomplished by the BG-Institute for Occupational Safety and Health and the
classification in category 3 according to EN 954-1 was confirmed.
Advantages of the restart lock -AS- :
— the DC bus link remains charged up, since the mains supply line remains active
— only low voltages are switched, so there is no contact wear
— very little wiring is required
— the functionality and the personnel safety when using the circuit recommendations in
this documentation have been approved by the Trade Liability Association.
8.17.1
Technical data and pinning
Input voltage
Input current
Peak current
8.17.2
20 V..30 V
40 mA – 75 mA (Ieff)
220 mA (Is)
Environment
Since the servo amplifier meets enclosure IP20, you must select the environment ensuring a safe operation of the servo amplifier. The environment must meet enclosure IP54
at least.
8.17.3
Wiring
If the wiring leads outside the demanded enclosure (IP54), the cables must be laid durably (firmly), protected from outside damage (e.g. laying in a cable duct), in different sheathed cables or protected individually by grounding connection.
If wiring remains within the demanded enclosure, then it has to meet the requirements of
the standard EN 60204-1, section 14-3.
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Electrical installation
Functional description
If the restart lock -AS- is not needed, then the input AS-ENABLE must be connected
directly with +24VDC. The restart lock is then passed by and cannot not be used.
In case of use of the restart lock the input AS Enable must be connected to the exit of
a security control or a safety relay, which meets at least to the requirements of the
category 3 after EN 954-1 (see the connection diagram on page 63).
Possible states of the servo amplifier in connection with restart lock -AS-:
AS-ENABLE ENABLE
Display
Motor has torque
0V
0V
-Sno
0V
+24 V
F27
no
+24 V
0V
normal status e.g. 06
no
+24 V
+24 V
normal status e.g. E06
yes
Safety cat. 3
yes
yes
no
no
If the restart lock is engaged during operation by separating input AS ENABLE from 24
VDC, the motor runs down out of control and the servo amplifier displays the error F27.
There is no possibility of braking the drive controlled. If a controlled braking before the
use of the restart lock is necessary, the drive must be braked and the input AS-ENABLE
has to be separated from +24 VDC time-delayed.
The restart lock -AS- does not provide an electrical separation from the power
output. If access to the motor power terminals is necessary, the servo amplifier
must be disconnected from mains supply considering the discharging time of the
intermediate circuit.
Since the restart lock is a single-channel system, erroneous engaging will not be recognized. When wiring the input AS-ENABLE within one enclosure it must be paid attention to
the fact that the used cables and the enclosure meet the requirements of EN 60204-1.
If the wiring leads outside the demanded enclosure, the cables must be laid durably
(firmly), and protected from outside damage.
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Electrical installation
8.17.4.1
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09/2006
Signal diagram (sequence)
The diagram shows how to use restart lock -AS- to ensure a safe stop of the drive and
error free operation of the servo amplifier.
1.
2.
3.
Brake the drive in a controlled manner (speed setpoint = 0 V)
When speed = 0 rpm, disable the servo amplifier (Enable = 0 V)
Activate the restart lock -AS- (AS-Enable = 0 V)
Suspended loads can set themselves to motion on motors without brake, because
the motor loses all torque when restart lock -AS- is engaged (AS Enable open
and/or 0 V).
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09/2006
Electrical installation
Control circuit
Emergency-stop circuit acc.
to EN 954-1 category 4
Safe stop acc. to EN954-1 category 3 for 3 drives
Safe stop acc. to EN 954-1 category 3 for 2 drives
The example shows a circuit diagram with two separated work areas connected to one
emergency stop circuit. For each work area individually "safe stop" of the drives is switched by a protective screen.
The safety switchgears used in the example are manufactured by Pilz and fulfill at least
the safety category 3 according to DIN 954-1. Further information to the safety switchgears is available from Pilz. The use of safety switchgears of other manufacturers is possible, if these also fulfill the safety category 3 according to DIN 954-1.
Consider the wiring instructions on page 60.
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Electrical installation
8.17.4.3
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Kollmorgen
Functional test
With initial starting and after each interference into the wiring of the drive or after
exchange of one or several components of the drive the function of the restart lock
must be tested.
1. Method:
1. Stop drive, with setpoint 0V, keep servo amplifier enabled.
Do not enter hazardous area!
2. Activate the restart lock -AS- e.g. by opening protective screen. (voltage at X4/5 0 V)
Now the BTB/RTO contact opens, the net contactor releases and the servoamplifier displays error F27.
2. Method:
1. Stop all drives, with setpoint 0V, disable servo amplifier.
2. Activate the restart lock -AS- e.g. by opening protective screen. (voltage at X4/5 0 V)
Now the servo amplifier displays -S-.
8.17.4.4
64
Mains supply circuit
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9
Setup
9.1
Important notes
Setup
Only professional personnel with extensive knowledge in the fields of electrical
engineering and drive technology are allowed to setup the servo amplifier.
The procedure for setup is described as an example. Depending on the application, a different procedure may be appropriate or necessary. In multi-axis systems, set up each
servo amplifier individually.
Before setting up, the manufacturer of the machine must generate a hazard
analysis for the machine, and take appropriate measures to ensure that unforeseen
movements cannot cause injury or damage to any person or property.
Check that all connection components that are live in operation are safely
protected against bodily contact. The equipment produces potentially lethal
voltages up to 900 V.
Never undo the electrical connections to the servo amplifier while it is live.
Capacitors can still have dangerous residual charges up to 300 seconds after
switching off the supply voltage.
The heat sink and front panel of the amplifier can reach temperatures up to 80°C in
operation. Check the heat sink temperature. Wait until the heat sink has cooled
down to 40°C before touching it.
If the servo amplifier has been stored for more than 1 year, it will be necessary to
re-form the capacitors in the DC bus link circuit. To do this, disconnect all
electrical connections and apply single-phase 230 V AC to terminals L1 / L2 of the
servo amplifier for about 30 minutes. This will re-form the capacitors.
Additional information on setting up the equipment:
The adaptation of parameters and the effects on the control loop behavior are
described in the online help of the setup software.
The setting up of any expansion card that may be fitted is described in the
corresponding manual on the CD-ROM.
We can provide further know-how through training courses (on request).
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Setup
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9.2
Setup software
9.2.1
General
This chapter describes the installation of the setup software DRIVEGUI.EXE for the
SERVOSTAR 300 digital servo amplifiers.
We offer training and familiarization courses on request.
9.2.1.1
Use as directed
The setup software is intended to be used for altering and saving the operating
parameters for the SERVOSTAR 300 series of servo amplifiers. The attached servo
amplifier can be set up with the help of this software, and during this procedure the drive
can be controlled directly by the service functions.
Only professional personnel who have the relevant expertise described on page 7
are permitted to carry out online parameter setting for a drive that is running.
Sets of data that have been stored on data media are not safe against unintended
alteration by other persons.
After loading a set of data you must therefore always check all parameters before
enabling the servo amplifier.
9.2.1.2
Software description
The servo amplifiers must be adapted to the requirements of your machine.
Usually you will not have to carry out this parameter setting yourself on the amplifier, but
on a PC, with the assistance of the setup software. The PC is connected to the servo
amplifier by a null-modem cable (serial, see p.58). The setup software provides the communication between the PC and SERVOSTAR 300.
You can find the setup software on the accompanying CD-ROM and in the download
area of our website.
With very little effort you can alter parameters and instantly observe the effect on the
drive, since there is a continuous (online) connection to the amplifier. At the same time,
important actual values are read out from the amplifier and displayed on the monitor of
the PC (oscilloscope functions).
Any interface modules (expansion cards) which may be built into the amplifier are automatically recognized, and the additional parameters which are required for position control or motion-block definition are made available.
You can save sets of data on data media (archiving) and load them again. You can also
print out the data sets.
We supply you with motor-specific default sets of data for the most common combinations
of servo amplifier and motor. In most applications you will be able to use these default
values to get your drive running without any problems.
An extensive online help with integrated description of all variables and functions supports you in each situation.
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9.2.1.3
09/2006
Setup
Hardware requirements
The PC interface (X6, RS232) of the servo amplifier is connected to the serial interface of
the PC by a null-modem cable (not a null-modem link cable!) (ð p.58).
Connect / disconnect the interface cable only when the electrical supply is
switched off for both the PC and the servo amplifier.
The interface in the servo amplifier has the same potential level as the CANopen interface.
Minimum requirements for the PC:
9.2.1.4
Processor
Operating system
Graphics adapter
Drives
:
:
:
:
Interface
:
at least Pentium® I or comparable
WINDOWS 2000 / XP
Windows compatible, color
hard disk with at least 10 MB free space
CD-ROM drive
one free serial interface (COM1 ... COM10)
Operating systems
WINDOWS 2000 / XP
DRIVEGUI.EXE will run under WINDOWS 2000 and WINDOWS XP.
Emergency operation is feasible through an ASCII terminal emulation (without graphical
user interface).
Interface settings : 38400 bps, databit 8, no parity, stopbit 1, no flow control
Unix, Linux
The functioning of the software has not been tested for WINDOWS running within Unix or
Linux.
9.2.2
Installation under WINDOWS 2000 / XP
On the CD-ROM you can find an installation program, which makes it easy to install the
setup software on your PC.
Installation
Autostart function activated:
Insert the CD-ROM into a free drive. A window with the start screen opens. There you
find a link to the setup software DRIVEGUI.EXE. Click it and follow the instructions.
Autostart function deactivated:
Insert the CD-ROM into a free drive. Click on START (task bar), then on Run. Enter the
program call: x:\autorun.exe (x = correct CD drive letter).
Click OK and proceed as described above.
Connection to the serial interface of the PC:
Connect the interface cable to a serial interface on your PC (COM1 to COM10) and to the
serial interface of the servo amplifier SERVOSTAR 300 (ð p.58).
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Setup
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9.3
Quickstart
9.3.1
Preparation
9.3.1.1
Unpacking, Mounting and Wiring the Servo Amplifier
1. Unpack servo amplifier and accessories
2. Observe safety instructions in the manuals
3. Mount the servo amplifier as described in chapter 7.3
4. Wire the servo amplifier as described in chapter 8.3 or apply the minimum wiring for
drive testing as described in chapter 9.3.1.3
5. Install the software as described in chapter 9.2
9.3.1.2
Documents
You need access to these documents (located on the product CD-ROM, you can
download the latest editions from our website):
l
Product Manual SERVOSTAR 300 (this manual)
l
CANopen communication profile Manual
Depending on the installed expansion card you need one of these documents:
l
PROFIBUS DP communication profile Manual
l
DeviceNet communication profile Manual
l
SERCOS communication profile Manual
l
EtherCat communication profile (in process) Manual
You need Acrobat Reader to read the PDFs, an installation link is on every screen of the
product CD-ROM.
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9.3.1.3
Setup
09/2006
Minimum Wiring for Drive Test
This wiring does not fulfill any requirements to safety or functionality of your
application, it just shows the required wiring for drive testing without load.
Motor-Feedback
X3 1
Power ON
2
Enable
24V ON
12
+
24V DC
-
X4 1
3
5
2
X8 4
5
Motor-Power
Motor
Power
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Setup
9.3.2
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Connect
l
Connect the interface cable to a serial interface on your PC and to the serial interface
X6 of the servo amplifier. USB to serial converter can be used optionally.
l
Switch on the 24 V power supply for the servo amplifier.
l
Wait about 30 seconds, until the front display of the servo amplifier displays the current class (e.g.
for 3 A). If the power supply voltage is switched on, too, a lea-
ding P is displayed (e.g.
for Power, 3 A).
If a fault code (
) or a warning (
) or a status message (./_ / E/S)
appears in the display, you will find the description on page 80 / 81. If there is fault,
fix the problem.
Double-Click the DRIVEGUI.EXE icon on your Windows desktop to
start the software.
You can work offline or online with
DRIVEGUI.EXE. Work ONLINE now.
If the communication is
started for the first time, you
have to setup the communication parameters.
Choose the communication
system and the interface,
where the servo amplifier is
connected to.
Click OK.
The software tries to communicate with these parameters. If it's not successful, you
receive this error message:
Frequent causes:
- wrong interface chosen
- wrong connector chosen at the servo amplifier
- interface is used by another software
- 24 V auxiliary voltage for the servo amplifier not
working
- interface cable broken or wrong wiring
Quit the error message. The software starts in the offline mode now, that requires the
manual selection of the amplifier's type. Quit this selection by closing the window.
Fix the communication problem. Restart the software in Online mode.
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Setup
If communication works, you see the start screen. Select "Setup Wizard" in the navigation
frame.
Make sure, that the amplifier is disabled (Input Enable connector X3 pin 12 must
be 0 V or open)!
9.3.3
Important Screen Elements
Help Function
The Online-Help gives detailed information to all parameters the servo amplifier can work
with.
Key F1
Menu bar ?
Starts Online Help for the actual screen page.
Starts Online Help with the first page.
Context Help. Click the help symbol first. Then click the function for which
you need help.
Tool Bar
Save to EEPROM, required if you changed parameters.
Reset, required if you changed configuration parameters.
Operation Mode, use "0: Digital Velocity" mode for
drive testing.
Status Bar
The status bar shows a green Online symbol, indicating that the communication works.
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Setup
9.3.4
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Kollmorgen
Setup Wizard
The Setup Wizard leads you through the necessary steps for configuring your servo
amplifier. Depending on the selected application, only the active screen pages are
necessary.
For a quick setup / drive
test, select the setup
type "Quick Motor/Drive
Setup".
Start the Wizard.
9.3.4.1
Basic Setup
Basic parameters are
setup here.
Response to Loss of Input Phase: Select Single-Phase or Three-Phase operation.
With three-phase operation you can select either warning "n05" or error "F19" in case of
phase loss. The reaction "F19" disables the output stage, "n05" is just a message.
Name: You can enter a name for the servo amplifier (up to 8 characters). This simplifies
the drive identification in the system.
Set Software Enable on Bootup: Don't select this option for the quick test.
Click NEXT.
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Setup
Units/Mechanical
The user units for all input fields in the setup
software can be preselected here.
Position, Velocity, Acceleration
Select usable units for your application referring to the moved load.
Mechanical Conversion
The relationship between motor shaft revolution (pole pait pitch with linear motors) and
motion distance of the load is specified here. Gear ratio can be calculated here as well.
Detailed information can be found in the online help.
Use the tool based on sample applications for calculating the resolution value:
Calculate PGEARI/PGEARO for..." button
If your application does not correspond to any of the listed examples,
enter the required parameters directly in the fields on the “Units”
screen.
First, select the application that corresponds to your own. Next, set the position unit.
Select the position unit that provides you with the required accuracy for your application.
Set the mechanical data for you application now. If a gearhead is flange-mounted on the
motor, you must also enter the gearhead data (either the number of teeth or the ratio of
the revolutions).
Then click the “Calculate conversion factors and return” button.
Click NEXT.
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Setup
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Motor (rotary) / Feedback
Simplified setting of the
motor related parameters.
Feedback: Select the feedback system used in the motor.
Attention: Resolver is fixed to 2 pole in the Quick Motor/Drive Setup.
Change "pole n°" on feedback screen in Complete Setup later, if required.
Motor type: Click the button "Select from Database...".
Open the database file (mdb_ _ _.csv) and select the used motor out of the list. Special
motors must be defined in the "Complete Setup".
Brake: If the amplifier shall control a brake, change the Brake parameter to "With"
Calculated quick tuning: If you know the Load-to-motor inertia ratio (0 is for no load),
enter the number here and select the desired servo performance. If you don't know the
inertia ratio, select "Do not tune". Click FINISH.
9.3.4.4
Motor (linear) / Feedback (Encoder)
Simplified setting of the
motor related parameters.
Feedback: Select the feedback system used.
Motor type: Click the button "Select from Database..".
Open the database file (mdb_ _ _.csv) and select the used motor. Special motors must
be defined in the "Complete Setup".
Encoder Lines (appears with Feedback Type Sine Encoder):
Click "Calculate" and fill in the Encoder signal period.
Brake: If the amplifier shall control a brake, change the Brake parameter to "With"
Calculated quick tuning: If you know the Load-to-motor inertia ratio, enter the number
here and select the desired servo performance. Otherwise select "Do not tune".
Click FINISH.
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Setup
09/2006
Save Parameters and Restart
You are going to finish the Setup Wizard and you have changed several basic parameters. Depending on the parameters you changed, two possible reactions will occure now:
Configuration parameters changed
A warning appears, that you have to restart the amplifier, this is called "coldstart".
Click "YES".
The parameters are
saved to the amplifier's EEPROM automatically and a reset
command restarts
the amplifier (takes some seconds).
Other parameters changed
No warning appears. Save the parameters to the EEPROM of the servo amplifier manually by clicking the symbol
sary.
in the tool bar. A coldstart of the amplifier is not neces-
Select the screen "Motion Service" in the navigation frame.
9.3.5
Motion Service (Jog Mode)
Be aware that the actual position of the load permits the subsequent moving operations. The axis could move to the hardware limit-switch or the mechanical stop.
Make sure that a jerk or a fast acceleration of the load cannot cause any damage.
l
Switch on the power supply for the drive.
l
AS-Enable: Apply +24 V to the input AS-Enable [X4/5]
l
Hardware-Enable: Apply +24 V to the input Enable [X3/12]. If AS-Enable is missed
or the sequence was wrong, the front display shows
l
Software-Enable: Click the symbol
shows an E and the current class (e.g.
.
in the tool bar. Now the front display
for Enable, 3 A). Click the symbol
to switch off the output stage (disable).
Jog
(Digital Velocity Mode):
You can move the drive with
constant speed. Enter the
desired speed.
Observe the "safe reduced
speed" requirements for
your application!
The drive moves with the
preset speed when the + or
– button is pressed. It stops
when the button is released.
Actual errors and warnings are listed on the screen "Status". A description of errors/warnings can be found in the online help or on p.80ff.
Now you have setup and tested the basic functions of the drive successfully.
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Setup
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More Setup Screens
Observe the safety instructions in the manuals and in the online help before you
change parameters in the additional setup screens.
For all setup functions detailed information can be found in the Online Help system and
the integrated command reference.
Select "Complete Setup" in the Setup-Wizard. Now you have access to:
76
l
Feedback: Adjust the used feedback unit
l
Motor: Adjust the used motor
l
Control Loops: Current-, Velocity- and Position-Loops can be optimized
l
Position Data: Adjust the position control for the requirements of your application.
l
Position Registers: up to 16 position values in the motion way can be monitored.
l
Electronic Gearing: If the servo amplifier will follow a setpoint as a slave with a gear
ratio, you can select the gearing source here and define the gear ratio.
l
Encoder Emulation: select the encoder emulation (position output)
l
Analog I/O: setup the analog inputs
l
Digital I/O: setup the digital inputs and outputs
l
Status (Errors/Warnings): displays amplifiers data with history, actual
faults/warnings
l
Monitor: displays the drive data (actual values)
l
Homing: definition and start of homing
l
Motion task: definition and start of motion task
l
Oscilloscope: 4 channel oscilloscope with multiple functionality
l
Bode Plot: tool for optimizing the drive
l
Terminal: setup the servo amplifier with ASCII commands
l
Expansion Card: depending on the built-in expansion card a menu appears
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9.4
Multi-axis systems
9.4.1
Station address for CAN-bus
During setup it makes sense to use the keypad on the front panel to preset the station
addresses for the individual amplifiers and the baud rate for communication (ð p.79).
9.4.2
Baud rate for CAN-bus
After changing the station address and baud rate you must turn the 24V auxiliary
supply for the servo amplifier off and on again.
Coding of the Baud rate in the LED display :
Coding
1
2
5
10
12
9.5
Baud rate in kbit/s
10
20
50
100
125
Coding
25
33
50
66
80
100
Baud rate in kbit/s
250
333
500
666
800
1000
Keypad operation / LED display
This section illustrates the two possible operating menus and the use of the keys on the
front panel. Normally, the SERVOSTAR 300 only presents the standard menu for your
use. If you want to operate the amplifier via the detailed menu, you must keep the right
key pressed while switching on the 24V supply.
9.5.1
Keypad operation
The two keys can be used to perform the following functions:
Key symbol Functions
press once : move up one menu item, increase number by one
press twice in rapid succession : increase number by ten
press once : decrease number by one
press twice in rapid succession : decrease number by ten
hold right key pressed, and then press left key as well :
to enter a number, “Return” function
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Setup
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Status display
ð p.77
9.5.3
78
Standard menu
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9.5.4
Setup
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Advanced menu
To operate the amplifier via the detailed menu, you must keep the right key pressed while
switching on the 24 V supply.
ð p.77
ð p.77
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Error messages
Any errors that occur are shown in coded form by an error number in the LED display on
the front panel. All error messages result in the BTB/RTO contact being opened, the output stage being switched off (motor loses all torque), and the holding brake is activated.
Number
E/P
...
-SF01*
Explanation
Status Messages
Status Message
Status Message
AS-Enable
Heat Sink Temperature
Status messages, no error, see p. 78
Amplifier is updating the startup configuration
Status message, no error, programming mode
AS-Enable input is 0V (with disabled drive only)
Heat sink temperature too high (default: 80°C)
Overvoltage in DC bus link. Limit depends on the
Overvoltage
F02*
electrical supply voltage
Following Error
Message from the position controller
F03*
Feedback
Cable break, short-circuit, short to ground
F04
Undervoltage
Undervoltage in DC bus link (default: 100 V)
F05*
Motor Temperature
Motor temperature too high or temp. sensor defect
F06
Internal Voltages
Internal supply voltages not ok
F07
Overspeed
Motor runs away, speed is too high
F08*
EEPROM
Checksum error
F09
Signal Failure X5
Signal failure X5 (cable break or similar)
F10
Brake
Cable break, short-circuit, short to ground
F11
Motor Phase
Motor phase missing (cable break or similar)
F12
Ambient Temperature Ambient temperature too high
F13*
Output Stage
Fault in the power output stage
F14
I²t max.
I²t maximum value exceeded
F15
Mains BTB/RTO
2 or 3 phases missing in the mains supply feed
F16*
Error in the analog-digital conversion, normally
A/D Converter
F17
caused by extreme electromagnetic interference
Regen
Regen circuit faulty or incorrect setting
F18
DC Bus Link
DC bus link breakdown
F19*
Slot error, depends on the type of expansion card
Slot Error
F20
(see ASCII object reference)
Handling Error
Handling error on the expansion card
F21
Reserved
Reserved
F22
CAN-Bus Off
Severe CAN bus communication error
F23
Warning
Warning is displayed as fault
F24
Commutation Error
Commutation error
F25
Limit Switch
Hardware limit switch error on homing move
F26
Operational error with -AS- , input for AS-Enable
AS
F27
and ENABLE have been set at the same time
Fieldbus Error
Fieldbus error (see ASCII command reference)
F28
Fieldbus communication is disturbed (see ASCII
Fieldbus Error
F29
object reference)
Emergency Timeout
Timeout emergency stop
F30
Reserve
Reserve
F31
System Error
System software not responding correctly
F32
* = these error messages can be cleared without a reset, by using the terminal screen
and sending the ASCII command CLRFAULT (or button
). If only one of these errors
is present and the RESET button
or the I/O RESET function is used, only the
CLRFAULT command will be executed.
More information to the messages can be found in the ASCII Object Reference
(Online Help), see parameter ERRCODE. Hints for removal can be found on page 82
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Setup
Warning messages
Faults which occur, but which do not cause a switch-off of the amplifier output stage
(BTB/RTO contact remains closed), are indicated in the LED display on the front panel by
a coded warning number. Detailled description see "ASCII command reference".
Number
E/P
...
-Sn01
n02
n03*
n04*
n05
n06*
n07*
n08
Designation
Status Messages
Status Message
AS-Enable
Status Message
I²t
Regen power
S_fault
Response monitoring
Supply phase
SW limit switch 1
SW limit switch 2
Motion task error
n09
No reference point
n10*
n11*
PSTOP
NSTOP
n12
Motor default values
loaded
n13*
Expansion card
n14
SinCos feedback
Explanation
Status messages, no error, see p. 78
Amplifier is updating the startup configuration
AS-Enable input is 0V (with disabled drive only)
Status message, no error, programming mode
I²t threshold exceeded
Reached preset regen power limit
Exceeded preset following error limit
Response monitoring (fieldbus) has been activated
Mains supply phase missing
Software limit switch 1 underrun
Software limit switch 2 overrun
A faulty motion task was started
No reference point (Home) set at start of motion
task
PSTOP limit-switch activated
NSTOP limit-switch activated
Only for ENDAT or HIPERFACE® :
discrepancy between motor number saved in the
encoder and the amplifier, motor default values
loaded
24V DC supply for I/O expansion card not ok
SinCos commutation (wake & shake) not completed, will be canceled when amplifier is enabled and
wake & shake carried out
Fault according to speed/current table INXMODE 35
Summarized warning for n17 to n31
CAN sync is not logged in
Max. number of motor turns exceeded
Table error
Summarized warning
Fieldbus-sync
Multiturn overflow
Motion task ramps are
Range overflow on motion task data
n19
limited
Invalid motion task
Invalid motion task
n20
PLC program error
For details see PLC code
n21
The user can shut down the process before the
Max. motortemperatur
temperature eror will interrupt the process immedin22
reached
ately
Sin Cos feedback
Warning level reached
n23
Digital I/O
Configuration is not logical
n24
Reserve
n25-n31 Reserve
Firmware beta version Firmware is an unreleased beta version
n32
* = these warning messages result in a controlled shut-down of the drive (braking by
emergency stop ramp)
n15
n16
n17
n18
More information to the messages can be found in the ASCII Object Reference
(Online Help), see parameter STATCODE. Hints for removal can be found on p. 82.
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Setup
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Trouble Shooting
The table below should be regarded as a “First-aid” box. There may be a wide variety of
reasons for the fault, depending on the conditions in your installation.
In multi-axis systems there may be further hidden causes of a fault.
Our customer service can give you further assistance with problems.
Fault
Possible causes
Measures
— wrong cable used
— use null-modem cable
HMI message: — cable plugged into wrong position — plug cable into the correct
on servo amplifier or PC
sockets on the servo amplifier
Communicatiand PC
on fault
— wrong PC interface selected
— select correct interface
F01 message:
— permissible heat sink tempe— improve ventilation
Heat sink
rature exceeded
temperature
— regen power is insufficient.
— reduce the RAMP braking
Regen power limit was reached
time.
and the regen resistor was
Use an external regen resistor
F02 message:
switched off.
with a higher power rating and
Overvoltage
This causes excessive voltage
adjust the regen power
in the DC bus link circuit.
parameter
— supply voltage too high
— use a supply transformer
— feedback connector not properly — check connectors
inserted
— feedback cable is broken,
— check cables
F04 message:
crushed, or otherwise damaged
Feedback Unit
— feedback unit is damaged or
— check feedback unit and
wrongly configured
settings
— supply voltage is not present, or
too low when the servo amplifier
F05 message:
is enabled
Undervoltage
—
F06 message:
Motor
—
temperature
F07 message: —
Aux. voltage
—
F08 message:
—
Overspeed
F09 message: —
EEPROM
—
F11 message: —
—
Brake
—
82
— only ENABLE the servo
amplifier when the electrical
supply voltage has been
switched on delay > 500 msec
motor thermostat has been
— wait till motor has cooled
activated
down, then check why it
became so hot.
feedback connector is loose, or
— screw connector up tight, or
a break in the feedback cable
use new feedback cable
the aux. voltage produced by the — return the servo amplifier to
servo amplifier is incorrect
the manufacturer for repair
motor phases swapped
— correct motor phase sequence
feedback device set up
— set up the correct offset angle
incorrectly
checksum error
— save data to EEPROM again
to force a new calculation
short-circuit in the supply cable
— remove the short-circuit
for the motor-holding brake
motor-holding brake is faulty
— replace motor
fault in brake cable
— check shielding of brake cable
no brake connected, although the — set brake parameter to
brake parameter is set to WITH
WITHOUT
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Fault
Possible causes
F13 message: — permissible internal temperature
has been exceeded
Internal temp.
— motor cable has a short-circuit or
earth/ground short
— motor has short-circuit or
earth/ground short
F14 message:
Output stage — output module is overheated
— output stage is faulty
fault
Measures
— improve ventilation
— replace cable
— replace motor
— improve ventilation
— return the servo amplifier to
the manufacturer for repair
— short-circuit or short to ground in — remove short-circuit / ground
the external regen resistor
short
— enable was applied, although the — only ENABLE the servo ampliF16 message:
supply voltage was not present.
fier when the electrical supply
Mains
voltage has been switched on
BTB/RTO
— at least 2 supply phases missed — check the electrical supply
— error in the analog-digital conver- — reduce EMC interference
sion, usually caused by EMC
check shielding and grounding,
F17 message:
interference
mount devices which produce
A/D converter
magnetic fields with more
distance to the amplifier.
— wrong cable used
— check cable
— offset is too large
— check resolver pole number
F25 message:
(RESPOLES), motor pole
Commutation
number (MPOLES) and offset
error
(MPHASE)
— wake & shake missed
— execute wake & shake
— check programming and wiring
F27 message: — -AS- enable AND HW enable
have been set at the same time
of the PLC / control system
error AS
— servo amplifier not enabled
— apply ENABLE signal
— software enable not set
— set software enable
— break in setpoint cable
— check setpoint cable
— motor phases swapped
— correct motor phase sequence
Motor does
— brake not released
— check brake control
not rotate
— drive is mechanically blocked
— check mechanism
— motor pole no. set incorrectly
— set motor pole no.
— feedback set up incorrectly
— set up feedback correctly
— gain is too high (speed controller) — reduce Kp (speed controller)
Motor oscilla— feedback cable shielding broken — replace feedback cable
tes
— AGND not wired up
— join AGND to CNC-GND
— increase Irms or Ipeak
Drive reports — Irms or Ipeak set too low
(keep within motor ratings!)
following er— shorten ramp +/— accel/decel ramp is too long
ror
Motor over— Irms/Ipeak is set too high
— reduce Irms/Ipeak
heating
— Kp (speed controller) too low
— increase Kp (speed controller)
— Tn (speed controller) too high
— use motor default value for
Tn (speed controller)
Drive too soft
— ARLPF / ARHPF too high
— reduce ARLPF / ARHPF
— ARLP2 too high
— reduce ARLP2
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Setup
Fault
Drive runs
roughly
Axis drifts at
setpoint = 0V
n12 message:
Motor default
values loaded
n14 message:
SinCos feedback
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Possible causes
— Kp (speed controller) too high
— Tn (speed controller) too low
— ARLPF / ARHPF too low
— ARLP2 too low
— offset not correctly adjusted for
analog setpoint provision
— AGND not joined to the
controller-GND of the controls
— Motor numbers stored in the
encoder and amplifier do not
match the parameters that have
been set
— SinCos commutation
(wake&shake) not completed
Measures
— reduce Kp (speed controller)
— use motor default value for
Tn (speed controller)
— increase ARLPF / ARHPF
— increase ARLP2
— adjust offset (analog I/O)
— join AGND and controller-GND
— default values for the motor
have been loaded, SAVE
automatically stores the
motor number in the EEPROM
— ENABLE the amplifier
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Expansions and Accessories
Expansions and Accessories
You can find information about availability and order numbers on page 106.
10.1
Expansion Cards
10.1.1
Guide to installation of expansion cards
l
Use a suitable screwdriver to lever off the cover of the option slot.
l
Take care that no small items (such as screws) fall into the open option slot.
l
Lever off the small metall sheet and push it back to the small slot. Dispose the
big metall sheet.
l
Push the expansion card carefully into the provided guide rails of the main
slot, without twisting it.
l
Press the expansion card firmly into the slot, until the front cover touches the
fixing lugs. This ensures that the connectors make good contact.
l
Screw the screws on the front cover into the threads in the fixing lugs.
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Expansions and Accessories
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Expansion card -I/O-14/08This section describes the additional features that the expansion card -I/O-14/08- provides for the SERVOSTAR 300. If you ordered the expansion card together with the servo
amplifier, then it will be delivered already inserted into the expansion slot of the servo
amplifier and screwed in place.
The -I/O-14/08- provides you with 14 additional digital inputs and 8 digital outputs. The
functions of the inputs and outputs are adjustable with the setup software.
The I/Os are used to initiate the motion tasks that are stored in the servo amplifier and to
evaluate signals from the integrated position control in the higher-level control system.
The functions of the inputs and signal outputs correspond to the functions that can be
assigned to the digital I/Os on connector X3. All inputs and outputs are electrically isolated from the servo amplifier by optocouplers.
10.1.2.1
Front view
10.1.2.2
Technical data
Control inputs
Signal output
Supply inputs, to IEC 1131
Fusing (external)
Connectors
Cables
Waiting time between 2 motion
tasks
Addressing time (minimum)
Starting delay (maximum)
Response time of digital outputs
10.1.2.3
24V / 7mA , PLC-compatible, IEC 1131
24V / max. 500mA , PLC-compatible, IEC 1131
24V (18 … 36V) / 100mA plus total current of the
outputs (depends on the input wiring of the controls)
The 24V DC voltage must be supplied by an
electrically isolated power supply (e.g. with
isolating transformer).
4 AT
MiniCombicon, 12-pin, coded on PIN1 and 12
Data – up to 50m long : 22 x 0.5 mm², unshielded,
Supply– 2 x 1mm², check voltage drop
depends on the response time of the control system
4ms
2ms
max. 10ms
LEDs
Two LEDs are mounted next to the terminals on the expansion card. The green LED signals that the 24V auxiliary supply is available for the expansion card. The red LED signals
faults in the outputs from the expansion card (overload of switching components,
short-circuit).
10.1.2.4
Entering a motion block number
Motion block number (decimal)
174
86
A7
1
Motion block number (binary)
A6
A5
A4
A3
A2
A1
0
1
0
1
1
1
A0
0
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09/2006
Expansions and Accessories
Connector assignments
The functions are adjustable with the setup software. In the table below the default values
are described.
Connector X11A
Default
Description
Pin Dir
function
1 In
A0
Motion block number, LSB
2 In
A1
Motion block number, 21
3 In
A2
Motion block number, 22
4 In
A3
Motion block number, 23
5 In
A4
Motion block number, 24
6 In
A5
Motion block number, 25
7 In
A6
Motion block number, 26
8 In
A7
Motion block number, MSB
Polls the home switch. If a digital input on the base unit is
used as a home input, then the input on the expansion card
9 In
Reference
will not be evaluated.
Clears the warning of a following error (n03) or the response
10 In F_error_clear
monitoring (n04)
The following task, that is defined in the motion task by “Start
with I/O” is started. The target position of the present motion
11 In Start_MT_Next task must be reached before the following task can be started.
The next motion block can also be started by an appropriately
configured digital input on the base unit.
Starts the "Jog Mode" with a defined speed. “x” is the speed
12 In Start_Jog v= x saved in the servo amplifier for the function "Jog Mode". A rising edge starts the motion, a falling edge cancels the motion.
Connector X11B
1 In
MT_Restart
2
In
Start_MT I/O
3
Out
InPos
4
Out
Next-InPos
PosReg 0
5
Out
F_error
6
7
8
9
10
11
12
Out
Out
Out
Out
Out
-
PosReg1
PosReg2
PosReg3
PosReg4
PosReg5
24V DC
I/O-GND
Continues the motion task that was previously interrupted.
Starts the motion task that is addressed by A0-A7 (connector
X11A/1...8).
When the target position for a motion task has been reached
(the InPosition window), this is signaled by the output of a
HIGH signal. A cable break will not be detected.
The start of each motion task in an automatically executed
sequence of motion tasks is signaled by an inversion of the
output signal. The output produces a LOW signal at the start
of the first motion task of the sequence. The form of the message can be varied by using ASCII commands.
Can only be adjusted by ASCII commands/setup software.
A LOW signal indicates that the position has gone outside the
acceptable following error window.
default: SW limit 1, indicated by a HIGH signal
default: SW limit 2, indicated by a HIGH signal
Can only be adjusted by ASCII commands/setup software.
Can only be adjusted by ASCII commands/setup software.
Can only be adjusted by ASCII commands/setup software.
Supply voltage for output signals.
Digital GND for the control system.
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Expansions and Accessories
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Connection diagram
SERVOSTAR 300
88
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10.1.3
09/2006
Expansions and Accessories
Expansion card -PROFIBUSThis section describes the PROFIBUS expansion card for the SERVOSTAR 300.
Information on the range of functions and the software protocol can be found in our
manual “Communication Profile PROFIBUS DP”..
The PROFIBUS expansion card has two 9-pin SubD sockets wired in parallel.
The supply voltage for the expansion card is provided by the servo amplifier.
10.1.3.1
Front view
10.1.3.2
Connection technology
Cable selection, cable routing, shielding, bus connector, bus termination and transmission times are all described in the “Installation Guidelines for PROFIBUS-DP/FMS” from
PNO, the PROFIBUS User Organization.
10.1.3.3
Connection diagram
SERVOSTAR 300
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Expansions and Accessories
10.1.4
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Kollmorgen
Expansion card -SERCOSThis section describes the SERCOS expansion card for SERVOSTAR 300. Information
on the range of functions and the software protocol can be found in our manual “IDN
Reference Guide SERCOS”.
10.1.4.1
Front view
10.1.4.2
LEDs
RT
TT
Indicates whether SERCOS telegrams are being correctly received. In the final
Communication Phase 4 this LED should flicker, since cyclical telegrams are being
received.
Indicates that SERCOS telegrams are being transmitted. In the final Communication Phase 4 this LED should flicker, since cyclical telegrams are being transmitted.
Check the station addresses for the controls and the servo amplifier if:
- the LED never lights up in SERCOS Phase 1 or
- the axis cannot be operated, although the RT LED is lighting up cyclically.
Indicates that SERCOS communication is faulty or suffering from interference.
If this LED is very bright, then communication is suffering strong interference, or is
non-existent. Check the SERCOS transmission speed for the controls and the
servo amplifier (BAUD RATE) and the fiber-optic connection.
ERR
10.1.4.3
If this LED fades or flickers, this indicates a low level of interference for SERCOS
communication, or the optical transmitting power is not correctly matched to the
length of cable. Check the transmitting power of the (physically) previous
SERCOS station. The transmitting power of the servo amplifier can be adjusted in
the setup software DRIVEGUI.EXE on the SERCOS screen page, by altering the
length parameter for the cable length.
Connection technology
For the fiber optic cable connection, only use SERCOS components to the SERCOS
Standard IEC 61491.
Receive data
The fiber optic cable carrying receive data for the drive in the ring structure is connected
to X13 with an F-SMA connector.
Transmit data
Connect the fiber optic cable for the data output to X14 by F-SMA connector.
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Expansions and Accessories
Connection diagram
Layout of the SERCOS bus system in ring topology, with optical fiber cables (schematic).
10.1.4.5
Modifying the station address
The drive address can be set to a value between 0 and 63. With address 0, the drive is
assigned as an amplifier in the SERCOS ring. Set the station address with the:
Keys on the front of the servo amplifier
The SERCOS address can be modified using the keys on the front of the amplifier (p. 78).
Setup software
The address can also be modified in the setup software, “CAN/Fieldbus” screen (please
refer to the setup software online help). Alternatively, enter the command ADDR # in the
“Terminal” screen, where # is the new address of the drive.
10.1.4.6
Modifying the baud rate and optical power
If the baud rate is not set correctly, communication is not possible.
The SBAUD # parameter can be used to set the baud rate, where # is the baud rate. If
the optical power is not set correctly, errors occur in telegram transmission and the red
LED on the drive lights up. During normal communication, the green send and receive
LEDs flash, giving the impression that the relevant LED is on.
The SLEN # parameter can be used to specify the optical range for a standard 1 mm²
glass fibre cable, where # is the length of the cable in metres.
2
4
8
16
SBAUD
2 Mbaud
4 Mbaud
8 Mbaud
16 Mbaud
0
1…< 15
15…< 30
³ 30
SLEN
Very short connection
Length of the connection with a 1 mm² plastic cable
Length of the connection with a 1 mm² plastic cable
Length of the connection with a 1 mm² plastic cable
Setup software
The parameters can be modified in the setup software, “SERCOS” screen (please refer to
the setup software the online help). Alternatively, the commands SBAUD # and SLEN #
can be entered in the “Terminal” screen.
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Kollmorgen
Expansion card -DEVICENETThis section describes the DeviceNet expansion card for SERVOSTAR 300.
Information on the range of functions and the software protocol can be found in our
manual “DeviceNet Communication Profile”.
10.1.5.1
Front view
10.1.5.2
Connection technology
Cable selection, cable routing, shielding, bus connector, bus termination and transmission times are all described in the “DeviceNet Specification, Volume I, II”, published by
ODVA.
10.1.5.3
Connection diagram
SERVOSTAR 300
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Expansions and Accessories
Combined module/network status-LED
LED
Meaning
The device is not online.
- The device has not yet finished the Dup_MAC_ID test.
off
- The device is possibly not yet switched on.
The device is operating as normal, is online, and the connections have been
green
established. The device has been assigned to a master.
The device is operating as normal, is online, but the connections have not
been established.
blinking - The device has passed the Dup_MAC_ID test and is online, but the
connection to other nodes have not been established.
green
- This device has not been assigned to a master.
- Missing, incomplete or wrong configuration.
blinking An error that can be cleared and/or at least one I/O connection are in a waiting
state.
red
- An error has occurred that cannot can be cleared; it may be necessary to
replace the device.
- Communication device failure. The device has detected a fault that
red
prevents communication with the network (for instance, a MAC ID appears
twice or BUSOFF).
10.1.5.5
Setting the station address (device address)
The station address for the servo amplifier can be set in three different ways:
10.1.5.6
l
Set the rotary switches at the front of the expansion card to a value between 0 and
63. Each switch represents a decimal figure. For example, to set the address for the
drive to 10, set MSD to 1 and LSD to 0.
l
Set the rotary switches at the front of the expansion card to a value higher than 63.
Now you can set up the station address by using the ASCII commands DNMACID x,
SAVE, COLDSTART, whereby “x” stands for the station address.
l
Set the rotary switches at the front of the expansion card to a value higher than 63.
Now you can set up the station address by using the DeviceNet Object (Class 0x03,
Attribute 1). This is normally carried out with the help of a DeviceNet software setup
tool. You must save the parameters in non-volatile memory (Class 0x25, Attribute
0x65) and then restart the drive after setting/altering the address.
Setting the transmission speed
The DeviceNet transmission speed can be set in three different ways:
l
Set the rotary switch for Baud rate (at the front of the option card) to a value between
0 and 2. 0 = 125 kbit/s, 1 = 250 kbit/s, 2 = 500 kbit/s.
l
Set the rotary switch for Baud rate (at the front of the option card) to a value higher
than 2. Now you can set the Baud rate by using the terminal commands DNBAUD x,
SAVE, COLDSTART, whereby “x” stands for 125, 250 or 500 .
l
Set the rotary switch for Baud rate (at the front of the option card) to a value higher
than 2. Now you can set the Baud rate by using the DeviceNet Object (Class 0x03,
Attribute 2) to a value between 0 and 2. This is normally carried out with the help of a
DeviceNet software setup tool. You must save the parameters in non-volatile memory (Class 0x25, Attribute 0x65) and then restart the drive after altering the baud rate.
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Kollmorgen
Bus cable
To meet ISO 898, a bus cable with a characteristic impedance of 120 W should be used.
The maximum usable cable length for reliable communication decreases with increasing
transmission speed. As a guide, you can use the following values which we have measured, but they are not to be taken as assured limits.
General characteristic
Bit rates
Specification
125 kbit, 250 kbit, 500 kbit
500 meters at 125 kBaud
Distance with larger
250 meters at 250 kBaud
bus connections
100 meters at 500 kBaud
Number of nodes
64
Signal environment
CAN
Modulation
Basic bandwidth
Coupling medium
DC-coupled differential transmit/receive operation
Isolation
500 V (option: optocoupler on the transceiver's node side)
Typical differential input im- Shunt C = 5pF
pedance (recessive state) Shunt R = 25KW (power on)
Shunt C = 24pF + 36 pF/m of the permanently
Min. differential input imattached stub cable
pedance (recessive state)
Shunt R = 20KW
-25 V to +18 V (CAN_H, CAN_L)
The voltages for CAN_H and CAN_L refer to the ground pin
Absolute max.
of the transceiver. The voltage is higher than that on the
voltage range
V-terminal by the amount of the forward voltage drop of the
Schottky diode. This voltage drop must be < 0.6V.
Grounding:
The DeviceNet network must only be grounded at one point, to avoid ground loops. The
circuitry for the physical layer in all devices are referenced to the V-bus signal. The
ground connection is made via the power supply for the bus system. The current flowing
between V- and ground must not flow through any device other than the power supply.
Bus topology:
The DeviceNet medium utilizes a linear bus topology. Termination resistors are required
at each end of the connecting cable. Stub cables are permitted up to a length of 6 meters,
so that at least one node can be connected.
Termination resistors:
DeviceNet requires a termination at each end of the connecting cable.
These resistors must meet the following requirements: 120W, 1% metal-film, 1/4 W
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09/2006
Expansions and Accessories
Expansion card -ETHERCATThis section describes the EtherCat expansion card for SERVOSTAR 300.
Information on the range of functions and the software protocol can be found in the EtherCat documentation. This expansion cards enables the servo amplifier to be connected to
the EtherCat network.
10.1.6.1
Front view
10.1.6.2
LEDs
LED
Function
flickering = Booting Error
blinking = Invalid Configuration
ERROR single flash = Unsolicited State Change
double flash = Watchdog Timeout
off = No Error
on = Device is in state OPERATIONAL
blinking = Device is in state PRE-OPERATIONAL
RUN
single flash = Device is in state SAFE-OPERATIONAL
off = Device is in state INIT
on = linked, but not active at X20A (in)
flickering = linked and active at X20A (in)
ACT IN
off = not linked at X20A (in)
on = linked, but not active at X20B (out)
ACT OUT flickering = linked and active at X20B (out)
off = not linked at X20B (out)
10.1.6.3
Connection diagram
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Expansions and Accessories
10.1.7
Kollmorgen
09/2006
Expansion card -SYNQNETThis section describes the SynqNet expansion card for SERVOSTAR 300.
Information on the range of functions and the software protocol can be found in the SynqNet documentation.
10.1.7.1
Front view
LED2 LED1
10.1.7.2
LED4 LED3
NODE ID Switch
With these hexadecimal switches you can set the main and low significant bytes of the
Node ID seperately. SynqNet does not require an address for correct operation in the network, however in some machines this can be a convenient way of identifying build options
to the application program.
10.1.7.3
10.1.7.4
Node LED table
LED#
Name
LED1
LINK_IN
LED2
CYCLIC
LED3
LINK_OUT
LED4
REPEATER
Function
ON = receive valid (IN port)
OFF= not valid, power off, or reset.
ON = network cyclic
BLINK = network not cyclic
OFF = power off, or reset
ON = receive valid (OUT port)
OFF = not valid, power off, or reset
ON = repeater on, network cyclic
BLINK = repeater on, network not cyclic
OFF = repeater off, power off, or reset
SynqNet Connection, Connector X21B/C (RJ-45)
Connection to the SynqNet network via RJ-45 connectors (IN and OUT ports) with integrated LEDs.
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Expansions and Accessories
09/2006
Digital inputs/outputs, connector X21A (SubD 15-pin, socket)
Inputs (In): 24V (20...28V), opto-isolated, one high-speed input (Pin 4)
Outputs (Out): 24V, opto-isolated, Darlington driver
Pinout connector X21A (SubD 15 pin)
Pin Type Description
In +24V
power supply
1
NODEA indicates a problem
Out
2
LARM
with the node
Out OUT_01 digital output
3
In IN_00
capture input (fast)
4
In IN_04
digital input
5
10.1.7.6
Pin Type Description
In GND
power supply
9
10
Out OUT_00
digital output
11
12
13
Out OUT_02
In IN_02
In IN_03
digital output
digital input
digital input
limit switch, negative direction
6
In
IN_01
digital input
14
In
NEGLIM
7
In
HOME
reference switch
15
In
NODEdisables Node
DISABLE
8
In
POSLIM
limit switch, positive
direction
Connection diagram digital inputs/outputs, connector X21A
SERVOSTAR 3xx
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09/2006
Expansion module -2CANConnector X6 of the SERVOSTAR is assigned to the signals for the RS232 interface and
the CAN interface. It is therefore not the standard pin assignment for these interfaces,
and a special cable is required to be able to use both interfaces simultaneously.
The -2CAN- expansion module provides the interfaces on separate Sub-D connectors.
The two CAN connectors are wired in parallel. A termination resistor (120 W) for the CAN
bus can be switched into circuit if the SERVOSTAR is at the end of the bus.
10.1.8.1
Installation
The modul must be placed onto the option slot after levering off the cover of the option
slot and replacing the small cover (see p. 85):
l
Screw the distance pieces into the fixing lugs of the option slot.
l
Place the expansion module onto the option slot.
l
Screw the screws into the threads of the distance pieces.
l
Plug the Sub-D9 socket into connector X6 on the SERVOSTAR
10.1.8.2
Front view
10.1.8.3
Connection technology
Standard shielded cables can be used for the RS232 and CAN interfaces.
If the servo amplifier is the last device on the CAN bus, then the switch for the bus
termination must be set to ON.
Otherwise, the switch must be set to OFF (condition as delivered).
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10.1.8.4
09/2006
Connector assignments
RS232
X6A Pin
1
2
3
4
5
6
7
8
9
10.1.8.5
Expansions and Accessories
Signal
Vcc
RxD
TxD
GND
CAN1=CAN2
X6B=X6C Pin
1
2
3
4
5
6
7
8
9
Signal
CAN-Low
CAN-GND
CAN-High
Connection diagram
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10.2
Accessories
10.2.1
External power supply 24 V DC / 5 A
Technical data
Input voltage
Input current
Frequency
Primary fusing
Output voltage
Max. output current
Residual ripple
Switching peaks
Output fusing
Temperature range
Mounting method
Weight
100
(not available in North America)
120 / 230 V
0.9 / 0.6 A
50/60 Hz
3.15 AT
24 V ± 1%
5A
<150 mVss
<240 mVss
short-circuit proof
0 to +60°C
DIN-rail, vertical mounting
50 mm free space required above and below the device
0.75 kg
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10.2.2
09/2006
Expansions and Accessories
External power supply 24 V DC / 20 A
Mounting Plate
(not available in
North America)
Input voltage
3 x 400 V AC ± 10%
Input current
approx. 1.1 A
Frequency
50/60 Hz
Primary fusing
none
Output voltage
24 V ± 1%
Max. output current 20 A
Residual ripple
<0.1%
Output fusing
short-circuit proof
Test voltage
as per VDE 0550
Temperature range -20 to +60°C
on mounting plate (supMounting method plied) keep necessary
space clear
Weight
3.5 kg
Technical data
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Expansions and Accessories
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09/2006
Kollmorgen
External regen resistor BAR(U)
Caution:
The surface temperature can exceed
200°C. Make sure that the necessary
space is kept clear.
Do not mount the instrument on
combustible surfaces!
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Expansions and Accessories
Motor chokes 3YLN
To use with motor cables longer than 25 m up to 50 m max. to reduce velocity ripple and
to protect the output power stage of the amplifier. The terminals BR are used to connect
the motor holding brake. Beside the terminal are block two shield connection terminals for
safe connection of the cables's shielding braid.
Mount the choke nearby the servo amplifier. The cable length between amplifier
and choke must never exceed 2 m. Connection see page 41 .
The increased absorption reduces the permissible rotative frequency and limits thereby
the permitted motor speed:
— with 6 poles motors to nmax = 3000 rpm
— with 8 poles motors nmax = 2250 rpm
— with 10 poles motors nmax = 1800 rpm
The increased leakage current at rising cable length leads to the reduction of usable
amplifier output current of about 1 A. Use only motors with more than 2 A rated current, to
get a good regulation quality.
Technical data
Rated current
Peak current
Winding inductance
Winding resistance
Power loss
Rotative frequ. (max)
Clock frequency
Test voltage
Overload
Climatic category
Weight
Connection diameter
A
B
C
D
E
F
Dim
A
A
mH
Ohm
W
Hz
kHz
A
kg
mm²
mm
mm
mm
mm
mm
mm
SERVOSTAR ® 300 Product Manual
3YLN06
3x6
12
0,9
24,7
4,5
4
155
130
70
55
190
5,5 x 8
3YLN10
3x10
30
0,9
14,9
3YLN14
3x14
28
0,9
12,7
40
150
2-8
Phase<->PE 2700 V DC 1s
1,5 x Inom, 1 min/h
DIN IEC 68 Part 1 25/085/21
5,5
10
4
4
155
190
130
170
85
115
70
75
190
220
5,5 x 8
6,5 x 10
3YLN20
3x20
40
0,45
7,6
10
6
190
170
115
75
230
6,5 x 10
103
Appendix
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09/2006
11
Appendix
11.1
Glossary
C
Clock
Clock signal
Common-mode voltage
The maximum amplitude of a disturbance (on both
inputs) which a differential input can eliminate
CONNECT modules
Modules built into the servo amplifier, with integrated position control, that provide special versions
of the interface for the connection to the higherlevel control.
Counts
Internal count pulses, 1 pulse = 1/220 turn-1
Continuous power of regen circuit
Mean power that can be dissipated in the regen
circuit
Current controller
Regulates the difference between the current
setpoint and the actual value to 0
Output : power output voltage
DC bus link
Rectified and smoothed power voltage
Disable
Removal of the ENABLE signal (0 V or open)
Earth short
electrical connection between a phase and
the protective earth (PE)
ENABLE
Enable signal for the servo amplifier (+24 V)
Fieldbus interface
CANopen, PROFIBUS, SERCOS etc.
Final speed (limit speed)
Maximum value for the speed normalization at
±10 V
G
GRAY-code
Special format for representing binary numbers
H
Holding brake
Brake in the motor, that can only be used when the
motor is at standstill
I
I²t threshold
Monitoring of the r.m.s. current that is actually
required
Input drift
Temperature and age-dependent alteration of an
analog input
Incremental encoder interface
Position signaling by 2 signals with 90° phase
difference (i.e. in quadrature), is not an absolute
position output
Ipeak, peak current
The effective value of the peak current
Irms, effective current
The r.m.s. value of the continuous current
K
Kp, P-gain
Proportional gain of a control loop
L
Limit speed (final speed)
Maximum value for speed normalization at ±10 V
Limit switch
Switch limiting the traverse path of the machine;
implemented as n.c. (break) contact
Machine
The complete assembly of all connected parts or
devices, of which at least one is movable
Motion block
Data packet with all the position control
parameters which are required for a motion task
Multi-axis system
Machine with several independently driven axes
Natural convection
Free movement of air for cooling
D
E
F
M
N
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Appendix
O
Optocoupler
Optical connection between two electrically
independent systems
P
P-controller
Control loop with purely proportional behavior
Phase shift
Compensation for the lag between the electromagnetic and magnetic fields in the motor
PI-controller
Control loop with proportional and
differential behavior
Position controller
Regulates the difference between the position
setpoint and the actual position to 0
Output: speed setpoint
Potential isolation
electrically decoupled, electrical isolation
Power contactor
System protection device with phase monitoring
Pulse power of the regen circuit
Maximum power which can be dissipated in the
regen circuit
regen circuit
Converts superfluous energy fed back by the
motor during braking (regenerated energy) into
heat.
Reset
New start of the microprocessor
Resolver/digital converter
Conversion of the analog resolver signals into
digital information
Reversing mode
Operation with a periodic change of direction
Ring core
Ferrite rings for interference suppression
ROD-interface
Incremental position output
Servo amplifier
Control device for regulating the speed, torque
and position of a servomotor
Setpoint ramps
Limits for the rate of change of the speed setpoint
Short-circuit
here: electrically conductive connection between
two phases
Speed controller
Regulates the difference between the speed
setpoint and the actual value to 0
Output : current setpoint
SSI-interface
Cyclically absolute, serial position output
Supply filter
Device to divert interference on the power supply
cables to PET
Tachometer voltage
Voltage proportional to the actual speed
Thermostat (contact)
Temperature-sensitive switch built into the
motor winding
Tn, I-integration time
Integral component of a control loop
Zero pulse
Output once per turn from incremental encoders,
used to zero the machine
R
S
Z
SERVOSTAR ® 300 Product Manual
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Appendix
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09/2006
11.2
Order codes
11.2.1
Servo amplifier, expansion cards
Article
SERVOSTAR 303
SERVOSTAR 306
SERVOSTAR 310
SERVOSTAR 341
SERVOSTAR 343
SERVOSTAR 346
Expansion card DeviceNet
Expansion card PROFIBUS DP
Expansion card SERCOS
Expansion card I/0-14/08
Expansion card EtherCat
Expansion card SynqNet
Expansion module 2CAN
EU order code
US order code
S30361-NA*
S30661-NA*
S31061-NA*
S30101-NA*
S30301-NA*
S30601-NA*
DE-103571
OPT-DN
DE-106712
OPT-PB3
DE-90879
OPT-SE
DE-90057
OPT-EI
DE-108350
OPT-EC
DE-200073
OPT-SN
DE-101174
not available
*= NA means without built-in expansion card
11.2.2
Mating connectors
Article
Mating connector X3
Mating connector X4
Mating connector X0 (115/230V)
Mating connector X8 (115/230V)
Mating connector X9 (115/230V)
Mating connector X0 (230/400/480V)
Mating connector X8 (230/400/480V)
Mating connector X9 (230/400/480V)
11.2.3
EU order code
DE-107554
DE-107555
DE-105856
DE-107556
DE-107631
DE-107557
DE-107558
DE-107467
US order code
CON-S3X3
CON-S3X4
CON-S3X0L
CON-S3X8L
CON-S3X9L
CON-S3X0H
CON-S3X8H
CON-S3X9H
EU order code
DE-107485
DE-107486
DE-107487
DE-107488
DE-107489
DE-107491
DE-107492
DE-107493
DE-107494
DE-107495
DE-107473
DE-107474
DE-107475
DE-107476
DE-107477
DE-107479
DE-107480
DE-107481
DE-107482
DE-107483
US order code
Motor cables with connectors
Article
Motor cable (230V) 5m (4x1)
Motor cable (230V) 10m (4x1)
Motor cable (230V) 15m (4x1)
Motor cable (230V) 20m (4x1)
Motor cable (230V) 25m (4x1)
Motor cable (230V) 5m (4x1+(2x0,75))
Motor cable (230V) 10m (4x1+(2x0,75))
Motor cable (230V) 15m (4x1+(2x0,75))
Motor cable (230V) 20m (4x1+(2x0,75))
Motor cable (230V) 25m (4x1+(2x0,75))
Motor cable (400V) 5m (4x1)
Motor cable (400V) 10m (4x1)
Motor cable (400V) 15m (4x1)
Motor cable (400V) 20m (4x1)
Motor cable (400V) 25m (4x1)
Motor cable (400V) 5m (4x1+(2x0,75))
Motor cable (400V) 10m (4x1+(2x0,75))
Motor cable (400V) 15m (4x1+(2x0,75))
Motor cable (400V) 20m (4x1+(2x0,75))
Motor cable (400V) 25m (4x1+(2x0,75))
Refer to information
in the US brochure, to
the Danaher Motion
Website or ask our
sales representative.
other lengths on request, up to 50m in Europe and up to 39m in USA
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11.2.4
Appendix
09/2006
Feedback cables with connectors
Article
Resolver cable 5m
Resolver cable 10m
Resolver cable 15m
Resolver cable 20m
Resolver cable 25m
Encoder cable 5m
Encoder cable 10m
Encoder cable 15m
Encoder cable 20m
Encoder cable 25m
Comcoder cable 5m
Comcoder cable 10m
Comcoder cable 15m
Comcoder cable 20m
Comcoder cable 25m
(4x(2x0.25))
(4x(2x0.25))
(4x(2x0.25))
(4x(2x0.25))
(4x(2x0.25))
(7x(2x0.25))
(7x(2x0.25))
(7x(2x0.25))
(7x(2x0.25))
(7x(2x0.25))
(8x(2x0.25))
(8x(2x0.25))
(8x(2x0.25))
(8x(2x0.25))
(8x(2x0.25))
EU order code
DE-84972
DE-84973
DE-84974
DE-84975
DE-87655
DE-90287
DE-91019
DE-91811
DE-91807
DE-92205
DE-107915
DE-107916
DE-107917
DE-107918
DE-107919
US order code
Refer to information
in the US brochure, to
the Danaher Motion
Website or ask our
sales representative.
other lengths on request, up to 50m in Europe and up to 39m in USA
11.2.5
Power supplies
Article
Power supply 24V/05A
Power supply 24V/20A
11.2.6
US order code
not available
not available
EU order code
DE-107161
DE-107162
DE-107163
DE-107164
DE-107165
DE-107166
US order code
BAR-300-66
BAR-600-66
BAR-1000-66
BAR-300-91
BAR-600-91
BAR-1000-91
EU order code
DE-107929
DE-107930
DE-107931
DE-107932
US order code
3YLN-06
3YLN-10
3YLN-14
3YLN-20
Regen resistors
Article
Regen resistor BAR(U) 300-66
Regen resistor BAR(U) 600-66
Regen resistor BAR(U)1000-66
Regen resistor BAR(U) 300-91
Regen resistor BAR(U) 600-91
Regen resistor BAR(U)1000-91
11.2.7
EU order code
DE-83034
DE-81279
Motor chokes
Article
Motor choke 3YLN06
Motor choke 3YLN10
Motor choke 3YLN14
Motor choke 3YLN20
SERVOSTAR ® 300 Product Manual
107
Appendix
11.3
09/2006
Index
!
24V aux. supply, interface . . . . . . . . 40
A
K
ACURO (BISS), interface . . . . . . . . 46
AGND . . . . . . . . . . . . . . . . . . 24
ambient temperature . . . . . . . . . . . 22
AS ENABLE . . . . . . . . . . . . . . . 50
assembly . . . . . . . . . . . . . . . . . 29
baud rate . . . . . . . . . . . . . . . . . 77
block diagram (overview). . . . . . . . . 36
brake, see also motor-holding brake . . . 23
BTB/RTO. . . . . . . . . . . . . . . . . 51
CAN-bus cable . . . . . . . . . . . . . . 59
CANopen interface . . . . . . . . . . . . 59
CE conformance . . . . . . . . . . . . . 12
ComCoder, interface . . . . . . . . . . . 43
conductor cross-sections. . . . . . . . . 22
connection diagram . . . . . . . . . . . 38
connection technology . . . . . . . . . . 34
connector assignments. . . . . . . . . . 37
DC bus link, interface . . . . . . . . . . 40
DeviceNet bus cable . . . . . . . . . . . 94
DGND . . . . . . . . . . . . . . . . . . 24
disposal . . . . . . . . . . . . . . . . . 13
EMC . . . . . . . . . . . . . . . . . . . 31
emergency stop strategies . . . . . . . . 27
ENABLE . . . . . . . . . . . . . . . . . 50
enclosure protection . . . . . . . . . . . 22
encoder emulation . . . . . . . . . . . . 52
encoder EnDat, interface. . . . . . . . . 45
encoder Hiperface, interface . . . . . . . 45
encoder, master-slave interface . . . . . 54
error messages . . . . . . . . . . . . . 80
expansion card
-2CAN- . . . . . . . . . . . . . . . . 98
-DeviceNet-. . . . . . . . . . . . . . 92
-EtherCat- . . . . . . . . . . . . . . 95
guide to installation . . . . . . . . . . 85
-I/O-14/08- . . . . . . . . . . . . . . 86
-PROFIBUS- . . . . . . . . . . . . . 89
-SERCOS- . . . . . . . . . . . . . . 90
-SynqNet-. . . . . . . . . . . . . . . 96
external fusing . . . . . . . . . . . . . . 21
Feedback. . . . . . . . . . . . . . . . . 42
forming . . . . . . . . . . . . . . . . . . 65
glossary . . . . . . . . . . . . . . . . . 104
ground symbol . . . . . . . . . . . . . . 33
grounding
connection diagram . . . . . . . . . 38
installation . . . . . . . . . . . . . . 32
Hall, interface . . . . . . . . . . . . . . 44
hardware requirements. . . . . . . . . . 67
humidity
in operation . . . . . . . . . . . . . . 22
storage . . . . . . . . . . . . . . . . 13
incremental encoder, interface . . . . . . 47
inputs
analog . . . . . . . . . . . . . . . . 49
digital . . . . . . . . . . . . . . . . . 50
installation
electrical . . . . . . . . . . . . . . . 31
expansion cards . . . . . . . . . . . 85
mechanical . . . . . . . . . . . . . . 28
software . . . . . . . . . . . . . . . 67
keypad operation. . . . . . . . . . . . . 77
L
LED display . . . . . . . . . . . . . . . 77
B
C
D
E
F
G
H
I
108
Kollmorgen
M
N
O
P
Q
R
S
T
U
V
W
maintenance . . . . . . . . . . . . . . . 13
master-slave . . . . . . . . . . . . . . . 54
motor choke. . . . . . . . . . . . . . . 103
motor interface . . . . . . . . . . . . . . 41
mounting position . . . . . . . . . . . . 22
nameplate . . . . . . . . . . . . . . . . 14
optical power . . . . . . . . . . . . . . . 91
order codes . . . . . . . . . . . . . . . 106
other operating systems . . . . . . . . . 67
outputs
BTB/RTO . . . . . . . . . . . . . . . 51
DIGI-OUT 1/2 . . . . . . . . . . . . 51
package supplied . . . . . . . . . . . . 14
packaging . . . . . . . . . . . . . . . . 13
PC cable . . . . . . . . . . . . . . . . . 58
PC connection . . . . . . . . . . . . . . 58
pollution level. . . . . . . . . . . . . . . 22
power supply 24V
05A . . . . . . . . . . . . . . . . . 100
20A . . . . . . . . . . . . . . . . . 101
pulse-direction, interface . . . . . . . . . 56
quickstart . . . . . . . . . . . . . . . . . 68
regen circuit . . . . . . . . . . . . . . . 24
regen resistor
dimensions . . . . . . . . . . . . . 102
interface, ext. . . . . . . . . . . . . . 41
technical data. . . . . . . . . . . . . 24
resolver, interface . . . . . . . . . . . . 42
restart lock -AS- . . . . . . . . . . . . . 60
ROD, interface . . . . . . . . . . . . . . 52
RS232/PC, interface . . . . . . . . . . . 58
safety instructions . . . . . . . . . . . . . 9
setup . . . . . . . . . . . . . . . . . . . 65
shielding
connection diagram, . . . . . . . . . 38
installation . . . . . . . . . . . . . . 32
sine-cosine encoder, interface . . . . . . 48
site . . . . . . . . . . . . . . . . . . . . 28
site altitude . . . . . . . . . . . . . . . . 22
SSI, interface. . . . . . . . . . . . . . . 53
stacking height . . . . . . . . . . . . . . 13
standards. . . . . . . . . . . . . . . . . 11
station address, CAN-bus . . . . . . . . 77
storage . . . . . . . . . . . . . . . . . . 13
storage duration . . . . . . . . . . . . . 13
storage temperature . . . . . . . . . . . 13
supply connection, interface . . . . . . . 39
supply networks . . . . . . . . . . . . . 17
supply voltage . . . . . . . . . . . . . . 22
switch-on/switch-off behavior. . . . . . . 26
system components, overview . . . . . . 18
technical data . . . . . . . . . . . . . . 19
tightening torques, connectors . . . . . . 21
transmission speed . . . . . . . . . . . 93
transport . . . . . . . . . . . . . . . . . 13
use as directed
servo amplifiers. . . . . . . . . . . . 10
setup software . . . . . . . . . . . . 66
ventilation
installation . . . . . . . . . . . . . . 28
technical data. . . . . . . . . . . . . 22
warning messages . . . . . . . . . . . . 81
wiring. . . . . . . . . . . . . . . . . . . 32
SERVOSTAR ® 300 Product Manual
Kollmorgen
09/2006
Appendix
This page has been deliberately left blank.
SERVOSTAR ® 300 Product Manual
109
Sales and Service
We are committed to quality customer service. In order to serve in the most effective way,
please contact your local sales representative for assistance.
If you are unaware of your local sales representative, please contact us.
Europe
Danaher Motion Customer Support Europa
Internet
E-Mail
Phone:
Fax:
www.DanaherMotion.net
support@danahermotion.net
+49(0)203 - 99 79 - 0
+49(0)203 - 99 79 - 155
North America
Danaher Motion Customer Support North America
Internet
www.DanaherMotion.com
E-Mail
DMAC@danahermotion.com
Phone:
+1 - 540 - 633 - 3400
Fax:
+1 - 540 - 639 - 4162