Kollmorgen S600 Servo Drive S640_S670 Instruction Manual EN

Kollmorgen S600 Servo Drive S640_S670 Instruction Manual EN
SERVOSTAR 640...670
Digital Servo Amplifier S600
Instructions Manual
Edition 07/2016
Translation of the original manual.
Valid for Hardware Revision 02.20
Keep all manuals as a product component
during the life span of the product.
Pass all manuals to future users / owners
of the product.
File sr640_e.***
Previous versions :
Edition
07/1999
11/1999
12/1999
10/2000
05/2001
01/2002
06/2002
02/2006
09/2006
04/2007
07/2007
06/2008
08/2008
07/2010
12/2010
12/2014
02/2015
12/2015
07/2016
Remarks
First edition
technical data, encoder connection diagram
encoder cable length
Dimensions mains filter, setup software on CD-ROM only, wiring diagrams electr. gearing, warning and error
messages, recommended torque, various corrections
some UL/cUL related hints
-Options -I/O-14/08- and -2CAN - incorporated, hardware-description incorporated for PROFIBUS and SERCOS, nameplate, motor list and connector assignment corrected, LED-display corrected, error messages
expanded, Regen resistor BAR replaced by BAS type
Front page new design, corrections to US english, motor table removed, order numbers added,
last page new design and contents, new: connection to diff. mains supply networks, block diagram to ch.III
Chapter 1 updated, motor choke added, DeviceNet, SynqNet and EtherCAT expansion cards added, chapter 6 restructured, order codes restructured, feedback section updated, cross section (awg)
Hardware Revision, disposal acc. to WEEE-2002/96/EG, new structure, new cover pages, Quickstart integrated, warnings updated
Part number scheme new, shock-hazard protection new, servo system graphics / different mains supply networks expanded&removed, feedback expanded, enc. emulation, switch-on and switch-off behavior expanded, AS expanded, accessories removed, DC Bus link expanded
Timing diagramm motor brake, example cat.3 EN954-1
Repair, deinstallation, syntax: "regen" => "brake", EMC standards, Hiperface, CE declaration
SCCR->42kA
Logo, notes holding brake, HWR 2.10, GOST-R, repair, disposal
Company name and address, name plat, CE certificate, fax form
Option -AS- according to EN954-1 (not functional safe any more), Certificates removed, HWR, export classification
Several corrections, AS note added to use as directed, chapter fuses updated, UL/cUL margings in EN+FR
Fax form removed, safe to touch voltage 60V->50V, LVD 2014-35-EG, EMCD 2014-30-EG
Chapter Handling extended, warning notes updated, Emergency-Off/Stop updated
Hardware Revision (HR)
Hardware Rev.
02.06
02.10
02.20
02.20
Firmware Rev.
>= 5.99
>=6.68
>=7.76
>=6.86
>= 9.00_ND1
>= 8.50_ND1
>= 9.00_ND0
>= 8.50_ND0
Export Classification
AL-3A225
AL-3A225
AL-3A225
AL-3A225
AL-3A225
AL-3A225
-
Remarks
Standard
with BiSS support
CAN Controller neu, Standard
CAN Controller new, BiSS/EtherCAT Support
New data structure, Standard
New data structure, BiSS/EtherCAT Support
New data structure, Standard
New data structure, BiSS/EtherCAT Support
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
EtherCAT is a registered trademark and patented technology, licensed by Beckhoff Automation GmbH.
sercos® is a registered trademark of sercos® international e.V
Technical changes which improve the performance of the equipment may be made without prior notice !
All rights reserved. No part of this work may be reproduced in any form (by photocopying, microfilm or any other method)
or stored, processed, copied or distributed by electronic means without the written permission of Kollmorgen Europe
GmbH.
Kollmorgen
07/2016
Contents
Page
1
General
1.1
1.2
1.3
1.4
1.5
2
About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hints for the online edition (PDF format) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standards used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abbreviations used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
7
8
9
Safety
2.1
2.2
2.3
2.4
3
You should pay attention to this . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prohibited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning notes placed on the product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
12
13
13
Handling
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
4
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decommissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassemble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
14
14
15
15
15
16
16
Approvals
4.1
4.2
4.3
5
UL and cUL- Conformance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
EC - conformance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
European directives and standards for the machine builder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Package
5.1
5.2
5.3
6
Package supplied. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Part number scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Technical description
6.1
6.2
The digital servo amplifiers of the series SERVOSTAR 640/670 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1
Recommended torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.2
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.3
Ambient conditions, ventilation, mounting position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.4
Conductor cross-sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3
LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4
Grounding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5
Control for motor holding brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6
Electrical brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7
Switch-on and switch-off behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.1
Behavior in standard operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7.2
Behavior in the event of an error (with standard setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8
Stop/Emergency Stop Function to EN 60204. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8.1
Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8.2
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8.3
Emergency Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9
Shock-hazard protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9.1
Leakage current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9.2
Residual-current circuit breakers (FI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9.3
Isolating transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
21
23
24
24
24
25
25
25
26
27
28
29
30
31
31
32
32
33
33
33
33
Mechanical Installation
7.1
7.2
7.3
7.4
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guide to mechanical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVOSTAR 640/670 Instructions Manual
34
34
35
36
3
Contents
07/2016
Kollmorgen
Page
8
Electrical Installation
8.1
8.2
8.3
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guide to electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.1
Technical data for cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.2
Shielding connection to the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4
Components of a servo system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6
Pin assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7
Connection diagram (overview) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8.1
Connection to various mains supply networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8.2
Mains supply connection (X0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8.3
24V auxiliary supply (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9
DC bus link (X0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9.1
External brake resistor (X0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.9.2
Capacitor Module KCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.10 Motor connection with brake (X0, X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.1
Resolver (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.2
Sine encoder with BISS (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.3
Sine Encoder with EnDat 2.1 or HIPERFACE (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.4
Sine Encoder without data channel (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.5
Incremental or sine encoder with hall sensors (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.6
ComCoder (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.11.7
Incremental Encoder (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12 Electronic Gearing, Master-slave operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.1
Connection to a SERVOSTAR master, 5 V signal level (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.2
Connection to incremental encoder master with 24 V signal level (X3) . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.3
Connection to a sine-cosine encoder master (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.4
Connection to a SSI encoder (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.5
Connection to stepper-motor controllers (step and direction). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.5.1 Step/Direction with 5 V signal level (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.12.5.2 Step/Direction with 24 V signal level (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.13 Encoder emulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.13.1
Incremental encoder output - A quad B (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.13.2
SSI output (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.14 Digital and analog inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.14.1
Analog inputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.14.2
Analog outputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.14.3
Digital inputs (X3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.14.4
Digital outputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.15 RS232 interface, PC connection (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.16 CANopen interface (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17 Restart lock -AS- according to EN 954-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.1
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.2
Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.3
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.4
Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.5
Signal diagram (sequence) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.6
Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.7
Connection diagram (principle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.8
Application example category 1 according to EN 954-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.8.1 Control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.8.2 Mains supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.9
Application example category 3 according to EN 954-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.9.1 Control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.9.2 Mains supply circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.17.9.3 Flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
37
38
39
40
40
41
42
43
44
45
45
46
46
46
47
47
49
50
51
52
53
54
55
56
57
58
59
59
60
61
61
62
62
63
63
64
65
65
66
67
68
69
70
71
71
72
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73
73
74
74
75
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SERVOSTAR 640/670 Instructions Manual
Kollmorgen
07/2016
Contents
Page
9
Setup
9.1
9.2
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.1.1
Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.1.2
Software description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.1.3
Hardware requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.1.4
Operating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.2
Installation under WINDOWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3
Quickstart Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.1
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.2
Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.3
Important Screen Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.4
Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.5
Motor (synchronous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.6
Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.7
Save Parameters and Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.8
Jogging the Motor (Speed Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.9
Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.10
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.11
Additional Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4
Multi-axis system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.1
Node address for CAN-bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.2
Baud rate for CAN-bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.3
Example of connections for a multi-axis system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5
Key operation / LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.1
Key operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.2
Status display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.3
Standard menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.4
Extended menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6
Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7
Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8
Removing faults / warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
78
79
79
79
79
80
80
80
81
81
83
84
85
86
87
88
89
90
90
90
91
91
91
92
93
93
93
94
94
95
96
97
Expansion Cards
10.1 Guide to installation of expansion cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.2 Expansion card -I/O-14/08- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.2.1
Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.2.2
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.2.3
Light emitting diodes (LEDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.2.4
Select motion task number (sample) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.2.5
Connector assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10.2.6
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10.3 Expansion cards -PROFIBUS- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.3.1
Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.3.2
Connection technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.3.3
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.4 Expansion card -SERCOS- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.4.1
Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.4.2
Light emitting diodes (LEDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.4.3
Connection technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.4.4
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10.4.5
Modifying the station address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10.4.6
Modifying the baud rate and optical power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10.5 Expansion card -DEVICENET-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.5.1
Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.5.2
Connection technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.5.3
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.5.4
Combined module/network status-LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.5.5
Setting the station address (device address) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.5.6
Setting the transmission speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.5.7
Bus cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
SERVOSTAR 640/670 Instructions Manual
5
Contents
07/2016
Kollmorgen
Page
10.6 Expansion card -ETHERCAT- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.6.1
Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.6.2
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.6.3
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7 Expansion card -SYNQNET- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.1
Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.2
NODE ID Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.3
Node LED table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.4
SynqNet Connection, Connector X21B/C (RJ-45) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.5
Digital inputs/outputs, connector X21A (SubD 15-pin, socket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.6
Connection diagram digital inputs/outputs, connector X21A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.8 Expansion module -2CAN-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.8.1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.8.2
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.8.3
Connection technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.8.4
Connector assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.8.5
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Appendix
11.1 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2 Order codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.1
Servo amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.2
Expansion cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.3
Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
108
108
108
108
109
109
109
109
109
110
110
111
111
111
111
112
112
113
115
115
115
115
117
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
07/2016
1
General
1.1
About this manual
General
This manual describes the digital servo amplifiers of the SERVOSTAR 640/670 series
(standard version).
A more detailed description of the expansion cards which are currently available and the
digital connection to automation systems can be found on the accompanying CD-ROM in
Acrobat-Reader format (system requirements: WINDOWS with Internet browser, Acrobat
Reader) in several language versions. Technical data and dimensional drawings of
accessories such as cables, brake resistors, mains supplies, etc., can be found in the
accessories manual.
More background information can be found in the "Product WIKI", please check
www.wiki-kollmorgen.eu.
1.2
Hints for the online edition (PDF format)
Bookmark:
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
Symbol
DANGER
Indication
Indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation which, if not avoided, could result
WARNING in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury.
This is not a safety symbol. Indicates situations which, if not
avoided, could result in property damage.
This is not a safety symbol. This symbol indicates important
notes.
Warning of a danger (general). The type of danger is specified by
the warning text next to it.
Warning of danger from electricity and its effects.
Warning of danger from hot surfaces.
Warning of danger from suspended loads.
Warning of danger from automatic start.
SERVOSTAR 640/670 Instructions Manual
7
General
1.4
07/2016
Standards used
Standard
ISO 4762
ISO 12100
ISO 13849
IEC 60085
IEC 60204
IEC 60364
IEC 60439
IEC 60664
IEC 60721
IEC 61000
IEC 61131
IEC 61491
IEC 61508
IEC 61800
IEC 62061
IEC 82079
UL 840
UL 508C
IEC
ISO
UL
8
Kollmorgen
Content
Hexagon socket head cap screws
Safety of machinery: Basic concepts, general principles for design
Safety of machinery: Safety-related parts of control systems
(former EN 954)
Electrical insulation - Thermal evaluation and designation Maintenance
Safety of Machinery: Electrical equipment of machinery
Low-voltage electrical installations
Low-Voltage Switchgear and Controlgear Assemblies
Insulation coordination for equipment within low-voltage systems
Classification of environmental conditions
Electromagnetic compatibility (EMC)
Programmable controllers
Electrical equipment of industrial machines – Serial data link for real-time
communications between controls and drives.
Functional safety of electrical/electronic/programmable electronic
safety-related systems
Adjustable speed electrical power drive systems
Functional safety of electrical/electronic/programmable electronic
safety-related systems
Preparation of instructions - Structuring, content and presentation
UL Standard for Safety for Insulation Coordination Including Clearances
and Creepage Distances for Electrical Equipment
UL Standard for Safety Power Conversion Equipment
International Electrotechnical Commission
International Organization for Standardization
Underwriters Laboratories
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
1.5
07/2016
General
Abbreviations used
The abbreviations used in this manual are explained in the table below.
Abbreviation
Meaning
AGND
Analog ground
AS
Restart Lock, option
BTB/RTO
Ready to operate
CAN
Fieldbus (CANopen)
CE
Communité Européenne (EC)
CLK
Clock signal
COM
Serial interface for a PC-AT
DGND
Digital ground
DIN
German Institute for industrial Standards
Disk
Magnetic storage (diskette, hard disk)
EEPROM
Electrically erasable programmable memory
EMC
Electromagnetic compatibility
EMI
Electromagnetic interference
EN
European standard
ESD
Electrostatic discharge
F-SMA
Fiber Optic Cable connector according to IEC 60874-2
IEC
International Electrotechnical Commission
IGBT
Insulated Gate Bipolar Transistor
INC
Incremental Interface
ISO
International Standardization Organization
LED
Light-emitting diode
MB
Megabyte
NI
Zero pulse
NSTOP
Limit-switch input for CCW rotation (left)
PELV
Protected low voltage
PGND
Ground for the interface
PSTOP
Limit-switch input for CW rotation (right)
PWM
Pulse-width modulation
RAM
Volatile memory
RB
Brake resistor
RBext
External brake resistor
RBint
Internal brake resistor
RES
Resolver
ROD
A quad B encoder, incremental encoder
PLC
Programmable logic controller
SRAM
Static RAM
SSI
Synchronous serial interface
UL
Underwriters Laboratory
VAC
AC voltage
VDC
DC voltage
VDE
Verein deutscher Elektrotechniker
XGND
Ground for the 24V supply
SERVOSTAR 640/670 Instructions Manual
9
Safety
2
07/2016
Kollmorgen
Safety
The S600 is not intended for reacting functional safety features. The integration into a
safety function according to EN 13849 or EN 62061 is not allowed. The STO function can
be carried out only by safe disconnection of the power supply of the machine.
2.1
You should pay attention to this
Read the documentation!
Read the available documentation before installation and commissioning. Improper handling of the servo amplifiers can cause harm to people or damage to property. The operator must therefore ensure that all persons entrusted to work on the SERVOSTAR 640/670
have read and understood the manual and that the safety notices in this manual are
observed.
Perform a risk assessment!
The manufacturer of the machine must generate a risk assessment for the machine, and
take appropriate measures to ensure that unforeseen movements cannot cause injury or
damage to any person or property. Additional requirements on specialist staff may also
result from the risk assessment.
Specialist staff required!
Only properly qualified personnel are permitted to perform such tasks as transport,
assembly, setup and maintenance. Qualified specialist staff are persons who are familiar
with the transport, installation, assembly, commissioning and operation of drives and who
bring their relevant minimum qualifications to bear on their duties:
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
The qualified personnel must know and observe IEC 60364 / IEC 60664 and national
accident prevention regulations.
Check the Hardware Revision!
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. If
the numbers do not match up, visit the Tech-WIKI (http://www.wiki-kollmorgen.eu). The
'Download' section contains the various manual versions based on the hardware version
number.
Pay attention to the technical data!
Adhere to the technical data and the specifications on connection conditions (rating plate
and documentation). If permissible voltage values or current values are exceeded, the
servo amplifiers can be damaged. Unsuitable motor or wrong wiring will damage the system components. Check the combination of drive and motor. Compare the rated voltage
and current of the units.
10
SERVOSTAR 640/670 Instructions Manual
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07/2016
Safety
Observe electrostatically sensitive components!
The servo amplifiers contain electrostatically sensitive components which may be damaged by incorrect handling. Discharge your body before touching the servo amplifier.
Avoid contact with highly insulating materials (artificial fabrics, plastic film etc.). Place the
servo amplifier on a conductive surface.
Automatic restart
The drive might restart automatically after power on, voltage dip or interruption of the supply voltage, depending on the parameter setting. Risk of death or serious injury for
humans working in the machine. If the parameter AENA is set to 1, then place a warning
sign to the machine (Warning: Automatic Restart at Power On) and ensure, that power on
is not possible, while humans are in a dangerous zone of the machine. In case of using
an undervoltage protection device, you must observe EN 60204-1:2006 chapter 7.5.
Hot surface!
The surfaces of the servo amplifiers can be hot in operation. Risk of minor burns!
The surface temperature can exceed 80°C. Measure the temperature, and wait until the
motor has cooled down below 40°C before touching it.
Earthing!
It is vital that you ensure that the servo amplifiers are safely earthed to the PE (protective
earth) busbar in the switch cabinet. Risk of electric shock. Without low-resistance
earthing no personal protection can be guaranteed and there is a risk of death from electric shock.
Leakage Current!
Since the leakage current to PE is more than 3.5 mA, in compliance with IEC61800-5-1
the PE connection must either be doubled or a connecting cable with a cross-section >10
mm² must be used. Deviating measures according to regional standards might be possible.
High voltages!
The equipment produces high electric voltages up to 900V. During operation, servo
amplifiers may have uncovered live sections, according to their level of enclosure protection. Capacitors can have dangerous voltages present up to five minutes after switching
off the supply power. There is a risk of death or severe injury from touching exposed contacts. 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.
There is a danger of electrical arcing when disconnecting connectors, because capacitors
can still have dangerous voltages present after switching off the supply power. Risk of
burns and blinding. Wait at least five minutes after disconnecting the servo amplifiers
from the main supply power before touching potentially live sections of the equipment
(such as contacts) or removing any connections. Always measure the voltage in the DC
bus link and wait until the voltage is below 50 V before handling components.
SERVOSTAR 640/670 Instructions Manual
11
Safety
07/2016
Kollmorgen
Reinforced Insulation!
Thermal sensors, motor holding brakes and feedback systems built into the connected
motor must have reinforced insulation (according to IEC61800-5-1) against system components with power voltage, according to the required application test voltage. All
Kollmorgen components meet these requirements.
Never modify the servo amplifiers!
It is not allowed to modify the servo amplifiers without permission by the manufacturer.
Opening the housing causes loss of warranty and all certificates become unvalid.
Warning signs are added to the device housing. If these signs are damaged, they must
be replaced immediately.
2.2
Use as directed
l
The servo amplifiers are components which are built into electrical equipment or machines, and can only be used as integral components of such equipment.
l The manufacturer of the machine must generate a risk assessment for the machine,
and take appropriate measures to ensure that unforeseen movements cannot cause
injury or damage to any person or property.
l The SERVOSTAR 640/670 family of servo amplifiers (overvoltage category III acc. to
EN 61800-5-1) can be connected directly to symmetrically earthed(grounded)
three-phase industrial mains supply networks [TN-system, TT-system with
earthed(grounded) neutral point, not more than 42,000rms symmetrical amperes,
480VAC maximum] when protected by fuses type Fusetron FRS-R-50 for
SERVOSTAR 640 or FRS-R-80 class RK5 for SERVOSTAR 670, manufactured by
Bussman, or equivalent, 480VAC min. Connection to other mains supply networks
ð p. 45.
The use of external mains chokes and mains filters is required.
l Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo
amplifier may not exceed 1000V (peak value).
Transient overvoltages (< 50µs) between the outer conductors may not exceed
1000V.
Transient overvoltages (< 50µs) between outer conductors and housing may not exceed 2000V.
l The brake resistors have to be protected by fuses type Limitron KLM, rated for
500VAC/DC
l The SERVOSTAR 640/670 family of servo amplifiers is only intended to drive specific brushless synchronous servomotors 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 of the servo amplifier. The motor must have integral thermal protection.
l The servo amplifiers may only be operated in a closed switchgear cabinet, taking
into account the ambient conditions defined on page 24 and the dimensions shown
on page 35. Ventilation or cooling may be necessary to prevent enclosure ambient
from exceeding 45°C (113°F).
l Use copper wire only. Wire size may be determined from EN 60204 (or table 310-16
of the NEC 60°C or 75°C column for AWG size).
l SERVOSTAR 640/670 does not have any safety functionality according to
IEC 61800-5-2. The optional restart lock function -AS- cannot be compared to the
safety function STO. The described function -AS- is proofen according to EN 954-1.
This standard is not listed in the EC Machine Directive 2006/42/EG since
31.12.2012. The requirements for a restart lock according to EN 954-1 are nevertheless fulfilled
l Consider the specifications on page 72 when you use the restart lock -AS-.
12
SERVOSTAR 640/670 Instructions Manual
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2.3
07/2016
Prohibited use
l
l
l
l
2.4
Safety
Other use than described in chapter II.52.2 is not intended and can lead to damage
of persons, equipment or things.
The use of the servo amplifier in the following environments is prohibited:
- potentially explosive areas
- environments with corrosive and/or electrically conductive acids, alkaline solutions,
oils, vapours, dusts
- directly on non-grounded supply networks or on asymmetrically grounded supplies
with a voltage >230V.
- on ships or off-shore applications
Commissioning the servo amplifier is prohibited if the machine in which it was installed,
- does not meet the requirements of the EC Machinery Directive
- does not comply with the EMC Directive or with the Low Voltage Directive
- does not comply with any national directives
The control of holding brakes by the SERVOSTAR 640/670 alone may not be used in
applications, where personnel security is to be ensured with the brake.
Warning notes placed on the product
Vorsicht !
Gefährliche Spannung.
Nach dem Abschalten
5 Minuten warten!
Translation:
Warning!
Residual Voltage.
Wait 5 minutes after
removing power!
If these signs are damaged, they must be replaced immediately.
SERVOSTAR 640/670 Instructions Manual
13
Handling
07/2016
3
Handling
3.1
Transport
l
l
l
l
l
Kollmorgen
Only by qualified personnel in the manufacturer’s original recyclable packaging
Avoid shocks
Temperature
–25 to +70°C (-13...158°F), max. 20K/hr rate of change
Humidity
max. 95% relative humidity, no condensation
If the packaging is damaged, check the unit for visible damage. In this case, inform
the shipper and the manufacturer.
The servo amplifiers contain electrostatically sensitive components which can be damaged by incorrect handling. Discharge yourself before touching the servo amplifier. Avoid
contact with highly insulating materials (artificial fabrics, plastic films etc.). Place the servo
amplifier on a conductive surface.
3.2
Packaging
l
l
l
l
3.3
Storage
l
l
l
l
l
14
Cardboard box, can be recycled
Dimensions:
(HxWxD) 410x470x490 mm
Weight incl. accessories approx. ca. 25 Kg
CAUTION: Heavy weight! Lifting unassisted could result in back injury. Lift and
move boxes with lifting tools only.
Labeling : nameplate outside at the box
Storage only in the manufacturer’s original recyclable packaging
Max. stacking height
3 cartons
Storage temperature
-25 to +55°C, max. rate of change 20°C / hour
Storage humidity
5 ... 95% relative humidity, no condensation
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.
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
3.4
07/2016
Handling
Decommissioning
Only professional staff who are qualified in electrical engineering are allowed to decommission parts of the drive system.
DANGER: Lethal voltages! There is a danger of serious personal injury or death by
electrical shock or electrical arcing.
l Switch off the main switch of the switchgear cabinet.
l Secure the system against restarting.
l Block the main switch.
l Wait at least 5 minutes after disconnecting.
3.5
Maintenance and cleaning
The device does not require maintenance. Opening the device voids the warranty. The
inside of the unit can only be cleaned by the manufacturer
Do not immerse or spray the device. Avoid that liquid enters the device.
To clean the device exterior:
1. Decommission the device (see chapter 3.4).
2. Casing: Clean with isopropanol or similar cleaning solution.
CAUTION: Highly Flammable! Risk of injury by explosion and fire.
- Observe the safety notes given on the cleaning liquid package.
- Wait at least 30 minutes after cleaning before putting the device back into
operation.
3. Protective grill on fan: Clean with a dry brush.
3.6
Disassemble
Only professional staff who are qualified in electrical engineering are allowed to disassemble parts of the drive system.
1. Decommission the device (see chapter 3.4).
2. Check temperature.
CAUTION: High Temperature! Risk of minor burns.
During operation, the heat sink of the drive may reach temperatures above
80 °C (176 °F). Before touching the device, check the temperature and wait until it
has cooled below 40 °C (104 °F).
3. Remove the connectors. Disconnect the potential earth connection last.
4. Demount: loosen the fastening screws. Remove the device.
SERVOSTAR 640/670 Instructions Manual
15
Handling
3.7
07/2016
Kollmorgen
Repair
Only professional staff who are qualified in electrical engineering are allowed to exchange
parts of the drive system.
CAUTION: Automatic Start! During replacement work a combination of hazards and
multiple episodes may occur.
- Work on the electrical installation may only be performed by trained and qualified
personnel, in compliance with the regulations for safety at work, and only with
use of prescribed personal safety equipment.
Exchange of servo amplifier
Only the manufacturer can repair the device. Opening the device voids the warranty.
1. Decommission the device (see chapter 3.4).
2. Demount the device (see chapter 3.6).
3. Contact Kollmorgen and clarify the logistics. Send the device to the address given by
Kollmorgen.
4. Install a new device as described in this manual.
5. Setup the servo amplifier as described in this manual.
Exchange of other drive system parts
If parts of the drive system ( for example cables) must be replaced, proceed as follows:
1. Decommission the device (see chapter 3.4).
2. Exchange the parts.
3. Check all connections for correct fastening.
4. Setup the servo amplifier as described in this manual.
3.8
Disposal
To dispose the unit properly, contact a certified electronic scrap disposal merchant.
In accordance with the WEEE-2002/96/EC-Guidelines and similar, the manufacturer
accepts returns of old devices and accessories for professional disposal. Transport costs
are the responsibility of the sender.
Decommission the device as described in chapter 3.4 and demount the device as
described in chapter 3.6.
Contact Kollmorgen and clarify the logistics. Send the device to the address given by
Kollmorgen.
16
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
4
Approvals
07/2016
Approvals
Certificates can be found in our Product WIKI on page Approvals.
4.1
UL and cUL- Conformance
This servo amplifier is listed under UL file number E217428.
UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfill the relevant U.S.
and Canadian standard (in this case UL 840 and UL 508C).
This standard describes the fulfillment 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 check-ups.
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 fulfillment 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 fulfillment by design of air and insulation creepage spacings for electrical equipment and printed circuit boards.
Markings
Marquages
l
Use 60°C or 75°C copper wire only.
l
Utilisez un fil en cuivre 60°C ou 75 °C min..
l
Use Class 1 wire only.
l
Utilisez seulement un fil de classe 1.
l
Tightening torque for field wiring terminals. l
X0: 6 to 8 Nm (53.10 to 70.81 lbf in).
l
Use in a pollution degree 2 environment.
l
Utilisation dans un environnement de pollution de niveau 2.
l
These devices provide solid state motor
overload protection at 130% of full load
current.
l
Ces variateurs offrent une protection contre
les surcharges de moteur à semi-conducteur à 130 % du courant FLA nominal.
l
These devices are not provided with motor l
over-temperature sensing.
Ces variateurs n’offrent pas de capteurs de
température excessive.
l
Suitable for use on a circuit capable of de- l
livering not more than 42 kA rms symmetrical amperes for a max. voltage of 480 Vac,
when protected by Class RK5 fuses.
Integral solid state short circuit protection l
does not provide branch circuit protection.
Branch circuit protection must be provided
in accordance with the National Electrical
Code and any additional local codes.
Ce produit est conçu pour une utilisation sur
un circuit capable de fournir 42 kA
symétriques (rms) maximum pour 480V,
lorsqu’il est protégé par classe RK5 fusibles
Une protection de court-circuit à
semi-conducteur intégrale ne fournit pas de
protection de la dérivation. Il convient de
garantir une protection de la dérivation
conforme au NEC (National Electrical Code)
et aux réglementations locales en vigueur,
ou aux directives équivalentes applicables.
Fusibles externes de circuit de dérivation:
Classe RK5, 50A, 480V min (S6400) ou
Classe RK5, 80A, 480V min (S6700)
l
l
Rating of external Branch Circuit Fuses:
Class RK5, 50A, 480V min (S6400) or
Class RK5, 80A, 480V min (S6700)
SERVOSTAR 640/670 Instructions Manual
l
Couples de serrage recommandée
X0: 6 to 8 Nm (53.10 to 70.81 lbf in).
17
Approvals
4.2
07/2016
Kollmorgen
EC - conformance
The servo amplifiers have been tested 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.
Kollmorgen declares the conformity of the products SERVOSTAR 640 (S640) and
SERVOSTAR 670 (S670) with the following directives
(2014/30/EC)
l EC EMC Directive
l
EC Low Voltage Directive
(2014/35/EC)
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 £ 25m). With a motor cable
length from 25m onwards, the servo amplifier meets the requirement to the category C3.
This product can cause high-frequency interferences in non industrial environments
which can require measures for interference suppression.
4.3
European directives and standards for the machine builder
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
(2006/42/EG)
l EC Machinery Directive
(2014/30/EC)
l EC EMC Directive
(2014/35/EC)
l EC Low Voltage Directive
Standards to be applied for conformance with the EC Machinery Directive (2006/42/EG)
EN 60204-1 (Safety and Electrical Equipment in Machines)
EN 12100 (Safety of Machines)
The manufacturer of the machine must generate a risk assessment for the machine, and
take appropriate measures to ensure that unforeseen movements cannot cause injury or
damage to any person or property.
The machine/plant manufacturer must check whether other standards or EC Directives
must be applied to the machine/plant.
Standards to be applied for conformance with the EC Low Voltage Directive(2014/35/EC)
EN 60204-1 (Safety and Electrical Equipment in Machines)
EN 60439-1 (Low Voltage Switchgear Combinations)
Standards to be applied for conformance with the EC EMC Directive (2014/30/EC)
EN 61000-6-1 / 2 (Interference Immunity in Residential & Industrial Areas)
EN 61000-6-3 / 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.
We only guarantee the conformance of the servo system with the standards cited in this
chapter if the components (motor, cables, chokes etc.) are those supplied by us.
18
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
Package
07/2016
5
Package
5.1
Package supplied
When you order a SERVOSTAR 640/670 series amplifier (order codes ð p.115), you will
receive:
—
—
SERVOSTAR 640/670
mating connectors X3, X4
The mating SubD connectors are not part of the package!
—
—
—
Assembly and Installation Instructions (product manual)
Online documentation on CD-ROM
Setup software DRIVE.EXE on CD-ROM
Accessories: (must be ordered separately; description see accessories manual)
—
—
—
—
—
—
—
—
—
5.2
Mains filter 3EF required
Mains choke 3L required
AC Servomotor (linear or rotary)
motor cable as a cut-off length
brake cable as a cut-off length
feedback cable (pre-assembled) or
both feedback connectors separately, with feedback cable as length
external brake resistor BAS, usually required
communications cable to the PC (ð p.69) or Y-adapter (ð p.91) for parameter
setting of up to 6 servo amplifiers from one PC
power cable, control cables, fieldbus cables (as lengths)
Nameplate
The nameplate depicted below is attached to the side of the servo amplifier.
The information described0 below is printed in the individual fields.
Servo amplifier type
Kollmorgen Europe GmbH
Pempelfurtstraße 1
D-40880 Ratingen
www.kollmorgen.com
Serial number
Comments
Customer Support
Europe
Tel. +49 (0)2102 / 93940
Italy
Tel. +39 (0)362 / 594260
North America Tel. +1 540 633 3545
Typenbezeichnung
Model Number Ser. Nr
Spannungsversorgung
Power Supply Nennstrom
E217428 C
UL
®
US
LISTED
IND. CONT. EQ.
1VD4
Ser. No. Bemerkung
Nom. Current Schutzart
Umgebungstemp.
Ambient temp.
Comment
Encl.Rating
Hardware
Revision
Made in
Austria
example
example
max. ambient
temperature
Enclosure Rating
Electrical supply
Installed load
SERVOSTAR 640/670 Instructions Manual
Output current
in S1 operation
Hardware Revision
19
Package
5.3
Kollmorgen
07/2016
Part number scheme
S 6 4 0 0 1 - S E*
Family
S6
S600
Expansions
NA no expansion
DN DeviceNet
PB PROFIBUS
SE SERCOS
SN SynqNet
EC ETHERCAT
IO
I/O-Expansion
Current rating
40
40A rms
70
70A rms
Voltage rating
0
230...480V
electr. option
1
AS
* additional coding defines customer specific specials.
Comparison (without expansion) device name -> part number
Device Name
SERVOSTAR 640
SERVOSTAR 670
20
Part Number
S64001-NA
S67001-NA
SERVOSTAR 640/670 Instructions Manual
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07/2016
Technical description
6
Technical description
6.1
The digital servo amplifiers of the series SERVOSTAR 640/670
Standard version
l 2 current ratings (40 A, 70 A)
+10%
)
l Wide range of rated voltage (3x208V –10% to 3x480V
l Overvoltage category III acc. to EN 61800-5-1
l Shield connection directly at the servo amplifier
l Integrated CANopen (default 500 kBaud), for integration into CANbus systems and
for setting parameters for several amplifiers via the PC-interface of one amplifier
l Integrated RS232, electrically isolated, integrated pulse-direction interface
built-in safety relay (personnel-safety starting lock-out), (ð p.71)
l -ASl Slot for an expansion card
l Synchronous servomotors, linear motors and asynchronous motors can be used
Power supply
l With external mains filter and mains choke directly off grounded 3~ system,
230V-10% ... 480V+10%, 50 Hz,
208V-10% ... 480V+10%, 60 Hz,
208...480V
60Hz
230...480V
50Hz
TN-system, TT-system with earthed (grounded) neutral point, not more than 42,000
rms symmetrical amperes, 480VAC maximum; when protected by fuses type
Fusetron FRS-R-80 (Class RK5), manufactured by Bussman, or equivalent 480VAC
min
Connection to other mains supply networks only with insulating transformer ð p. 45
l BB6 rectifier bridge, off 3-phase earthed (grounded) supply, integral inrush circuit
l Fusing (e.g. fusible cutout) provided by the user
l All shielding connections directly on the amplifier
l Output stage: IGBT- module with isolated current measurement
l Brake circuit: with dynamic distribution of the brake power between several
amplifiers on the same DC bus link circuit, external brake resistor
l DC bus link voltage 260 ... 900 VDC, can be switched in parallel
l Interference suppression filter for the 24V aux. supply (to category C2) is integrated
External interference suppression filter for the supply input (to category C2) required.
External mains choke required.
Integrated safety
l Safe electrical separation between the power input / motor connections and the signal electronics, provided by appropriate insulation/creepage distances and complete
electrical isolation
l Soft-start, overvoltage recognition, short-circuit protection, phase-failure monitoring
l Temperature monitoring of servo amplifier and motor
(when using our motors with our pre-assembled cables)
Auxiliary supply voltage 24VDC
l Electrically isolated, internal fusing, from an external 24VDC psu, e.g. with isolating
transformer
SERVOSTAR 640/670 Instructions Manual
21
Technical description
07/2016
Kollmorgen
Operation and parameter setting
l With our user-friendly software for setup through the serial interface of a PC
l Direct operation by means of two keys on the servo amplifier and a 3-character LED
display for status display in case of no PC available
l Fully programmable via RS232 interface
Completely digital control
l Digital current controller (space vector pulse-width modulation, 62.5 µs)
l Freely programmable digital speed controller (62.5 µs or 250 µs)
l Integral position controller with adaptation possibilities for customer needs (250 µs)
l Pulse direction interface integrated for connection of a servomotor to a stepping
motor control
l Evaluation of the resolver signals and sine-cosine signals of a high-resolution
encoder
l Encoder simulation (incremental or SSI)
Comfort functions
l 2 analog monitor outputs
l 4 programmable digital inputs (normally, two are defined as limit-switch inputs)
l 2 programmable digital outputs
l Freely programmable combinations of all digital signals
Expansions
l -I/O-14/08- expansion card, ð p. 99
l PROFIBUS DP expansion card, ð p. 102
l SERCOS expansion card, ð p. 103
l DeviceNet expansion card, ð S. 105
l EtherCAT expansion card, ð S. 108
l SynqNet expansion card, ð S. 109
l -2CAN- Expansion module, separated connectors for CAN bus and RS232 ð p. 111
l Third party expansion cards (ModBus, FireWire, LightBus etc. - contact distributors
for further information)
22
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
6.2
Technical description
07/2016
Technical data
Rated data
Rated-supply voltage (grounded system)
(L1,L2,L3)
Rated installed load for S1 operation
Rated DC bus link voltage
Rated output current (rms value, ± 3%)
at 230V
at 400V
at 480V
Peak output current (max. ca. 5s, ± 3%)
at 230V
at 400V
at 480V
Clock frequency of the output stage
Technical data of the brake circuit
Overvoltage protection threshold
Form factor of the output current
(at rated data and min. load inductance)
Bandwidth of subordinate current controller
Residual voltage drop at rated current
Quiescent dissipation, output stage disabled
Dissipation at rated current (incl. power
supply losses, without brake dissipation)
Inputs/Outputs
Setpoint 1/2, resolution 14bit/12bit
Common-mode voltage max.
Input resistance to AGND
Digital inputs
Digital outputs, open collector
BTB/RTO output, relay contacts
Aux. power supply, electrically isolated
without brake
Aux. power supply, electrically isolated
with brake (consider voltage loss!)
Min/max. output current, brake
Connections
Control signals
Power signals
Resolver input
Sine-cosine encoder input
PC-interface, CAN
Encoder simulation, ROD (EEO) / SSI
Thermal control, Motor
Mechanical
Weight
Height without shield sheet, w/o eyes (w. eyes)
Height with shield sheet, w/o eyes (w. eyes)
Width
Depth without connectors
Depth with connectors
SERVOSTAR 640/670 Instructions Manual
DIM
V~
V~
kVA
V=
Arms
Arms
Arms
SERVOSTAR 640 SERVOSTAR 670
3 x 230V-10% ... 480V+10%, 50 Hz
3 x 208V-10% ... 480V+10%, 60 Hz
30
50
290...675
40
40
40
85
80
70
80
80
80
160
160
140
kHz
—
V
8
ð p.27
450...900
—
1.01
kHz
V
W
> 1.2
5
40
W
400
V
V
kW
V
mA
V
mA
V
mA
V
A
V
A
A
±10
±10
20
low 0...7 / high 12...36
7
max. 30
10
DC max. 30, AC max. 42
500
24 (-0% +15%)
2 (max. 16)
24 (-0% +15%)
5 (max. 16)
0.75 / 3
—
—
—
—
—
—
—
Combicon 5,08 / 18 pole , 2,5mm²
Terminals 10mm² — 50mm²
SubD 9pole (socket)
SubD 15pole (socket)
SubD 9pole (plug)
SubD 9pole (plug)
min. 15VDC, 5mA
kg
mm
mm
mm
mm
mm
700
19.5
21
345 (375)
484 (495)
250
300
325
23
Technical description
6.2.1
Recommended torques
Connector
X3, X4
X10
X0
6.2.2
Kollmorgen
07/2016
Recommended torque
0.3 Nm (2.25 in lb)
0,3 Nm (2.25 in lb)
6...8 Nm (45... 60 in lb)
Fusing
Tips and detailed information can be found in the Product-Wiki (follow the link on
www.wiki-kollmorgen.eu) on page "Fuses".
Internal fusing
Circuit
Auxiliary supply 24V
Brake resistor
Internal fuse
4 AT
electronic
External fusing
Fusible cutouts or similar
(Fuse UL time delay)
AC supply
FN1/2/3
Brake resistor
FB1/2
*
**
6.2.3
SERVOSTAR 640
SERVOSTAR 670
50 A*
16 A**
80 A*
20 A**
EU fuses gRL or gL 400V/500V
US fuses: class RK5, 600VAC 200kA, time-delay
EU fuses: Bussmann HLS, 690V
US fuses: Bussmann FWP-xxA14F, Size 14x51mm with 800Vdc UL approval
Ambient conditions, ventilation, mounting position
ð p.14
ð p.14
Storage, hints
Transport, hints
Supply voltage tolerances
Input power (ð p.45)
208...480V
60Hz
230...480V
50Hz
Aux. power supply
Ambient temperature in operation
Humidity in operation
Site altitude
Pollution level
Vibrations
Noise emission
Enclosure protection
Mounting position
Ventilation
min 3x230V-10% AC / max 3x 480V+10%, 50 Hz
min 3x208V-10% AC / max 3x 480V+10%, 60 Hz
24 VDC (-0% +15%), check voltage drop
0 to +45oC (32 to 113 °F) at rated data
+45 to +55°C (113 to 131 °F) with power
derating 2.5% / K
rel. humidity 85%, no condensation
up to 1000m a.m.s.l. without restriction
1000...2500m a.m.s.l. with power derating
1.5%/100m
Pollution level 2 to EN 60664-1
Class 3M1 according to IEC 721-3-3
max. 45 dB(A)
IP 20 according to EN 60529
generally vertical. ð p.35
forced convection by built-in fans
Make sure that there is sufficient forced ventilation within the switchgear cabinet.
24
SERVOSTAR 640/670 Instructions Manual
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6.2.4
07/2016
Technical description
Conductor cross-sections
Observe the technical data for connection cables ð p. 40.
Following EN 60204 (for AWG: table 310-16 of the NEC 60°C or 75°C column), we recommend for single-axis systems:
25 mm² (2 awg), shielded between filter and amplifier, 600V,
AC connection
80°C (176°F)
25 mm² (2 awg), shielded for lengths > 20 cm, 600V, 80°C
DC bus link
(176°F)
ð p.40, cross section see manual of the used motor series,
Motor cables
capacitance <250pF/m, 600V, 80°C (176°F)
4x2x0.25 mm² (22awg) twisted pairs, shielded, max.100m,
Resolver, thermal control
capacitance <120pF/m
7x2x0,25 mm² (22awg) twisted pairs, shielded, max.50m,
Encoder, thermal control
capacitance <120pF/m
Setpoints, monitors,
0.25 mm² (22awg) twisted pairs, shielded
AGND
Control signals, BTB,
0.5 mm² (20 awg)
DGND
min. 1.5 mm² (14 awg), 600V, 80°C (176°F), shielded,
Holding brake (motor)
check voltage drop
+24 V / XGND
max. 2.5 mm² (12 awg), check voltage drop
Brake resistor
ð p.40, min. 10 mm² (6 awg), shielded, 1000V, 80°C (176°F)
For multi-axis systems, please note the special operating conditions in your installation
To reach the max. permitted cable length, observe cable requirements ð p. 40.
* Kollmorgen North America delivers cables up to 39m length.
* Kollmorgen Europe delivers cables up to the maximum length.
6.3
LED display
A 3-character LED display shows the amplifier status after switching on the 24V supply
(ð p.94). During operation and parameter setting of the amplifier via the keys on the front
panel, the parameter and function numbers (ð p.94) are displayed, as well as the numbers of any errors which occur (ð p.95).
6.4
Grounding system
AGND — ground for analog inputs/outputs, internal analog/µC ground
DGND — ground for digital inputs/outputs, optically isolated
XGND — ground for external 24V aux. voltage, optically and inductively isolated
PGND — ground for encoder emulation, RS232, CAN, PROFIBUS, optically isolated
The potential isolation is shown in the block diagram (ð p. 42).
SERVOSTAR 640/670 Instructions Manual
25
Technical description
6.5
Kollmorgen
07/2016
Control for motor holding brake
A 24 V / max. 3 A holding brake in the motor can be controlled directly by the servo amplifier.
CAUTION
No functional safety! Danger by falling load (in case of suspended load,
vertical axes). An additional mechanical brake is required for funktional
safety, which must be safely operated.
The brake only works with sufficient voltage level (ð p.24). Check voltage drop, measure
the voltage at brake input and check brake function (brake and no brake).
The brake function must be enabled through the BRAKE parameter (setting: WITH
BRAKE). In the diagram below you can see the time and functional relationships between
the ENABLE signal, speed setpoint, speed and braking force.
U
Analog-In
X3/4-5
t
U
ENABLE
X3/15
U
emergency stop
ramp
TBRAKE0 def. 20ms
t
SW internal
ramp
t
5
n
Speed
VEL0
U
t
max.5s
ENABLE
internal
U
t
TBRAKE def. 100ms
BRAKE
X4/1-2
t
F
Braking force
t
tbrH
tbrL
During the internal ENABLE delay time of 100 ms (DECDIS) the speed setpoint of the
servo amplifier is internally driven down a 10 ms ramp to 0. The brake output is switched
on when a speed of 5rpm is reached or after 5s (EMRGTO) the latest.
The release delay time (tbrH) and the engage delay time (tbrL) 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 49.
26
SERVOSTAR 640/670 Instructions Manual
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6.6
07/2016
Technical description
Electrical brake circuit
During braking with the aid of the motor, energy is fed back to the servo amplifier. This
energy is converted into heat in the brake resistor (ð p. 112). The brake resistor is
switched into circuit by the brake circuit. The brake circuit (thresholds) are adjusted to the
supply voltage with the help of the setup software.
Our customer service can help you with the calculation of the brake power which is
required. A simple method is described in the "Product Wiki" which is accessible at
www.wiki-kollmorgen.eu. A description of the interface can be found on page 47.
Functional description:
1.- Individual amplifiers, not coupled through the DC bus link (DC+, DC-)
The circuit starts to respond at a DC bus link voltage of 400V, 720V or 840V (depending
on the supply voltage). If the energy which is fed back from the motor, as an average over
time or as a peak value, is higher than the preset brake power, then the servo amplifier
will output the status “brake power exceeded” and the brake circuit will be switched off. At
the next internal check of the DC bus link voltage (after a few ms) an overvoltage will be
detected and the servo amplifier will be switched off with the error message “Overvoltage
F02” (ð p. 95).
The BTB/RTO contact (terminal X3/2,3) will be opened at the same time (ð p. 68).
2.- Several servo amplifiers coupled through the DC bus link circuit (DC+, DC-)
Thanks to the built-in brake circuit with its patented power distribution, several amplifiers
(even with different current ratings) can be operated off a common DC bus link. This is
achieved by an automatic adjustment of the brake thresholds (which vary, because of tolerances).
The brake energy is distributed equally among all the amplifiers. The combined power of
all the amplifiers is always available, as continuous or peak power. The switch-off takes
place as described under 1. (above) for the servo amplifier with the lowest switch-off
threshold (resulting from tolerances). The RTO (BTB) contact of this amplifier (terminals
X3/2,3) will be opened at the same time (ð p. 68).
Brake circuit: technical data
Supply
Rated data
DIM
voltage
External regen resistor
Ohm
Upper switch-on level of regen circuit
V
Switch-off level of regen circuit
V
3 x 230 V
Overvoltage F02
V
Continuous power of regen circuit (RBext) max. kW
Pulse power, external (RBext max. 1s)
kW
External regen resistor
Ohm
Upper switch-on level of regen circuit
V
Switch-off level of regen circuit
V
3 x 400 V
Overvoltage F02
V
Continuous power of regen circuit (RBext) max. kW
Pulse power, external (RBext max. 1s)
kW
External regen resistor
Ohm
Upper switch-on level of regen circuit
V
Switch-off level of regen circuit
V
3 x 480 V
Overvoltage F02
V
Continuous power of regen circuit (RBext) max. kW
Pulse power, external (RBext max. 1s)
kW
SERVOSTAR
640
670
15
10
400 - 430
380 - 410
450
6
10
16
15
10
720 - 750
680 - 710
800
6
35
50
15
10
840 - 870
800 - 830
900
6
45
70
Suitable external regen resistors can be found in our accessories manual.
SERVOSTAR 640/670 Instructions Manual
27
Technical description
6.7
07/2016
Kollmorgen
Switch-on and switch-off behavior
This chapter describes the switch-on and switch-off behavior of the SERVOSTAR 6xx
and the steps required to achieve operational stopping or emergency stop behavior that
complies with standards.
The servo amplifier’s 24 V supply must remain constant. The ASCII commands
ACTFAULT (error response, also depends on the specific error, see ERRCODE) and
STOPMODE (Enable signal response) dictate how the drive will behave.
STOPMODE
ACTFAULT
0 (default)
1
0
1 (default)
Behavior (see also ASCII reference in the online help of
the setup software)
Motor coasts to a standstill in an uncontrolled manner
Motor is braked in a controlled manner
Behavior during a power failure
The servo amplifiers use an integrated circuit to detect if one or more input phases
(power supply feed) fail. The behavior of the servo amplifier is set using the setup software: Under “Response to Loss of Input Phase” (PMODE) on the Basic Setup screen,
select:
l Warning if the higher-level control system is to bring the drive to a standstill: Warning n05 is output if an input phase is missing, and the motor current is limited. The
servo amplifier is not disabled. The higher-level control system can now selectively
end the current cycle or start bringing the drive to a standstill. Therefore, the error
message “MAINS BTB, F16" is output on a digital output of the servo amplifier and
evaluated by the control system, for instance.
l Error message if the servo amplifier is to bring the drive to a standstill: Error message F19 is output if an input phase is missing. The servo amplifier is disabled and
the BTB contact opens. Where the factory setting is unchanged (ACTFAULT=1), the
motor is braked using the set “EMERGENCY STOP RAMP”.
Behavior when undervoltage threshold is reached
If the undervoltage threshold is undershot in the DC bus link (the threshold value
depends on the type of servo amplifier), the error message “UNDERVOLTAGE, F05" is
displayed. The drive response depends on the ACTFAULT/STOPMODE setting.
Behavior with enabled “holding brake” function
Servo amplifiers with an enabled holding brake function have a special procedure for
switching off the output stage ( ð p. 26). Removing the ENABLE signal triggers electrical
braking. As with all electronic circuits, the general rule applies that there is a possibility of
the internal “holding brake” module failing. Bringing a motor to a standstill using a holding
brake in a way that is personnel safe also requires an electromechanical “make” contact
for the holding equipment and a suppressor device for the brake.
Behavior of the restart lock -ASWith the restart lock –AS-, the drive can be secured on standstill using its internal electronics so that even when power is being supplied, the drive shaft is protected against
unintentional restart. The chapter “Restart lock -AS-” describes how to use the restart
lock –AS-. See page 71 onwards.
28
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
6.7.1
07/2016
Technical description
Behavior in standard operation
The behavior of the servo amplifier always depends on the current setting of a number of
different parameters (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see online
help). The diagram below illustrates the correct functional sequence for switching the
servo amplifier on and off.
U
24V
X4
t
X3/2,3
t
U
< 5s (Boot-time)
L1,L2,L3
X0
t
U
DC bus link
X0
t
HW-ENABLE
X3/15 &
SW-ENABLE
U
~ 2000 ms
~ 5 min.
t
n
5
Motor speed
VELO
t
U
Power stage
Enable (internal)
t
Devices which are equipped with a selected “Brake” function use a special sequence for
switching off the output stage (ð p. 26).
SERVOSTAR 640/670 Instructions Manual
29
Technical description
6.7.2
Kollmorgen
07/2016
Behavior in the event of an error (with standard setting)
The behavior of the servo amplifier always depends on the current setting of a number of
different parameters (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see online
help).
Caution
Some faults (see ERRCODE ) force the output stage to switch-off
immediately, independant from the ACTFAULT setting. Danger of injury
by uncontrolled coasting of the load. An additional mechanical brake is
required for funktional safety, which must be safely operated
The diagram shows the startup procedure and the procedure that the internal control system follows in the event of one or more electrical supply phases failing, assuming that the
standard parameter settings apply.
Standard Operation
Start
Power Fail
24V
t
t
Boot-Time
Main Power
t
3%
~2000ms
DC-Bus
VBUSMIN
t
Power Stage
enable
t
F16 / F19
t
F05
t
ENABLE
extern
5
t
Motor Speed
VELO
t
(F16/F19 = error messages Mains BTB /input phase, F05 = error message Undervoltage)
Even if there is no intervention from an external control system (in the example, the
ENABLE signal remains active), the motor is immediately braked using the emergency
stop ramp if an input phase error is detected and assuming that no changes have been
made to the factory setting (ACTFAULT=1).
30
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
6.8
07/2016
Technical description
Stop/Emergency Stop Function to EN 60204
With the restart lock –AS- (see page 71 onwards) the drive can be secured on standstill
(torque-free) using its internal electronics so that even when power is being supplied, the
drive shaft is protected against unintentional restart.
The parameters “STOPMODE” and “ACTFAULT” must be set to 1 in order to implement
the stop categories. If necessary, change the parameters via the terminal screen of the
setup software and store the data in the EEPROM.
Examples for implementation can be found in the Product WIKI on page "Stop and
Emergency Stop Function".
6.8.1
Stop
The Stop function is used to shut down the machine in normal operation. The Stop functions are defined by EN 60204.
Category 0:
Shut-down by immediate switching-off of the energy supply to the
drive machinery (i.e. an uncontrolled shut-down);
Category 1:
A controlled shut-down , whereby the energy supply to the drive
machinery is maintained to perform the shut-down, and the energy
supply is only interrupted when the shut-down has been completed;
Category 2:
A controlled shut-down, whereby the energy supply to the drive
machinery is maintained.
The Stop Category must be determined by a risk evaluation of the machine. In addition,
suitable means must be provided to guarantee a reliable shut-down.
Category 0 and Category 1 Stops must be operable independently of the operating mode,
whereby a Category 0 Stop must have priority. Stop functions must be implemented by
disconnection of the appropriate circuitry, and have priority over assigned start functions.
If necessary, provision must be made for the connection of protective devices and
lock-outs. If applicable, the Stop function must signal its status to the control logic. A reset
of the Stop function must not create a hazardous situation.
Examples for implementation can be found in the Product WIKI on page "Stop and
Emergency Stop Function".
SERVOSTAR 640/670 Instructions Manual
31
Technical description
6.8.2
07/2016
Kollmorgen
Emergency Stop
The Emergency Stop function is used for the fastest possible shutdown of the machine
in a dangerous situation. The Emergency Stop function is defined by IEC 60204. Principles of emergency stop devices and functional aspects are defined in ISO 13850.
The Emergency Stop function will be triggered by the manual actions of a single person.
It must be fully functional and available at all times. The user must understand instantly
how to operate this mechanism (without consulting references or instructions).
The Stop Category for the Emergency Stop must be determined by a risk evaluation of
the machine.
In addition to the requirements for stop, the Emergency Stop must fulfil the following
requirements:
l Emergency Stop must have priority over all other functions and controls in all operating modes.
l The energy supply to any drive machinery that could cause dangerous situations
must be switched off as fast as possible, without causing any further hazards ( Stop
Category 0) or must be controlled in such a way, that any movement that causes
danger, is stopped as fast as possible (Stop Category 1).
l The reset must not initiate a restart.
Examples for implementation can be found in the Product WIKI on page "Stop and
Emergency Stop Function".
6.8.3
Emergency Off
The Emergency Off function is used to switch-off the electrical power supply of the
machine. This is done to prevent users from any risk from electrical energy (for example
electrical impact). Functional aspects for Emergency Off are defined in IEC 60364-5-53.
The Emergency Off function will be triggered by the manual actions of a single person.
The result of a risk evaluation of the machine determines the necessity for an Emergency
Off function.
Emergency Off is done by switching off the supply energy by electro-mechanical switching devices. This results in a category 0 stop. If this stop category is not possible in the
application, then the Emergency Off function must be replaced by other measures (for
example by protection against direct touching).
32
SERVOSTAR 640/670 Instructions Manual
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07/2016
6.9
Shock-hazard protection
6.9.1
Leakage current
Technical description
Leakage current via the PE conductor results from the combination of equipment and
cable leakage currents. The leakage current frequency pattern comprises a number of
frequencies, whereby the residual-current circuit breakers definitively evaluate the 50Hz
current. For this reason, the leakage current cannot be measured using a conventional
multimeter. As a rule of thumb, the following assumption can be made for leakage current
on our low-capacity cables at a mains voltage of 400 V, depending on the clock frequency of the output stage:
Ileak = n x 20mA + L x 1mA/m at 8kHz clock frequency at the output stage
Ileak = n x 20mA + L x 2mA/m at a 16kHz clock frequency at the output stage
(where Ileak=leakage current, n=number of amplifiers, L=length of motor cable)
At other mains voltage ratings, the leakage current varies in proportion to the voltage.
Example:
2 x servo amplifiers + a 25m motor cable at a clock frequency of 8kHz:
2 x 20mA + 25m x 1mA/m = 65mA leakage current.
Since the leakage current to PE is more than 3.5 mA, in compliance with EN 61800-5-1
the PE connection must either be doubled or a connecting cable with a cross-section
>10mm² must be used.
The following measures can be used to minimise leakage currents.
— Reduce the length of the engine cable
— Use low-capacity cables (see p.40)
6.9.2
Residual-current circuit breakers (FI)
In conformity with DIN IEC 60364-4-41 – Regulations for installation and EN 60204 –
Electrical equipment of machinery, residual-current circuit-breakers (called FI below) can
be used provided the requisite regulations are complied with.
The SERVOSTAR 640/670 is a 3-phase system with a B6 bridge. Therefore, FIs which
are sensitive to all currents must be used in order to detect any d.c. fault current. Refer
to chapter 6.9.1 for the rule of thumb for determining the leakage current.
Rated residual currents in the FI
Protection against "indirect contact" (personal fire protection) for stationary
and mobile equipment, as well as for "direct contact".
Protection against "indirect contact" (personal fire protection) for stationary
50 -300 mA
equipment
10 -30 mA
Recommendation: In order to protect against direct contact (with motor cables <5m) we
recommend that each servo amplifier be protected individually using a 30mA residual-current circuit-breaker which is sensitive to all currents.
If you use a selective FI circuit-breaker, the more intelligent evaluation process will prevent spurious tripping of the circuit-breakers.
6.9.3
Isolating transformers
If protection against indirect contact is absolutely essential despite a higher leakage current, or if an alternative form of shock-hazard protection is sought, the SERVOSTAR
640/670 can also be operated via an isolating transformer.
A ground-leakage monitor can be used to monitor for short circuits.
We would advise you to keep the length of wiring between the transformer and the servo
amplifier as short as possible.
SERVOSTAR 640/670 Instructions Manual
33
Mechanical Installation
07/2016
7
Mechanical Installation
7.1
Important notes
Kollmorgen
CAUTION
High leakage current! There is a danger of electrical shock by high EMC
level which could result in injury, if the servo amplifier (or the motor) is not
properly EMC-grounded.
l Do not use painted (i.e. non-conductive) mounting plates.
l In unfavourable circumstances, use copper mesh tape between the
earthing bolts and earth potential to deflect currents.
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.
The servo amplifier will switch-off itself in case of overheating. 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 24.
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.
7.2
Guide to mechanical installation
The following notes should assist you to carry out the mechanical installation in a sensible sequence, without overlooking anything important.
Site
Ventilation
34
In a closed switchgear cabinet. Observe page 24 .
The site must be free from conductive or corrosive materials.
For the mounting position in the cabinet ð p. 35
Check that the ventilation of the servo amplifier is unimpeded
and keep within the permitted ambient temperature ð p. 24 .
Keep the required space clear above and below the servo amplifier ð p
35.
Assembly
Assemble the servo amplifier and power supply, filter and choke close
together on the conductive, grounded mounting plate in the cabinet.
Grounding
Shielding
EMC-compliant (EMI) shielding and grounding (ð p. 44)
Earth (ground) the mounting plate, motor housing and CNC-GND of the
controls.
Notes on connection techniques are on page 40
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
7.3
Mechanical Installation
07/2016
Assembly
Ask our customer service for information for pass through mounting
Material :
4 hexagon socket screws to EN 4762, M6
Tool required :
5 mm Allen key
>85mm
3.5"
215mm
8.46"
>70mm
2.8"
>92mm
3.6"
361mm
14.21"
3.6"
>70mm
2.8"
92mm
Cable duct
shielding sheet
shielding sheet
mounting panel
conductive (zinc-coated)
Cabinet door
300mm (with connector 325mm)
screw for hex key DIN 912
M6
>325mm
>12.8"
tightening torque
8-10 Nm
Cable duct
SERVOSTAR 640/670
SERVOSTAR 640/670 Instructions Manual
35
Mechanical Installation
7.4
Kollmorgen
07/2016
Dimensions
0m
m
mm
wit
h
ne
cto
r)
495mm (19.5")
345mm (13.6")
375mm (14.76")
30
5
(32
n
co
25
0m
m(
9.8
36
")
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
07/2016
8
Electrical Installation
8.1
Important notes
Electrical Installation
WARNING
High voltage up to 900V!
There is a danger of serious personal injury or death by electrical shock
or electrical arcing. Capacitors can still have dangerous voltages present
up to 5 minutes after switching off the supply power. Control and power
connections can still be live, even if the motor is not rotating.
l Only install and wire the equipment when it is not live.
l
Make sure that the cabinet is safely disconnected (for instance, with a
lock-out and warning signs).
l
Never remove electrical connections to the drive while it is live.
l
Wait at least 5 minutes after disconnecting the drive from the main
supply power before touching potentially live sections of the equipment (e.g. contacts) or undoing any connections.
To be sure, measure the voltage in the DC bus link and wait until it
has fallen below 50 V.
l
Wrong mains voltage, unsuitable motor or wrong wiring will damage the amplifier.
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 39.
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).
The use of external mains chokes and mains filters is required. Excessively high external
fusing will endanger cables and devices. The fusing of the AC supply input and 24V supply must be installed by the user, best values are given on p.24. Hints for use of Residual-current circuit breakers (FI) ð p.33.
The servo amplifier's status must be monitored by the PLC to acknowledge critical situations. Wire the BTB/RTO contact in series into the emergency stop circuit of the installation. The emergency stop circuit must operate the supply contactor.
It is permissible to use the setup software to alter the settings of the servo amplifier. Any
other alterations will invalidate the warranty.
SERVOSTAR 640/670 Instructions Manual
37
Electrical Installation
8.2
07/2016
Kollmorgen
Guide to electrical installation
Correct wiring is the basis for reliable functioning of the servo system.
Route power and control cables separately. We recommend a distance of at least
200mm. This improves the interference immunity. 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. 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 40.
Feedback lines may not be extended, since thereby the shielding would be interrupted
and the signal processing could be disturbed. Lines between amplifiers and external
brake resistor must be shielded. Install all power cables with an adequate cross-section,
as per EN 60204 (ð p.25) and use the requested cable material (ð p. 40) to reach max.
cable length.
The following notes should assist you to carry out the electrical installation in a sensible
sequence, without overlooking anything important.
Cable selecSelect cables according to EN 60204 (ð p. 25)
tion
Grounding
Shielding
Wiring
Final check
38
EMC-compliant (EMI) shielding and grounding (ð p. 44)
Earth (ground) the mounting plate, motor housing and CNC-GND of the
controls.
Notes on connection techniques are on page 40
— Route power leads and control cables separately
— Wire the BTB/RTO contact in series into the emergency stop circuit
of the system.
— Connect the digital control inputs to the servo amplifier
— Connect up AGND (also if fieldbuses are used)
— Connect the analog setpoint, if required
— Connect up the feedback unit (resolver and/or encoder)
— Connect the encoder emulation, if required
— Connect the expansion card (see corresponding manual on the
CD-ROM)
— Connect the motor cables, connect shielding to EMI connectors at
both ends
— Connect motor-holding brake, connect shielding to EMI connectors at
both ends
— Connect the external regen resistor (with fusing)
— Connect aux. supply (for max. permissible voltage values ð p. 24)
— Connect mains choke and mains filter (shielded lines between filter
and servo amplifier)
— Connect main power supply (for max. permissible voltage values
ð p. 24)
— Connect PC (ð p. 69).
— Final check of the implementation of the wiring,
— according to the wiring diagrams which have been used.
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
8.3
Electrical Installation
07/2016
Wiring
The installation procedure is described as an example. A different procedure may be sensible or necessary, depending on the application of the equipment. We provide further
know-how through training courses (on request).
DANGER
High voltage up to 900V!
There is a danger of electrical arcing with damage to contacts and
serious personal injury.
l 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.
l Make sure that the cabinet is safely disconnected (for instance, with a
lock-out and warning signs).
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 possible
surface area between the unit indicated and the mounting plate in the switchgear cabinet.
This connection is for the effective grounding of HF interference, and must not be confused with the PE- symbol W (a protective measure to EN 60204).
Use the following connection diagrams:
Overview
Mains power
Motor
Feedback
Electronic Gearing / Master Slave
Master-Slave
Pulse-Direction
Encoder Emulation
ROD (A quad B)
SSI
Analog/Digital Inputs/Outputs
RS232 / PC
CAN Interface
Restart lock -ASMulti-axis systems, example
Expansion cards
I/O-14/08
PROFIBUS
SERCOS
DeviceNet
EtherCAT
SynqNet
-2CAN-
SERVOSTAR 640/670 Instructions Manual
: page 44
: page 46
: page 49
: page 50ff
: page 58
: page 61
: page 63
: page 64
: page 65ff
: page 69
: page 70
: page 74
: page 92
: page 101
: page 102
: page 104
: page 105
: page 108
: page 109
: page 112
39
Electrical Installation
8.3.1
Kollmorgen
07/2016
Technical data for cables
Further information on the chemical, mechanical and electrical characteristics of the
cables can be obtained from out customer service .
Observe the restrictions in the chapter "Conductor cross-sections" on page 25.
To operate the amplifier with the max. permitted cable length, you must use cable material which meets the requirements on the capacity given below.
Insulation material
Sheathing
Core insulation
Capacitance
Motor cable
PUR (polyurethane, code 11Y)
PETP (polyesteraphtalate, code 12Y)
£ 4mm² : less than 150 pF /m
>4mm² : less than 250 pF/m
less than 120 pF/m
Feedback cable
Technical data
For a detailed description of cable types and how to assemble them, please refer to the
accessories manual.
8.3.2
Shielding connection to the front panel
Remove the outer covering of
the cable and the shielding braid
from the cores for the required
length. Secure the cores with a
cable tie.
cable tie
30
30
AR
ST
O
RV
SE
Remove the outer covering of
the cable over a length of about
30mm, without damaging the
shielding braid.
70
0/6
64
70
0/6
4
6
AR
T
OS
RV
E
S
40
Pull a cable tie through the slot
in the shielding rail (front panel)
of the servo amplifier.
Use the cable tie to clamp
the shielding braid of the cable firmly to the shielding rail.
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
8.4
Electrical Installation
07/2016
Components of a servo system
SERVOSTAR 640/670
PC
Control / PLC
Restart lock -AS-
24V-power
supply
Mains filter
Fuses
Mains choke
Brake resistor
Drive contactor
Fuses
Motor
Terminals
Cables drawn bold are shielded. Electrical ground is drawn
with dash-dotted lines. The required accessories are described in our accessories manual.
SERVOSTAR 640/670 Instructions Manual
41
Electrical Installation
8.5
Kollmorgen
07/2016
Block diagram
The block diagram below is just an overview.
VCC
=
=
RS
232
X6
RS232
CAN
X3
2k2
D
Analog-Out 1
A
CAN
AGND
2k2
D
Analog-Out 2
A
PGND
X5
X0
ROD
SSI
ROD/SSI
L1
L2
L3
D
A
X3
PE
DIGITAL-IN1
DIGITAL-IN2
~
PSTOP
NSTOP
=
Controller
ENABLE
DIGITAL-OUT1
DIGITAL-OUT2
DGND
Inrush circuit
BTB/RTO
D
VBUS
BTB/RTO
A
Intermediate circuit
X0
+DC
-DC
20K
-
Analog-In 1+
A
20K
+
Analog-In 1-
Rb1
D
-AS-
+
-AS-
20K
-
Analog-In 2+
A
20K
+
Analog-In 2-
=
D
~
-AS-
AGND
Power stage
D
I
A
U
U1
V
V1
W
W1
X0
Resolver
X10
KSI+
RDC
X2
-AS-
and/or
KSI-
G
M3~
X1
KSO1
SinCos
-AS-
Sine-Cosine
Encoder
KSO2
BRAKE+
BRAKE-
X4
X4
+24V
XGND
42
EMI
=
=
Internal power supply
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
8.6
Electrical Installation
07/2016
Pin assignments
X2 RESOLVER
X1 Digital Feedback
5 R2
4 S3
3 S4
2
1 SHIELD
R1 9
S1 8
S2 7
6
1
2
3
4
5
ENDAT
HIPERFACE
X5 ROD/SSI
pulse-direction
master-slave
X6 PC/CAN
CANL 6
7
8
CANH 9
8
7
6
5
4
3
2
1
15
14
13
12
11
10
9
+8V
RxD
TxD
N.C.
PGND
1 PGND
2 NI+
3 NIA- (CLK)
4
A+ (CLK)
5
B+ (DATA)
6
7
B- (DATA)
+5V 8
N.C. 9
X3 I/O
AGND
1
BTB/RTO
2
BTB/RTO
3
Analog-In 1+
4
Analog-In 1-
5
Analog-In 2+
6
Analog-In 2-
7
Analog-Out 1
8
Analog-Out 2
9
AGND 10
11
DIGITAL-IN1
DIGITAL-IN2 12
PSTOP 13
NSTOP 14
ENABLE 15
DIGITAL-OUT1 16
DIGITAL-OUT2 17
DGND 18
X10 -AS-
X4 24V/Brake
Brake+
1
Brake-
2
4 KSI+
+24V
3
3 KSI-
+24V
4
2 KSO2
XGND 5
1 KSO1
XGND 6
View: looking at
the face of the
X0 Power
built-in connectors
PE
L1
L2
L3
1
2
3
4
+DC
5
-DC
6
Rb1
U
V
W
PE
7
8
9
10
11
SERVOSTAR 640/670 Instructions Manual
43
Electrical Installation
8.7
Kollmorgen
07/2016
Connection diagram (overview)
Reference Safety Instructions (ð p.10)
and Use As Directed (ð p.12) !
thermal control
included
X1
X3
Analog-In 1+
Endat
Hiperface
digital
Feedback
Control
SERVOSTAR 640/670
Analog-In 1-
ð p.65
ð p.52ff
AGND
4
+
5
-
1
CNC-GND
6
+
Analog-In 2+
Analog-In 2-
and or
thermal control
included
Analog-Out 1
X2
ð p.66
8
Analog-Out 2
Resolver
Resolver
AGND
+/-10V speed
setpoint1
referred to
CNC-GND
7
8
+/-10V speed
setpoint1
referred to
CNC-GND
Analog 1
10
CNC-GND
9
Analog 2
ð p.51
CNC-GND
18
I/O-GND
DGND
M
W1
10
V1
9
U1
8
W
X0
V
ð p.49
PSTOP
U
PE
PE
NSTOP
ð p.67
+24V referred
to 0V/GND
13
+
14
12
B+
1
2
B-
3
4
5
6
X4
ENABLE
15
16
Digital1
+24V
ð p.46
ð p.68
17
Digital2
XGND
2
FB1
Regeneration
resistor
BRAKE+
BRAKE-
7
5
X0
Rb1
+DC
Emergency Stop
3
Circuit
ð p.47
FB2
X10
KSO1
+
1
Safety
circuit
2
1
2
3
4
-
PE
KSO2
L1
KSI-
L2
ð p.46
L3
ð
I/O-GND
4
KSI+
X5
ð p.63
ð p.64
ð p.58
ð p.61
Mains filter
3EF-xx
3
encoderevaluation,
stepper motor
control,
slave/master
amplifier
ROD
SSI
Ma./Sl.
Pulse
3
X6
ð p.70 CAN
CAN-Master
+
-
supply unit
24V DC
ð p.69
Mains
contactor
I/O-14/08
FN1 FN2 FN3
FH1 FH2 FH3
PROFIBUS
SERCOS
DEVICENET
ETHERCAT
SYNQNET
PE
44
L1 L2 L3
ð p.99
ð p.102
ð p.103
ð p.105
ð p.108
ð p.109
COM1/COM2
PC
3
PE-connection (protective earth)
chassis ground connection (panel)
shield connection via plug
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
Electrical Installation
07/2016
8.8
Power supply
8.8.1
Connection to various mains supply networks
This page illustrates all the possible connection variations for different electrical supply
networks.
An isolating transformer is always required for 400...480V mains networks without earth
(ground) and for networks with asymmetrical earth (ground).
208V with 60Hz only
230...480V with 50Hz or 60Hz
mains
208...480V
choke
L1
SERVOSTAR
L2
L3
PE
mains
choke
400...480V
mains filter
L1
Isolation transformer
1:1
choke
L1
SERVOSTAR
mains filter
mains
208...230V
L2
L3
PE
mains
choke
400...480V
mains filter
L1
1:1
choke
SERVOSTAR
L1
L2
L3
mains
choke
400...480V
mains filter
L1
1:1
choke
SERVOSTAR
L2
L3
400...480V
mains filter
L1
1:1
choke
SERVOSTAR
L2
L3
400...480V
L1
mains filter
SERVOSTAR
L2
L3
PE
mains
choke
L3
L1
SERVOSTAR
L2
L3
PE
SERVOSTAR 640/670 Instructions Manual
Isolation transformer
1:1
choke
L1
mains filter
mains
L2
Isolation transformer
PE
208...230V
SERVOSTAR
PE
mains
choke
L3
L1
mains filter
mains
L2
Isolation transformer
PE
208...230V
SERVOSTAR
PE
mains filter
mains
L3
Isolation transformer
PE
208...230V
L2
PE
mains filter
mains
208...230V
SERVOSTAR
SERVOSTAR
L2
L3
PE
45
Electrical Installation
8.8.2
Kollmorgen
07/2016
Mains supply connection (X0)
—
—
EMI filter and mains choke (required) provided by the user
Fusing (e.g. fusible cut-outs) provided by the user ð p. 24
SERVOSTAR 640/670
X0
FN1
2
L1
L1
=
U
U
FN2
~
L2
U
L2
3EF-xx
3
208...480V
60Hz
230...480V
50Hz
L3
1
PE
PE
24V auxiliary supply (X4)
—
—
—
Electrically isolated, external 24VDC supply, e.g. with insulating transformer
Required current rating ð p. 23
Integrated EMI filter for the 24V auxiliary supply
SERVOSTAR 640/670
X4
3
+24V
+24V
+
39V
8.9
208...230V
60Hz
FN3
4
L3
8.8.3
208...230V
60Hz
4
+24V
5
XGND
6
XGND
=
L1
L2
-
L3
-
~
PE
DC bus link (X0)
Can be connected in parallel, thanks to patented circuit to distribute the brake power
among all the amplifiers connected to the same DC bus link circuit. (Connection example
ð p. 92).
l Only servo amplifiers with mains supply from the same mains (identical mains supply
voltage) may be connected by the DC bus link.
l The sum of the rated currents for all of the servo amplifiers connected in parallel
to an SERVOSTAR 640/670 must not exceed 300A.
l Use unshielded single cores (>=10mm²) with a max. length of 500 mm. Use shielded
cables for longer lengths.
46
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
8.9.1
Electrical Installation
07/2016
External brake resistor (X0)
Fusing and brake resistor provided by the user.
SERVOSTAR 640/670
X0
5
+DC
FB1
10mm²
4mm²
+DC
7
-DC
RBext
FB2
10mm²
4mm²
Rb1
8.9.2
Capacitor Module KCM
KCM modules (KOLLMORGEN Capacitor Modules) absorb energy generated by the motor when it is operating in generator mode. Normally, this
energy is dissipated as waste via brake resistors. SERVOSTAR 640
modules, however, feed the energy they have stored back into the DC
Bus link as and when it is required.
Dimensions (HxWxD) : 300x100x201 mm
KCM-S Saves energy: The energy stored in the capacitor module during regenerative
braking is available the next time acceleration happens. The module’s inception
voltage is calculated automatically during the first load cycles.
KCM-P Power in spite of power failure: If the power supply fails, the module provides
the servo amplifier with the stored energy that is required to bring the drive to a
standstill in a controlled manner (this only applies to the power supply voltage;
battery-back the 24 V supply separately).
KCM-E Expansion module for both applications. Expansion modules are available in
two capacitance classes.
The KCM modules can be connected to S601 ... S640 devices (mains supply voltage
400/480V). Information for mounting, installation and setup can be found in the KCM
Instructions Manual and in the Product WIKI.
Technical Data KCM Modules
Storage
capacity
Typ
KCM-S200
KCM-P200
KCM-E200
KCM-E400
[Ws]
1600
2000
2000
4000
Rated
supply
voltage
[V DC]
max.
850 VDC
Peak supply
Power
voltage
[V DC]
[kW]
max.
950 VDC
(30s in 6min)
18
SERVOSTAR 640/670 Instructions Manual
Protection Inception
class
voltage
IP20
[V DC]
evaluated
470 VDC
-
Weight
[kg]
6.9
6.9
4.1
6.2
47
Electrical Installation
Kollmorgen
07/2016
Wiring example KCM Modules
Maximum cable length between servo amplifier and KCM module: 500 mm.
Twist the cables +DC/-DC. Longer cable lengths require shielding. Ensure that the polarity is correct; swapping round DC+/DC- will destroy the KCM modules.
DANGER
High DC voltage up to 900 V!
There is a danger of serious personal injury or death by electrical shock
or electrical arcing. It can take over an hour for the modules to
self-discharge.
l Switch off (disconnect) the line voltage. You must only work on the
connections when the system is disconnected.
l Check the state of charge with a measuring device that is suitable for
a DC voltage of up to 1,000 V.
l When measuring a voltage of over 50V between the DC+/DC- terminals or to ground, wait some minutes and measure again or discharge
the modules as described in the KCM instructions manual.
KCM-S: Connect the BR connection to the servo amplifier with the most frequent regenerative braking processes in the system. For setup, enable the servo amplifier and operate the driving profile that causes the brake chopper to respond. The KCM-S determines
the chopper threshold and begins to charge; LED flashes. The energy stored is available
the next time acceleration happens.
KCM-P: The KCM-P begins the charging process at approx. 470 V DC. If the power supply fails, the module provides the servo amplifier with the stored energy (this only applies
to the power supply voltage; battery-back the 24 V supply separately).
More information see Product WIKI.
+ 24 VDC
Ready
1k...100kOhm
4
X1
X1
KCM-P
1
SERVOSTAR
2
3
X4
1
X2
KCM-E
RS422
-DC
-DC
+DC
RS422
X1
KCM-S
+DC
5
BR
6
2
3
X4
X0
-DC
6
+DC
5
Rb1
7
-DC
PE
48
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
8.10
Electrical Installation
07/2016
Motor connection with brake (X0, X4)
Cable cross section see motor documentation.
SERVOSTAR 640/670
1
X4
Brake+
Brake-
2
XGND
X0
11
³10mm²
see motor data
PE
8
U
9
V
10
SERVOSTAR 640/670 Instructions Manual
M
W
49
Electrical Installation
8.11
Kollmorgen
07/2016
Feedback
Every closed servo system will normally require at least one feedback device for sending
actual values from the motor to the servo drive. Depending on the type of feedback
device used, information will be fed back to the servo amplifier using digital or analog
means.
SERVOSTAR 640/670 supports the most common types of feedback device whose functions must be assigned with the parameters
FBTYPE
(screen page FEEDBACK), primary Feedback
EXTPOS
(screen page POSITION), secondary Feedback
GEARMODE
(screen page GEARING), secondary Feedback
in the setup software. Scaling and other settings must always be made here.
ASCII Parameter
FBTYPE
One Feedback motor
motor
FBTYPE
EXTPOS
Two Feedbacks
externally
GEARMODE
Configuration
Location
Commutation
X
X
Speed Position- electr.
control control gearing
X
X
X
X
X
For a detailed description of the ASCII parameters, please refer to the online help of the
setup software.
The table below provides an overview of the supported feedback types, their corresponding parameters and a reference to the relevant connection diagram in each case. On
each of these, the pin assignment shown on the encoder side relates to the Kollmorgen
motors.
Connector
Resolver
X2
SinCos Encoder BISS
X1
SinCos Encoder ENDAT
X1
SinCos Encoder HIPERFACE
X1
SinCos Encoder w/o data channel
X1
SinCos Encoder + Hall
X1
RS422 5V + Hall
X1
ComCoder
X1
RS422 5V
X5
Sensorless (w/o feedback)
-
Primary feedback type
Wiring
diagram
ð p.51
ð p.52
ð p.53
ð p.53
ð p.54
ð p.55
ð p.55
ð p.56
ð p.57
-
FBTYPE
0, 3
20*
3, 4
2, 3
6, 7 (16*)
11*
12*
12*
8*, 9*
10*
* Can only be set on the terminal screen of the setup software
** RS422 means “incremental encoder AquadB”.
Hints for combining primary with secondary feedback systems for position control/electr.
gearing can be found from page 58.
50
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
8.11.1
07/2016
Electrical Installation
Resolver (X2)
Connection of a Resolver (2 to 36-poles) as a feedback system. The thermal control in
the motor is connected via the resolver cable to the SERVOSTAR and evaluated there.
If cable lengths of more than 100 m are planned, please contact our customer service .
FBTYPE 0, 3
SERVOSTAR 640/670
Resolver
33k
47k
470R
X2
7
7
470R
3
3
-
+
47k
+
sine / cosine
depending on
mounting situation
33k
33k
47k
470R
4
4
470R
8
8
-
+
47k
+
cosine / sine
depending on
mounting situation
33k
10R
5
5
9
9
+
reference
Motor
2
2
6
6
thermal control
min. 15VDC/5mA
The pin assignment shown on the encoder side relates to the Kollmorgen motors.
SERVOSTAR 640/670 Instructions Manual
51
Electrical Installation
8.11.2
Kollmorgen
07/2016
Sine encoder with BISS (X1)
Wiring of a single-turn or multi-turn sine-cosine encoder with BISS interface as a feedback system (firmware revision from 6.68). During start-up of the servo amplifier the
parameters stored in the encoder eeprom are uploaded, after that phase only the
sine/cosine signals are used.
The thermal control in the motor is connected via the encoder cable to X1 and evaluated
there. All signals are connected using our pre-assembled encoder connection cable.
If cable lengths of more than 50m are planned, please consult our customer service.
Frequency limit (sin, cos): 250 kHz
FBTYPE 20
10k
X1
1
1
10k
9
9
SERVOSTAR 640/670
B-
+
-
Encoder
cosine
B+
10k
3
3
10k
11
11
A-
+
-
sine
A+
A
B
A
B
5
5
13
13
DATA
DATA
8
8
15
15
CLOCK
CLOCK
12
12
10
10
UP
UP
Sense
0V
5V +/-5
4
4
2
2
UP
UP
max. 250mA
Sense
0V
0V
voltage supply
0V
Motor
14
14
7
7
thermal control
min. 5VDC/5mA
The pin assignment shown on the encoder side relates to the Kollmorgen motors.
52
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
8.11.3
Electrical Installation
07/2016
Sine Encoder with EnDat 2.1 or HIPERFACE (X1)
Connection of a single-turn or multiturn sine-cosine encoder. Preferred types are
ECN1313 and EQN1325.
The thermal control in the motor is connected via the resolver cable to the SERVOSTAR
and evaluated there. All signals are connected using our pre-assembled encoder connection cable.
If cable lengths of more than 50 m are planned, please consult our customer service.
Frequency limit (sin, cos): 250 kHz
Encoder with EnDat: FBTYPE 3, 4
Encoder with HIPERFACE: FBTYPE 2, 3
SERVOSTAR 640/670
SubD15
10k
1
10k
9
9
+
-
10k
3
3
10k
11
11
+
-
Encoder
17pol.round
X1
1
5
5
13
13
EnDat
HIPERFACE®
B-
+ SIN
B+
REFSIN
A-
+ COS
A+
REFCOS
DATA
RS485
DATA
8
8
15
15
CLOCK
CLOCK
12
12
10
10
UP
ADJ
sense
0V
VO
VI
LM317
4
4
2
2
UP
0V
0V
+15V
US
voltage supply
+15V
Motor
14
14
7
7
thermal control
min.15VDC/5mA
The pin assignment shown on the encoder side relates to the Kollmorgen motors.
SERVOSTAR 640/670 Instructions Manual
53
Electrical Installation
8.11.4
Kollmorgen
07/2016
Sine Encoder without data channel (X1)
Connection of a sine-cosine encoder without data channel as feedback unit. Every time
the 24V auxiliary voltage is switched on, the amplifier needs start-up information for the
position controller (parameter value MPHASE). Depending on the feedback type either
wake&shake is executed or the value for MPHASE is read out of the amplifier's
EEPROM.
WARNING
With vertical load the load could fall during wake&shake, because the
brake is not active and torque is not sufficient to hold the load. Don't use
this feedback type with vertical load (hanging load).
The thermal control in the motor is connected via the encoder cable to X1 and evaluated
there. If lead lengths of more than 50 m are planned, please consult our customer service. Frequency limit (sin, cos): 250 kHz
Encoder type
SinCos 5V
SinCos 5V
Resolver+SinCos5V
FBTYPE
6
7
16
Remarks
MPHASE from EEPROM
MPHASE with wake & shake
Commutation with Resolver, speed&position with Encoder
SERVOSTAR 640/670
10k
X1
1
10k
9
B-
+
-
cosine
B+
10k
3
10k
11
A-
+
-
Encoder
sine
A+
5
zero
13
RS 485
12
UP
sense
UP
10
0V
sense
0V
4
5V +/-5
max. 250mA
UP
UP
2
0V
voltage supply
0V
Motor
14
7
thermal control
min. 15VDC/5mA
54
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
8.11.5
07/2016
Electrical Installation
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 25 m are planned, please consult our customer service.
Frequency limit (A, B): 250 kHz
RS422 with Hall: FBTYPE 12
Encoder with Hall: FBTYPE 11
SERVOSTAR 640/670
SubD15
10k
X1
1
10k
9
+
-
ROD (AqB)
Encoder
B
Bcosinus
B+
B
10k
3
10k
11
-
Asinus
A+
A
+
A
5
NI+
Zero
NI-
Z
13
Z
12
UP
Sense
10
Sense
0V
4
5V +/-5
max. 250mA
UP
UP
2
0V
0V
+
HALL
6
Hall-U
8
Hall-V
15
Hall-W
Motor
14
7
thermal control
min. 15VDC/5mA
SERVOSTAR 640/670 Instructions Manual
55
Electrical Installation
8.11.6
Kollmorgen
07/2016
ComCoder (X1)
Connection of a ComCoder as feedback unit. For the commutation hall sensors are used
and for the resolution an incremental encoder.
The thermal control in the motor is connected via the ComCoder cable to X1 and evaluated there.
If cable lengths of more than 25 m are planned, please consult our customer service.
Frequency limit (A, B): 250 kHz
RS422 with Hall: FBTYPE 12
SERVOSTAR 640/670
SubD15
round, 17 pin
Comcoder
10k
X1
1
1
10k
9
2
B
+
-
B
10k
3
3
10k
11
4
A
+
-
A
5
5
13
6
Z
Z
+
6
15
8
16
15
17
Hall-U
Hall-V
Hall-W
12
10
10
7
UP
sense
UP
0V
5V +/-5
max. 250mA
sense
0V
4
10
2
7
UP
UP
0V
voltage supply
0V
Motor
14
9
7
8
thermal control
min. 15VDC/5mA
The pin assignment shown on the encoder side relates to the Kollmorgen motors.
56
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
8.11.7
Electrical Installation
07/2016
Incremental Encoder (X5)
An incremental encoder can be used as standard motor feedback.
Every time the 24V auxiliary voltage is switched on, the amplifier needs start-up information for the position controller (parameter value MPHASE). Depending on the feedback
type either wake&shake is executed or the value for MPHASE is read out of the amplifier's EEPROM. The thermal control in the motor is connected to X1 (see p.53) or X2 (see
p.51).
WARNING
With vertical load the load could fall during wake&shake, because the
brake is not active and torque is not sufficient to hold the load. Don't use
this feedback type with vertical load (hanging load).
If lead lengths of more than 50 m are planned and for questions concerning the power
supply of the encoder, please consult our customer service.
AGND and DGND (connector X3) must be joined together !
Frequency limit: 1.5 MHz
Encoder type
RS422 5V
RS422 5V
FBTYPE
9
8
Remarks
MPHASE from EEPROM
MPHASE with wake & shake
Incremental Encoder
SERVOSTAR 640/670
X5
A+
5
4
track A
150Ù*
RS 485
ANI+
2
3
5V
zero I
150Ù*
RS 485
NI-
8
=
=
1
PGND
B+
6
7
GND
track B
150Ù*
RS 485
B-
Motor
X1/X2
thermal control
min. 15VDC/5mA
* according to line impedance
SERVOSTAR 640/670 Instructions Manual
57
Electrical Installation
8.12
Kollmorgen
07/2016
Electronic Gearing, Master-slave operation
In the case of the “electronic gearing” functionality (see setup software and description of
GEARMODE parameter), the servo amplifier is controlled by a secondary feedback
device as a slave. More information can be found in the Online Help of the setup software.
It is possible to set up master/slave systems, use an external encoder as a setpoint
encoder or connect the amplifier to a stepper motor control.
The amplifier is parameterized using the setup software (electronic gearing).
Primary Feedback: adjust on screen page "Feedback" (FBTYPE)
Secondary Feedback: adjust on screen pages "Position" and "Gearing" (EXTPOS,
GEARMODE)
Master-/Slave adjustment
Master: adjust encoder emulation on screen page "ROD/SSI/Encoder" (ENCMODE)
Slave: adjust on screen pages "Position" and "Gearing" (EXTPOS, GEARMODE)
The following types of external encoder can be used:
Secondary Feedback type
Incremental Encoder 5V
Incremental Encoder 24V
Sine/Cosine Encoder
SSI Encoder
Pulse and Direction 5V
Pulse and Direction 24V
Connector
X5
X3
X1
X5
X5
X3
Wiring
diagram
ð p.59
ð p.59
ð p.60
ð p.61
ð p.62
ð p.62
GEARMODE
3, 5*, 13*, 15*
0, 2*, 10*, 12*
6, 8*, 9*, 16*
7*, 17*
4, 14*
1, 11*
* adjustable via terminal screen of the setup software
The follwing table shows the allowed feedback combinations:
Secondary Feedback for Position control/Following
Sine Encoder
Increment. Enco- Pulse&Direct.
Primary Feedback
(X1)
der5V/24V (X5/X3) 5V/24V (X5/X3)
EXTPOS = 1,2,3
EXTPOS = 1,2,3 EXTPOS = 1,2,3
GEARMODE =
GEARMODE = GEARMODE =
Resolver (X2)
0,2,3,5,10,12,13,15 1,4,11,14
6,8,9,16
FBTYPE = 0
FPGA = 0
FPGA = 0
FPGA = 0
ENCMODE = 0
ENCMODE = 0 ENCMODE = 0
EXTPOS = 1,2,3
EXTPOS = 1,2,3
GEARMODE =
GEARMODE =
Sine Encoder (X1)
0,2,3,5,10,12,13,15 1,4,11,14
FBTYPE = 2,4,6,7,20
FPGA = 1
FPGA = 1
ENCMODE = 0
ENCMODE = 0
EXTPOS = 1,2,3
EXTPOS = 1,2,3
GEARMODE =
GEARMODE =
Encoder & Hall (X1)
0,2,3,5,10,12,13,15 1,4,11,14
FBTYPE = 11,12
FPGA = 1
FPGA = 1
ENCMODE = 0
ENCMODE = 0
RS422 Encoder (X5)
FBTYPE = 8,9
EXTPOS = 1,2,3
EXTPOS = 1,2,3
GEARMODE =
GEARMODE =
Sensorless
0,2,3,5,10,12,13,15 1,4,11,14
FBTYPE = 10
FPGA = 0
FPGA = 0
ENCMODE = 0
ENCMODE = 0
58
SSI Encoder
(X5)
EXTPOS = 1,2,3
GEARMODE =
7,17
FPGA = 1
ENCMODE = 2
EXTPOS = 1,2,3
GEARMODE =
7,17
FPGA = 1
ENCMODE = 2
-
EXTPOS = 1,2,3
GEARMODE =
7,17
FPGA = 1
ENCMODE = 2
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
8.12.1
Electrical Installation
07/2016
Connection to a SERVOSTAR master, 5 V signal level (X5)
You can link several SERVOSTAR amplifiers together in master-slave operation. Up to
16 slave amplifiers can be controlled by the master via the encoder output. The connector
X5 must be used.
Frequency limit: 1.5 MHz, slew rate tv £ 0,1 µs
AGND and DGND (connector X3) must be joined together !
Slave
SERVOSTAR 640/670
X3
10
AGND
Master
18
DGND
X5
RS 485
SERVOSTAR
X5
A+
5
A
5
4
4
RS 485
A+5V
=
1
PGND
1
6
B+
6
=
PGND
RS 485
7
7
B
RS 485
B-
8.12.2
Connection to incremental encoder master with 24 V signal level (X3)
This interface can be used to operate the SERVOSTAR 640/670 as a slave, mastered by
an encoder with 24 V signal level (master-slave operation). The digital inputs DIGITAL-IN
1 and 2 at connector X3 must be used.
Frequency limit: 250 kHz, slew rate tv £ 0.1 µs
AGND and DGND (connector X3) must be joined together !
encoder
SERVOSTAR 640/670
X3
DIGITAL-IN1
11
DIGITAL-IN2
12
A
track A
track B
B
+24V ref. to GND
DGND
AGND
18
GND
10
SERVOSTAR 640/670 Instructions Manual
59
Electrical Installation
8.12.3
Kollmorgen
07/2016
Connection to a sine-cosine encoder master (X1)
You can operate the SERVOSTAR 640/670 as a slave, mastered by a sine-cosine
encoder (master-slave operation). The connector X1 must be used.
If cable lengths of more than 25 m are planned, please consult our customer service.
Frequency limit: 250 kHz
AGND and DGND (connector X3) must be joined together!
SERVOSTAR 640/670
Encoder
10k
X1
1
1
10k
9
9
B-
+
-
10k
3
3
10k
11
11
A-
+
-
cosine
B+
sine
A+
5
5
13
13
8
8
15
15
RS485
CLOCK
CLOCK
12
12
10
10
UP
ADJ
sense
0V
VO
VI
LM317
4
4
2
2
UP
voltage supply
0V
+15V
X3
10
AGND
18
DGND
60
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
8.12.4
Electrical Installation
07/2016
Connection to a SSI encoder (X5)
You can set up the SERVOSTAR 640/670 as a slave following a synchronous serial
absolute-encoder (master-slave operation). This application uses the SubD connector X5.
If lead lengths of more than 50 m are planned and for questions concerning the power
supply of the encoder, please consult our customer service.
Frequency limit: 1.5MHz
AGND and DGND (connector X3) must be joined together!
SSI Encoder
SERVOSTAR 640/670
X5
6
7
RS 485
150Ù*
RS 485
8
=
=
1
PGND
5
CLOCK
150Ù*
4
RS 485
GND
RS 485
CLOCK
CLOCK
* according to line impedance
8.12.5
Connection to stepper-motor controllers (step and direction)
This interface can be used to connect the servo amplifier to a third-party stepper-motor
controller. The parameters for the servo amplifier are set up with the aid of the setup software (electrical gearing). The number of steps can be adjusted, so that the servo amplifier can be adjusted to the pulse-direction signals of any stepper-motor controller. Various
monitoring signals can be output.
Observe the frequency limit! Using an A quad B encoder provides better EMC noise
immunity.
Speed profile and signal diagram
+v1
a=0
+a
a=0
-a
a=0
+a
a=0
t
-v2
1
Pulse
0
Direction
t
1
0
t
Equivalences
path traversed s
velocity v
acceleration a
number of pulses
pulse frequency
rate of change of pulse frequency
SERVOSTAR 640/670 Instructions Manual
61
Electrical Installation
8.12.5.1
Kollmorgen
07/2016
Step/Direction with 5 V signal level (X5)
This interface can be used to connect the servo amplifier to a stepper-motor controller
with 5 V signal level. The connector X5 must be used.
Frequency limit: 1.5 MHz
AGND and DGND (connector X3) must be joined together !
SERVOSTAR 640/670
X3
10
AGND
18
DGND
Master
X5
Pulse+
5
RS 485
150Ù*
4
RS 485
Pulse
Pulse+5V
=
=
1
PGND
6
Direction+
PGND
RS 485
150Ù*
7
RS 485
Direction
Direction* according to line impedance
8.12.5.2
Step/Direction with 24 V signal level (X3)
This interface can be used to connect the servo amplifier to a stepper-motor controller
with 24 V signal level. The digital inputs DIGITAL-IN 1 and 2 at connector X3 must be
used.
Frequency limit: 250 kHz
AGND and DGND (connector X3) must be joined together!
Master
SERVOSTAR 640/670
X3
DIGITAL-IN1
11
DIGITAL-IN2
12
DGND
18
direction
direction
pulse
pulse
+24V ref. to GND
AGND
62
GND
10
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
Electrical Installation
07/2016
8.13
Encoder emulations
8.13.1
Incremental encoder output - A quad B (X5)
The incremental-encoder interface is part of the package supplied. Select the encoder
function ROD (screen page “Encoder”). In the servo amplifier, the position of the motor
shaft is calculated from the cyclic-absolute signals of the resolver or encoder. Incremental-encoder compatible pulses are generated from this information. Pulses are output on
the SubD-connector X5 as two signals, A and B, with 90° phase difference and a zero
pulse. The resolution (lines before quadrature) can be changed with the RESOLUTION
parameter:
Encoder function
(ENCMODE)
Feedback Resolution
Resolver
ROD (1)
Encoder
ROD interpolation (3) Encoder
Zero position
256...4096
256...524288
(28 ... 219)
22...27
TTL lines per sine line
one per revolution
(only if A=B=1)
one per revolution
(only if A=B=1)
analog pass through from
X1 to X5
You can also adjust and store the position of the zero pulse within one mechanical turn
(parameter NI-OFFSET).
The drivers are supplied from an internal supply voltage. PGND must always be connected to the controls. The max. admissible cable length is 10 m.
Connections and signal description for incremental-encoder interface :
The count direction is upwards when the motor shaft is rotating clockwise (looking at the
shaft end).
SERVOSTAR 640/670
Control
X5
A+
5
150Ù*
4
RS 485
RS 485
ANI+
2
150Ù*
3
RS 485
RS 485
zero I
NI-
8
=
1
=
PGND
GND
B+
6
150Ù*
7
RS 485
RS 485
track B
B* according to line impedance
tv
a
A
a
a
a
5V
tv
Edge spacing a ³ 0,20 µs
Edge steepness tv £ 0.1 µs
Delay N-I-td £ 0.1 µs
B
5V
IÄUI ³ 2V/20mA
5V
N-I
td
td
SERVOSTAR 640/670 Instructions Manual
63
Electrical Installation
8.13.2
Kollmorgen
07/2016
SSI output (X5)
The SSI interface (synchronous serial absolute-encoder simulation) is part of the delivered package. Select the encoder function SSI (screen page “Encoder”). In the servo
amplifier, the position of the motor shaft is calculated from the cyclically absolute signals
from the resolver or encoder. This information is used to create a position output in a format that is compatible with the standard SSI-absolute-encoder format. 24 bits are transmitted.
SINGLE TURN selected: The upper 12 bits are fixed to ZERO, the lower 12 bits contain
the position information. For 2-pole resolvers, the position value refers to the position
within one turn of the motor, for 4-pole resolvers it is within half a turn, and for 6-pole
resolvers it is within a third of a turn.
Exception: If an encoder with a commutation track is used as the feedback unit, then the
upper 12 bits are set to 1 (data invalid!) until a homing run is performed.
MULTI TURN selected: The upper 12 bits contain the number of motor turns, the lower
12 bits contain the position information.
The signal sequence can be output in Gray code (standard) or in binary code (parameter
SSI-CODE). The servo amplifier can be adjusted to the clock frequency of your SSI-evaluation with the SSI-CLOCK parameter (cycle time 200 kHz or 1.5 MHz and inverted).
The drivers are supplied from internal supply voltage. PGND must always be connected.
Connection and signal description for SSI interface :
The count direction is upwards when the motor shaft is rotating clockwise (looking at the
shaft end).
Control
SERVOSTAR 640/670
X5
6
RS 485
7
RS 485
8
=
1
=
PGND
GND
CLOCK
4
CLOCK
RS 485
5
RS 485
CLOCK
* according to line impedance
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Clock
T
tp
tv
Binary
2
11
2
10
2
9
2
8
2
7
2
6
2
5
2
4
2
3
2
2
2
1
2
0
Singleturn
Gray
Binary
G11
2
23
2
22
2
21
2
20
2
19
2
18
2
17
2
16
2
15
2
14
2
13
2
12
2
11
G10
2
10
G9
2
9
G8
2
8
G7
2
7
G6
2
6
G5
2
5
G4
2
4
G3
2
3
G2
2
2
G1
2
1
G0
2
0
Multiturn
Gray
G23 G22 G21
Transfer bit rate
64
G20
G19
G18
G17
G16
G15
Monoflop stabilize time
200 KBaud
tp ~ 13µs
1,5 MBaud
tp ~ 3µs
G14
G13
G12 G11
G10
G9
G8
G7
G6
G5
G4
G3
G2
G1
G0
Switch over time Data tv £ 300nsec
Period T = 600 ns
Output
Input
IÄUI ³ 2V/20mA
IÄUI ³ 0,3V
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
Electrical Installation
07/2016
8.14
Digital and analog inputs and outputs
8.14.1
Analog inputs (X3)
The servo amplifier is equipped with two differential inputs for analog setpoints which are
programmable. AGND (X3/1) must always be joined to the CNC-GND of the controls as
a ground reference.
Technical characteristics
—
—
—
—
—
—
Differential-input voltage max. ± 10 V
Resolution 1.25 mV
Ground reference : AGND, terminal X3/1
Input resistance 20 kW
Common-mode voltage range for both inputs ± 10 V
Update rate 62.5 µs
control
SERVOSTAR 640/670
X3
10k
10k
Analog-In 1+
4
Analog-In 1-
5
AGND
1
+
-
10k
10k
10n
10k
10n
10k
Analog-In 2+ 6
10k
Analog-In 2- 7
+
-
10k
1n
1n
+
-
setpoint1 +/-10V
ref. to CNC-GND
CNC-GND
+
-
setpoint2 +/-10V
ref. to CNC-GND
CNC-GND
Input Analog-In1 (terminals X3/4-5)
Differential input voltage max. ± 10 V, resolution 14-bit, scalable
Standard setting : speed setpoint
Input Analog-In2 (terminals X3/6-7)
Differential input voltage max. ± 10 V, resolution 12-bit, scalable
Standard setting : torque setpoint
Application examples for setpoint input Analog-In2:
—
adjustable external current limit
—
reduced-sensitivity input for setting-up/jog operation
—
pre-control / override
Fixing the direction of rotation
Standard setting : clockwise rotation of the motor shaft (looking at the shaft end)
—
Positive voltage between terminal X3/4 (+ ) and terminal X3/5 ( - ) or
—
Positive voltage between terminal X3/6 (+ ) and terminal X3/7 ( - )
To reverse the direction of rotation, swap the connections to terminals X3/4-5 and. X3/6-7
or change the ROT. DIRECTION parameter in the “Speed controller” screen.
SERVOSTAR 640/670 Instructions Manual
65
Electrical Installation
8.14.2
Kollmorgen
07/2016
Analog outputs (X3)
Technical characteristics
—
—
—
—
—
Reference ground is analog-GND (AGND, terminal X3/1 and X3/10)
Output resistance : 2.2 kW
Output voltage ±10 V
Resolution : 10 bit.
Update rate 62.5 µs
control
SERVOSTAR 640/670
X3
2k2
10R
Analog-Out 1 8
AGND 1
AGND 10
Analog-Out 2 9
Analog 1
CNC-GND
CNC-GND
Analog 2
CNC-GND
Programmable analog outputs Analog-Out 1 / Analog-Out 2
The terminals X3/8 (Analog-Out 1) or X3/9 (Analog-Out 2) can have the following analog
signals assigned to them:
Standard setting :
Analog-Out 1 : Tachometer voltage nact (speed)
The output delivers ±10 V at the preset limit speed.
Analog-Out 2 : Current actual value Iact (torque)
The output delivers ± 10 V at the preset peak current (effective r.m.s. value).
You can use the terminals X3/8 (Analog-Out 1) or X3/9 (Analog-Out 2) to output converted analog values for digital measurements which are contained in the servo amplifier.
You can find a list of pre-programmed functions on the "analog I/O" screen of our setup
software.
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Electrical Installation
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Digital inputs (X3)
All digital inputs are electrically isolated through optocouplers.
Technical characteristics
—
—
—
—
Reference ground is Digital-GND (DGND, terminal X3/18)
Inputs at X3 meet PLC standards (IEC 61131-2 Typ 1)
High: 11...30 V / 2...11 mA, Low -3...+5 V / <1 mA
Update rate: 250 µs
Control
SERVOSTAR 640/670
X3
DIGITAL-IN1
11
DIGITAL-IN2
12
PSTOP
13
PSTOP
NSTOP
14
NSTOP
ENABLE
15
ENABLE
DGND
18
+24V against CNC-GND
I/O-GND
ENABLE input
The output stage of the servo amplifier is activated by the enable signal
(terminal X3/15, input 24 V, active-high).
In the inhibited state (low signal) the motor which is attached does not have any torque.
Programmable digital inputs :
You can use the digital inputs PSTOP / NSTOP / DIGITAL-IN1 and DIGITAL-IN2 to initiate
preprogrammed functions that are stored in the servo amplifier.
You can find a list of pre-programmed functions on the "digital I/O" screen of our setup
software.
If an input is freshly assigned to a pre-programmed function, then the data set must be
stored in the EEPROM of the servo amplifier, and the 24 V auxiliary supply of the servo
amplifier must be switched off and on again (to reset the amplifier software).
Limit-switches PSTOP / NSTOP
Terminals X3/13 and X3/14 are normally programmed for the connection of limit switches.
If these inputs are not needed for the connection of limit switches, then they are programmable for other input functions.
Limit-switch positive/negative (PSTOP / NSTOP, terminals X3/13 and X3/14), high level
in normal operation (fail-safe for a cable break).
A low signal (open) inhibits the corresponding direction of rotation, the ramp function
remains effective.
DIGITAL-IN 1 / DIGITAL-IN 2
The digital inputs on terminals X3/11 (DIGITAL-IN 1) or terminal X3/12 (DIGITAL-IN 2)
can be logically combined in a pre-programmable function.
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Digital outputs (X3)
Technical characteristics
—
—
—
—
Reference ground is digital-GND (DGND, terminal X3/18)
All digital outputs are floating
DIGITAL-OUT1 and 2: Open-collector, max. 30 VDC, 10 mA
BTB/RTO:
Relay output, max. 30 VDC or 42 VAC, 0.5 A
Update rate:
250 µs
control
X3
SERVOSTAR 640/670
BTB/RTO 2
1k
Emergency Stop
100n
Circuit
BTB/RTO 3
A1
14
A2
13
A1
14
A2
13
+24V
DIGITAL-OUT1 16
25R
DIGITAL-OUT2 17
25R
DGND 18
ref. to I/0-GND
Digital 1
+24V
ref. to I/0-GND
Digital 2
I/O-GND
Ready-to-operate contact BTB/RTO
Operational readiness (terminals X3/2 and X3/3 ) is signalled by a floating relay contact.
The contact is closed when the servo amplifier is ready for operation, the signal is not
influenced by the enable signal, the I²t- limit, or the brake threshold.
All faults cause the BTB/RTO contact to open and the switch-off of the output stage (if the
BTB contact is open, the output stage is disabled -> no power). A list of the error messages can be found on page 95.
Programmable digital outputs DIGITAL-OUT 1 / 2:
You can use the digital outputs DIGITAL-OUT1 (terminal X3/16) and DIGITAL-OUT2 (terminal X3/17) to outputs messages from pre-programmed functions that are stored in the
servo amplifier.
You can find a list of pre-programmed functions on the "digital I/O" screen of our setup
software.
If an input is freshly assigned to a pre-programmed function, then the data set must be
stored in the EEPROM of the servo amplifier, and the 24 V auxiliary supply of the servo
amplifier must be switched off and on again (to reset the amplifier software).
Evaluate the outputs via inverting interface relays (see connection diagram), for example
Phönix DEK-REL-24/I/1 (turn-on delay 6 ms, turn-off delay 16ms).
The described logic in the online help of the setup software refers to the output of the
inverting interface relays. Consider the delay of the applied relay !
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8.15
Electrical Installation
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RS232 interface, PC connection (X6)
The setting of the operating, position control, and motion-block parameters, can be carried out on an ordinary commercial PC.
Connect the PC interface (X6) of the servo amplifier while the supply to the equipment
is switched off via a normal commercial 3-core null-modem cable to a serial interface on
the PC.
Do not use a null-modem link cable!
The interface is electrically isolated through an optocoupler, and is at the same potential
as the CANopen interface.
The interface is selected and set up in the setup software.
Further notes can be found on page 79.
With the optional expansion card -2CAN- the two interfaces for RS232 and CAN, which
otherwise use the same connector X6, are separated onto two connectors (ð p. 111).
SERVOSTAR 640/670
X6
RxD
PC
Pin-No.
see below
2
TxD
RS 232
RS 232
PGND
5
=
=
PGND
TxD
3
RxD
RS 232
RS 232
Interface cable between the PC and servo amplifiers of the SERVOSTAR 640/670 series:
(View : looking at the face of the built-in SubD connectors, this corresponds to the solder
side of the SubD sockets on the cable)
Sub-D 9 poles
1
6
X6
PC
RS232
Sub-D 9 poles
Sub-D 9 poles
PC
RS232
X6
RxD
Sub-D 25 poles
1
14
TxD
1
6
RxD
RxD
RxD
TxD
TxD
9
9
GND
1
6
TxD
9
GND
5
5
5
GND
GND
female
female
25
female
13
female
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Electrical Installation
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CANopen interface (X6)
The interface for connection to the CAN bus (default 500 kBaud). The integrated profile is
based on the communication profile CANopen DS301 and the drive profile DSP402. The
following functions are available in connection with the integrated position controller:
Jogging with variable speed, reference traverse (zeroing), 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 electrically
isolated by optocouplers, and is at the same potential as the RS232 interface. The analog
setpoint inputs can still be used.
With the optional expansion card -2CAN- the two interfaces for RS232 and CAN, which
otherwise use the same connector X6, are separated onto two connectors (ð p. 111).
AGND and DGND (connector X3) must be joined together !
SERVOSTAR 640/670
X3
10
AGND
18
DGND
(in case analogue
setpoints are not
in use)
CAN-Server/Client
X6
CANH
9
120Ù*
120Ù*
6
CANL
5
PGND
CAN
CAN
+5V
=
=
* according to line impedance
PGND
CAN ref. to ISO 11898
CAN bus cable
To meet ISO 11898 you should use a bus cable with a characteristic impedance of 120
W. 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 capacity
max. 60 nF/km
Lead resistance (loop)
159.8 W/km
Cable length, depending on the transmission rate
Transmission rate / kbaud
1000
500
250
max. cable length / m
20
70
115
Lower cable capacity (max. 30 nF/km) and lower lead resistance
(loop, 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 fulfil the following conditions:
—
metal or metallized housing
—
provision for cable shielding connection in housing, large-area connection
Master
X6
X6
X6
CANL
CANL
CANL
CANH
CANH
CANH
GND
GND
GND
Shield
Shield
* according to line impedance about 120W
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8.17
07/2016
Electrical Installation
Restart lock -AS- according to EN 954-1
A frequently required application task is the protection of personnel against the restarting
of drives. This can not be achieved by an electronic inhibit, but must be implemented with
mechanical elements (positively driven relay contacts).
A safety relay in the servo amplifier is activated either by the PLC or manually. Positively
driven contacts provide a safe disconnection of the amplifier, the setpoint input of the
servo amplifier is inhibited, and a signal is sent to the safety circuit.
The suggested circuits (ð p. 75) fulfills safety category 1 (EN 954-1) or category 3 with
additional safety relay (e.g. PNOZ of PILZ company).
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
Moving single axis-groups in setting-up operation
In setting-up operation, people will frequently be within the danger zone of the machinery.
Axes will normally be moved under the control of permission switches. An additional
switch-off of the unused axes, by means of the restart lock, increases the safety margin
and avoids the repeated switching of main contactors or motor contactors.
Switching off grouped axes with separate working areas
Even when several SERVOSTAR 640/670 are operating off a common mains supply and
DC bus link, it is possible to set up groups for separate working areas. These groups can
then be switched off separately.
SERVOSTAR 640/670 does not have any safety functionality according to
IEC 61800-5-2. The optional restart lock function -AS- cannot be compared to the safety
function STO. The described function -AS- is proofen according to EN 954-1. This standard is not listed in the EC Machine Directive 2006/42/EG since 31.12.2012. The requirements for a restart lock according to EN 954-1 are nevertheless fulfilled.
8.17.1
Important notes
l
l
l
l
Observe the chapter "use as directed" for the restart lock -AS- (ð p. 72)
The monitoring contacts (KSO1/2) for each amplifier must be looped into the control
circuit. This is vital, so that a malfunction of the internal safety relay or a cable break
can be recognized.
If the restart lock -AS- is automatically activated by a control system (KSI1/2), then
make sure that the output of the control is monitored for possible malfunction. This
can be used to prevent a faulty output from activating the restart lock -AS- while the
motor is running.
Keep to the following functional sequence when the restart lock -AS- is used :
1.Brake the drive in a controlled manner (speed setpoint = 0V)
2.When speed = 0 rpm, disable the servo amplifier (enable = 0V)
3.If there is a suspended load, block the drive mechanically
4.Activate the restart lock -AS-
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Use as directed
The restart lock -AS- is exclusively intended to preventing the restart of a system. To
achieve this functionality, the wiring of the safety circuits must meet the safety requirements of EN60204, EN12100 and EN 954-1..
The -AS- restart lock must only be activated,
—
when the motor is no longer rotating (setpoint = 0V, speed = 0rpm, enable = 0V).
Drives with a suspended load must have an additional safe mechanical
blocking (e.g. by a motor-holding brake).
—
when the monitoring contacts (KSO1/2) for all servo amplifiers are wired into
the control signal loop.
The -AS- restart lock may only be controlled by a CNC if the control of the internal safety
relay is arranged for redundant monitoring.
The -AS- restart lock must not be used if the drive is to be made inactive for the following
reasons :
—
—
8.17.3
cleaning, maintenance and repair operations or long inoperative periods
In such cases, the entire system should be disconnected from the supply by the
personnel, and secured (main switch).
emergency-stop situations
In an emergency-stop situation, the main contactor is switched off
(by the emergency-stop button).
Block diagram
charging
circuit
DC+/2
3
mains
3~
2
2
=
3
+
M
3~
6
activation
2
24V
=
=
driver
supply
6
X10
KSI+ 4
KSIKSO1
3
1
6
KSO2
2
setpoint
= restricted
guidance
72
control logic
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8.17.4
Electrical Installation
07/2016
Functional description
The connector (X10) is mounted on the front panel of the SERVOSTAR 640/670.The coil
connections and a make (n.o.) contact of a safety relay are made available through 4 terminals on this connector.
The 24VDC safety relay in the servo amplifier (approved) is controlled externally. All the
relay contacts have positive action.
Two contacts switch off the driver supply of the output stage in the servo amplifier, and
short the internal setpoint signal to AGND (0 V).
The make (n.o.) contact used for monitoring is looped into the control circuit.
If the safety relay is not energized, then the monitoring contact is open and the servo
amplifier is ready for operation.
If the drive is electronically braked, the servo amplifier is disabled and the motor-holding
brake is on, then the safety relay is energized (manually or by the controls).
The supply voltage for the driver circuit of the output stage is switched off in a safe manner, the internal setpoint is shorted to 0V, and the monitoring contact bridges the safety
logic in the control circuit of the system (monitoring of protective doors etc.)
Even if the output stage or driver is destroyed, it is impossible to start the motor.
If the safety relay itself is faulty, then the monitoring contact cannot bridge the safety logic
of the system. Opening the protective devices will then switch off the system.
8.17.5
Signal diagram (sequence)
terminal Analog-In 1 +/-
+
setpoint
(input)
internal setpoint lock
t
0
-
+24V
Enable
(input)
t
terminal BRAKE+
£1s
motor blocked mechanically
t
0
+24V
restart
lock
(input)
motor locked by controller
0
+24V
brake
(output)
terminal ENABLE
terminal KSI+
t
danger zone accessible
0
1
>0,2s
terminal KS01/2
supervisory
contact
0
(output)
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Electrical Installation
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Functional test
The functioning of the restart lock must be tested during setup, after every alteration in
the wiring of the system, or after exchanging one or more components of the system.
1.
2.
3.
4.
5.
6.
8.17.7
Stop all drives, with setpoint 0V, disable drives, mechanically block any
suspended loads.
Activate the restart lock -AS-.
Open protective screens (but do not enter hazardous area)
Pull off the X10 connector from an amplifier: the mains contactor must drop out
Reconnect X10. Switch on mains contactor again.
Repeat steps 4 and 5 for each individual servo amplifier.
Connection diagram (principle)
control
SERVOSTAR 640/670
10k
10k
Analog-In 1+
4
Analog-In 1-
5
AGND
1
X3
+
+
-
10k
10n
10k
10n
-
setpoint1 +/-10V
acc.to CNC-GND
CNC-GND
CNC-GND
2
safetycircuit
3
KSO1
1
KSO2
2
KSI-
3
KSI+
4
X10
+
-
I/O-GND
AS
+24V acc.
to I/O-GND
X3
ENABLE
15
DGND
18
ENABLE
I/O-GND
Application examples for category 1 see chapters 8.17.8.
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Electrical Installation
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Application example category 1 according to EN 954-1
Flowchart for stop and emergency stop category 0.
8.17.8.1
Control circuit
+24V
EMERG.
OFF
lock
drives 1&2
BTB Drive 1
lock
drive 3
OFF
KSO1
BTB Drive 2
Drive 1
KSO2
S1
KSO1
BTB Drive 3
Drive 2
KSO2
KSO1
S2
Drive 3
KSO2
K1
ON
K2
K1
KSI+
KSI+
KSI+
KSI-
KSI-
KSI-
Drive 2
Drive 3
K2
0V
mains contactor
8.17.8.2
auxiliary contactor
Drive 1
Mains supply circuit
3~ 480V
max.
3
3
BTB
BTB
BTB
BTB
BTB
BTB
KSI+
+
KSO1 KSI+
KSO2
KSI-
+
KSI-
KSO1
KSI+
KSO2
KSI-
+
KSO2
Drive 1
Drive 2
Drive 3
M
M
M
S1
SERVOSTAR 640/670 Instructions Manual
KSO1
S2
75
Electrical Installation
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Application example category 3 according to EN 954-1
Flowchart for stop and emergency stop category 1.
8.17.9.1
Control circuit
+24V
K10t
K10t
K30t
K40
ON
K20t
KSO1
Terminals
Drive 1
K20t
KSI+
KSIKSO1
KSO2
Enable
DGND
BTB/RTO
BTB/RTO
KSO2
KSO1
Drive 2
KSO2
X10.4
X10.3
X10.1
X10.2
X3.15
X3.18
X3.2
X3.3
OFF
BTB/RTO
Drive 1
BTB/RTO
BTB/RTO
Drive 2
Safety Circuit
BTB/RTO
S1
EMERG.
OFF
KSI+
Enable
AS
K1
K10t
AS
K20t
K30t
K40
KSI-
DGND
0V
1 Drive 2
8.17.9.2
1 Drive 2
Mains supply circuit
3~480V
max.
3
3
Enable
Enable
BTB
BTB
BTB
BTB
KSI+
+
KSO1 KSI+
KSO2
KSI-
+
KSO1
KSO2
KSI-
Drive 1
Drive 2
M
M
S1
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8.17.9.3
07/2016
Electrical Installation
Flow chart
t(K30t)
t(K10t) / t(K20t)
24V
AS Relais
ON
OFF
K1
K10t / K20t
K30t / Enable
Speed
t(K30t) ³ 500ms
t(K10t) and t(K20t) ensure that the drive remains active until the axis has come to a
standstill. This time depends on the application and must exceed the deceleration ramp.
The drive must have been brought to a safe standstill by the time t(K10t) and t(K20t) have
elapsed. After this point, active braking with the servo amplifier is no longer possible.
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Setup
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Setup
The setup procedure is described as an example. Depending on the application, a different procedure may be sensible or necessary. In multi-axis systems, setup each servo
amplifier individually.
The manufacturer of the machine must generate a risk assessment for the machine, and
take appropriate measures to ensure that unforeseen movements cannot cause injury or
damage to any person or property.
9.1
Important notes
DANGER
Lethal voltage!
Risk of electric shock. Lethal danger exists at live parts of the device.
l Built-in protection measures such as insulation or shielding may not
be removed.
l Work on the electrical installation may only be performed by trained
and qualified personnel, in compliance with the regulations for safety
at work, and only with switched off mains supply, and secured against
restart.
WARNING
Automatic restart!
Risk of death or serious injury for humans working in the machine. The
drive might restart automatically after power on, depending on the
parameter setting. If the parameter AENA is set to 1,
l then place a warning sign to the machine (Warning: Automatic Restart
at Power On) and
l ensure, that power on is not possible, while humans are in a dangerous zone of the machine.
If the servo amplifier has been stored for longer than 1 year, then the DC bus link capacitors will have to be re-formed.
To do this, disconnect all the electrical connections.Supply the servo amplifier for about
30 min. from single-phase 230VAC to the terminals L1 / L2. This will re-form the
capacitors.
Further setup information:
The adaptation of parameters and the effects on the control loop behavior are described
in the online help. The setup of the expansion card (if present) 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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9.2
Setup software
9.2.1
General
Setup
This chapter describes the installation of the setup software for the SERVOSTAR
640/670 digital servo amplifiers.
We offer training and familiarisation courses on request.
9.2.1.1
Use as directed
The setup software is intended to be used for setting up and storing the operating parameters for the SERVOSTAR 640/670 series of servo amplifiers. The attached servo amplifier can be setup with the assistance of the software - during this process 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 which is running.
Sets of data which are stored on data media are not safe against unintended alteration by
other persons. After loading a set of data you must therefore check all parameters thoroughly before enabling the servo amplifier.
9.2.1.2
Software description
The servo amplifiers must be adapted to the requirements of your installation. 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 (ð p. 69). The setup software provides the communication between
SERVOSTAR 640/670 and the PC.
You will find the setup software on the accompanying CD-ROM and at our web site in the
download area.
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.
Simultaneously, important actual values are read out from the amplifier and displayed on
the PC monitor (oscilloscope function).
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.
Sets of data can be stored on data media (archived) and loaded again. Sets of data which
are stored on data media can be printed.
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.
SERVOSTAR 640/670 Instructions Manual
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Setup
9.2.1.3
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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. 69).
Connect / disconnect the interface cable only when the supply is switched off for both the
PC and the servo amplifier.
The interface in the servo amplifier is electrically isolated by an optocoupler, and is at the
same potential as the CANopen interface.
Minimum requirements for the PC:
9.2.1.4
Processor
Operating system
Graphics adapter
Drives
:
:
:
:
Main memory
Interface
:
:
Pentium®II or higher
WINDOWS
Windows compatible, color
hard disk with at least 10 MB free space
CD-ROM drive
at least 8MB
one free serial interface (COM1...COM10)
Operating systems
WINDOWS 95(c) / 98 / 2000 / ME / NT / XP / Vista / 7
DRIVE.EXE is executable under WINDOWS 95(c) / 98 / 2000 / ME / NT 4.0 / XP / Vista /
7.
The HTML help system is not available under WINDOWS 95a and 95b.
WINDOWS FOR WORKGROUPS 3.xx, DOS, OS2
DRIVE.EXE is not executable under WINDOWS 3.xx, DOS and OS2.
In emergency, operation is possible through an ASCII terminal emulation (without
user-interface).
Interface settings : 9600 bps, no parity, no handshake
Unix, Linux
The software function has not been tested running within Unix or Linux.
WINDOWS 8, 10
DRIVE.EXE is not tested with WINDOWS 8 or 10.
9.2.2
Installation under WINDOWS
The CD-ROM includes an installation program for the setup software.
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 DRIVE.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:\index.htm (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 and the PC interface (X6) of
the SERVOSTAR 640/670 (ð p. 69).
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9.3
Quickstart Guide
9.3.1
Preparation
Setup
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
5. Install the software as described in chapter 9.2
6. You need this information concerning the drive components:
- rated mains supply voltage
- motor type (motor data, if the motor type is not listed in the motor database,
see online help
- feedback unit built into the motor (type, poles, lines, protocol etc.)
- moment of inertia of the load
Documents
You need access to these documents (located on the product CD-ROM, you can download the latest editions from our website):
l
l
l
Instructions Manual (this manual)
CANopen Communication Profile Manual
Accessories 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 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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Setup
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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.
PC
CAN
ENC
RES
Motor-Feedback
X3
Power ON
2
3
Enable
15
18
24V ON
24V DC
4
X4 3
5
+
-
Motor-Power
Power
Choke
Filter
Motor
Brake Res.
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9.3.2
Setup
07/2016
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 classe (e.g.
for 40 amps). If the power supply voltage is switched on, too,
a leading P is displayed (e.g.
for Power, 40 amps).
If a fault code (
) or a warning (
) or a status message (./_ / E/S) appears in
the display, you will find the description on page 95ff. If there is fault, fix the problem.
Double-Click the DRIVE.EXE icon on your Windows desktop to start the software.
You can work offline or online with .
Work ONLINE now. Select the interface where the
servo amplifier is connected to.
The software tries to communicate
with the drive and to upload the 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
Click OK to remove the error message. Detect and remove the error source. Restart the
software.
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If communication works, parameters are transmitted from the servoamplifier to the computer.
Then you see the start screen.
Make sure, that the amplifier is
disabled (Input HW-Enable
connector X3 pin 15 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 ? or
Online HTML Help
Starts online help for the actual screen page.
Starts online help with table of contents.
Tool Bar
Save to EEPROM,
required if you changed parameters.
Reset (coldstart),
required if you changed important configuration parameters.
Operation Mode, use Digital Velocity mode for drive testing.
Disable and Enable of the amplifier's output stage via software.
Status Bar
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9.3.4
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Setup
Basic Setup
On the start screen click "Basic Setup" button.
Regen Resistor: Select "external" brake resistor
max.Regen Power: Fill in the power of the connected brake resistor.
max. Mains Voltage: Select the nominal mains AC voltage
Mains Phase Missing: You can select either warning "n05" or error "F19" in case of
phase loss. The setting "F19" disables the output stage, "n05" is just a message.
Units: Acceleration, Velocity, Position
Select usable units for your application referring to the moved load.
Leave all other fields unchanged.
Click OK. On the start screen click "Motor" button.
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Setup
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07/2016
Motor (synchronous)
Press function key F12 (SW disable) before changing motor parameters.
Motor Type: Select Synchronous Motor. If you use a linear motor or an induction motor,
please contact our support department.
Number-Name: Click the list to start uploading the motor parameter table, which is stored
in the servo amplifier. Search and select the connected motor. If your motor is not listed,
please contact our support department.
Leave all other fields unchanged.
Click OK.
If your motor has a built-in brake, click
Yes, otherwise "No".
If Software Enable is active, a warning
appears. You can proceed, but after the
amplifier is restarted, you must check
whether the holding brake configuration
is correct.
Click OK.
Parameters are uploaded to the amplifier's RAM now (takes some seconds).
When this is done, you have to accept
the changed configuration with "Yes" or
to discard the changes in the appearing
screen.
If you click "Yes", the parameters are
saved in the EEPROM and the amplifier
makes a coldstart (reset). This takes
some seconds.
On the start screen, click "Feedback" button.
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9.3.6
Setup
07/2016
Feedback
Press function key F12 (disable) before
changing feedback parameters.
Feedback Type:
Select the feedback type used.
Leave all other fields unchanged.
If Software Enable is active, a warning appears. The configuration change cannot be
performed.
Click OK on the warnings, press F12 (SW
disable) and start the Feedback procedure
again.
If everything was ok, the same procedure
(parameter upload) that has been described
for the motor selection starts.
If you click "Yes", the parameters are saved
in the EEPROM and the amplifier makes a
coldstart (reset). This takes some seconds.
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Setup
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Save Parameters and Restart
You are going to finish setup and you have changed several basic parameters. Depending on the parameters you changed, two possible reactions can occur:
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 a few seconds). For example, this happens after
motor or feedback selection.
Other parameters changed
No warning appears. Parameters are saved in the volatile RAM only. Save the parameters to the EEPROM of the servo amplifier manually by clicking the symbol
tool bar. A coldstart of the amplifier is not necessary.
in the
Reset the amplifier
You can reset the amplifier manually (e.g. in case of an error). Click the icon
88
.
SERVOSTAR 640/670 Instructions Manual
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9.3.8
07/2016
Setup
Jogging the Motor (Speed Control)
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 Hardware-Enable: +24 VDC to Enable [connector X3 pin 15].
l
Software-Enable: Click the "Enable" button
on the start screen or
use key combination Shift+F12. Now, the front display shows an E and the current
rating (e.g.
for Enable, 40 amps)
l
Click the icon "Oscilloscope"
l
Select Service-Mode "Speed F6", then click "Parameter" button
l
Enter a safe speed. The sign defines the direction of movement.
Observe the "safe reduced speed" requirements for your application!
l Click OK.
l Start the service function ("Start" button or press F6).
Click OK on the warning notice.
l
l
Opmode is switched to "0" and the output stage is enabled automatically. The symbol's color changes to green as long as the function is active.
The function is active until you click the "Stop" button or press F9.
The output stage can be disabled by pressing function key F12.
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Status
Actual warnings and errors are listed on the Status screen, which can be accessed on
the start screen by clicking the "Status" button. This button monitors the current status of
the amplifier and can appear with different text.
The Reset button can be used to clear some actual error messages. A description of
errors/warnings can be found on page 95.
Now you have setup and tested the basic functions of the drive successfully.
9.3.10
Monitor
Click the icon "Monitor"
The Monitor screen shows
all important electrical and
mechanical actual values
9.3.11
Additional Setup Parameters
Detailed information on all setup functions can be found in the Online Help systemand
and the integrated command reference.
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9.4
Setup
07/2016
Multi-axis system
Using a special multilink cable, you can connect up to six servo amplifiers together and to
your PC :
X6
PC/CAN
Add.:01
Add.:02
PC
Add.:03
Add.:04
Cable -SR6YCOMx
RS232
Baud rates are the same for all amplifiers,
see table below
Cable type -SR6Y- (for 4 amplifiers) or -SR6Y6- (for 6 amplifiers).
With the PC connected to just one servo amplifier you can now use the setup software to
select all amplifiers through the preset station addresses and set up the parameters.
9.4.1
Node address for CAN-bus
During setup it makes sense to preset the station addresses for the individual amplifiers
and the baud rate for communication by means of the keypad on the front panel (ð p.94).
9.4.2
Baud rate for CAN-bus
After changing the station address and baud rate you must turn the 24V auxiliary supply
of the servo amplifier off and on again.
Coding of the baud rate in the LED display :
Coding
0
1
2
3
4
Baud rate in kbit/s
10
20
50
100
125
SERVOSTAR 640/670 Instructions Manual
Coding
5
6
7
8
9
10
Baud rate in kbit/s
250
333
500
666
800
1000
91
92
PE
L3
L2
L1
M
X0
X4
X3
AGND
SW+
SW-
SERVOSTAR 640/670
3EF-xx
Regeneration
resistor
M
FB1
X0
X4
X3
W
V
U
PE
BRAKE+
BRAKE-
XGND
+24V
BTB
BTB
ENABLE
DGND
NSTOP
PSTOP
AGND
An. In1-
An. In1+
-DC
-DC
+DC
Rb1
FB2
Rb1
PE
+DC
L3
PE
L3
L2
PSTOP
L2
BTB
L1
NSTOP
L1
W
V
Mains choke
DGND
U
PE
BRAKE+
BRAKE-
XGND
+24V
BTB
BTB
ENABLE
DGND
NSTOP
PSTOP
AGND
An. In1-
An. In1+
Power supply
24V/20A
ENABLE
FB2
=
Mains
contactor
9.4.3
FB1
~
Line
protection
07/2016
Regeneration
resistor
Master switch
Setup
Kollmorgen
Example of connections for a multi-axis system
BTB
Reference Safety Instructions (ð p.10)
and Use As Directed (ð p.12) !
NSTOP
PSTOP
SW+
SW-
SERVOSTAR 640/670
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
9.5
Setup
07/2016
Key operation / LED display
In this chapter the two possible operation menus and the use of the keys in the front
panel are shown. Normally, the SERVOSTAR 640/670 only places the standard menu at
your disposal. If you want to attend the amplifier via the detailed menu, you must keep the
right key pressed while switching on the 24V-supply.
9.5.1
Key operation
The two keys can be used to perform the following functions:
Key symbol Functions
press once : go up one menu item, increase number by one
press twice in rapid succession : increase number by ten
press once : go down one menu item, decrease number by one
press twice in rapid succession : decrease number by ten
press and hold right key, then press left key as well :
enters a number, return function
9.5.2
Status display
Switch on
24V
Option -AS- is active
Reset input active
The "Reset" function is assigned to a digital
input where a High signal is connected
status 1 : 24V switched on
unit indicates software version
after 1 sec. shift to status 2, 3 or 4
status 2 : 24V switched on
unit indicates current (here 1A)
status 3 : 24V switched on, mains supply switched on
unit indicates current and mains supply on
status 4 : 24V and mains supply on, unit enabled
unit indicates current, mains supply on and enable
1s
1s
1s
1s
fault/warning signal : each error/warning
that has occurred will be indicated
successively for 4 blinks each
Parameters
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Setup
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Standard menu structure
State
see p.91
the entry will be stored automatically,
when you exit the input field.
to
9.5.4
Extended menu structure
Keep the right key pressed while switching on the 24V-supply.
State
to
station adress see p.91
to
baudrate see p.91
to
KP-speed control
to
Tn-speed control [ms]
to
setpoint-offset [mV]
to
motor type - see reference guide "motor database"
or
or
or
brake
or
Multidrive
positon output
load data from EEPROM
save data to EEPROM
ASCII-command RSTVAR (parameter will be reset to default values)
ASCII-command M_Reset (macros are newly compiled)
Block1
Block2
Block3
serial number : 9-digit number
divided in 3 blocks, decimal dot
indicates number of block
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9.6
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Setup
Error messages
Errors which 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, and the
output stage of the amplifier being switched off (motor loses all torque). If a motor-holding
brake is installed, it will be activated.
Number
E/S/A/P
...
F01*
F02*
F03*
F04
F05*
F06
F07
F08*
F09
F10
F11
F12
F13*
F14
F15
F16*
F17
F18
F19*
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
F31
F32
Designation
Status Messages
Status Message
Status Message
Explanation
Status messages, no error, see p. 93
Updating the startup configuration
Programming mode
Heat sink temperature too high
Heat sink temperature
limit is set by manufacturer to 80°
Overvoltage in DC bus link
Overvoltage
limit depends on the electrical supply voltage
Following error
Message from the position controller
Feedback
Cable break, short-circuit, short to ground
Undervoltage in DC bus link
Undervoltage
limit is set by manufacturer to 100V
Motor temperature too high or temp. sensor defect
Motor temperature
limit is set by manufacturer to 145°C
Internal voltage supply Internal amplifier supply voltages are out of tolerance
Overspeed
Motor runs away, speed is too high
EEPROM
Checksum error
Flash-EPROM
Checksum error
Brake (motor)
Cable break, short-circuit, short to ground
Motor phase
Motor phase missing (cable break or similar)
Internal temperature
Internal temperature too high
Output stage
Fault in the power output stage
I²t max.
I²t maximum value exceeded
Supply BTB/RTO
2 or 3 phases missing in the mains supply feed
Error in the analog-digital conversion, normally caused
A/D converter
by extreme electromagnetic interferences.
Brake
Brake circuit faulty or incorrect setting
A phase is missing in the mains supply power feed
Supply phase
(can be switched off for 2-phase operation)
Slot fault
Slot error (hardware fault on expansion card)
Handling error
Software error on the expansion card
Earth short circuit
Short-circuit between motor phase and ground
CAN-bus off
Severe CAN bus communication error
Warning
Warning is displayed as fault
Commutation error
Commutation error
Homing error (machine has driven onto hardware limit
Limit switch
switch)
Operational error with -AS- , input for AS-Enable and
AS
ENABLE have been set at the same time
External position profile generator created a step, that
External Trajectory
exceeded the maximum value
Slot Fault
depends on expansion card, see online help
Emergency timeout
Timeout emergency stop
Macro
Macro program error
System Error
system software not responding correctly
* = These error messages can be cancelled by the ASCII command CLRFAULT, without executing a reset. If
only these errors are present, and the RESET button or the I/O-function RESET is used, the CLRFAULT command is also all that is carried out.
More information to the messages can be found in the ASCII Object Reference (Online
Help), see parameter ERRCODE. Hints for removal can be found in section "Trouble-Shooting" of the online help.
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Setup
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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.
Number
E/S/A/P
...
n01
n02
n03*
n04*
n05
n06*
n07*
n08
n09
n10*
n11*
n12
n13*
n14
n15
n16
n17
n18
n19
n20
n21
n22
Designation
Status Messages
Status Message
Status Message
I²t
Brake power
S_fault
Explanation
Status messages, no error, see p. 93
Updating the startup configuration
Programming mode
I²t threshold exceeded
Reached preset electrical brake power limit
Exceeded preset following error limit
Response monitoring (fieldbus) has been actiResponse monitoring
vated
Supply phase
Mains supply phase missing
SW limit switch 1
Underrun software limit switch 1
SW limit switch 2
Overrun software limit switch 2
Motion task error
A faulty motion task was started
No reference point (Home) set at start of motion
No reference point
task
PSTOP
PSTOP limit-switch activated
NSTOP
NSTOP limit-switch activated
Only for ENDAT or HIPERFACE® :
Motor default values
discrepancy between motor number saved in
loaded
the encoder and the amplifier, motor default values loaded
24V supply of the I/O expansion board is missSlot warning
ing
SinCos commutation (wake & shake) not comSinCos feedback
pleted, will be canceled when amplifier is enabled and wake&shake carried out
Fault according to speed/current table
Table error
INXMODE 35
Summarized warning
Summarized warning for n17 to n31
The mode synchronization SYNCSRC is seFielbus Synchronization
lected but the drive isn’t in synchronies cycle
Using Multiturn encoder feedback, an overrun
Multiturn overrun
over the maximum number of resolutions was
detected
Motion task ramps are limited Range overflow on motion task data
Wrong GMT data
Wrong "Graphical Motion Task" data
PLC program error
For details see plc code
The user can shut down the process before the
max. motor temperatur
temperature eror will interrupt the process imreached
mediately
n23...n3
reserved
1
firmware beta version
n32
reserved
Firmware is an unreleased beta version
* = These warning messages lead to a controlled shut-down of the drive (braking with the emergency ramp)
More information to the messages can be found in the ASCII Object Reference (Online
Help), see parameter STATCODE. Hints for removal can be found in section "Trouble-Shooting" of the online help.
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9.8
07/2016
Setup
Removing faults / warnings
Depending on the conditions in your installation, there may be a wide variety of reasons
for the fault. In multi-axis systems there may be further hidden causes of a fault.
Eliminate errors and faults in compliance with work safety rules. Troubleshooting only by
qualified and trained staff.
Detailled hints for removal of faults can be found in the Online Help, chapter "Trouble-Shooting".
Our customer service can give you further assistance with problems.
Measures to remove the cause
Fault
possible causes
of
the fault
HMI mes— use null-modem cable
— wrong cable used
— cable plugged into wrong position — plug cable into the correct
sage:
sockets on amplifier and PC
in servo amplifier or PC
communica— select correct interface
— wrong PC interface selected
tion fault
— apply enable signal
— servo amplifier not enabled
— check setpoint cable
— break in setpoint cable
— correct motor phase sequence
— motor phases swapped
motor does
— check brake control
— brake not released
not rotate
— check mechanism
— drive is mechanically blocked
— set no. of motor poles
— no. of motor poles set incorrectly
— set up feedback correctly
— feedback set up incorrectly
— reduce Kp (speed controller)
— gain too high (speed controller)
motor
— shielding in feedback cable broken — replace feedback cable
oscillates
— join AGND to CNC-GND
— AGND not wired up
drive reports — Irms or Ipeak is set to low
— increase Irms or Ipeak
following er(keep within motor data !)
—
shorten setpoint ramp +/—
setpoint
ramp
is
too
long
ror
motor over— Irms/Ipeak set too high
— reduce Irms/Ipeak
heating
— increase Kp (speed controller)
— Kp (speed controller) too low
— use motor default value for
— Tn (speed controller) too high
Tn (speed controller)
drive too soft
— reduce PID-T2
— PID-T2 too high
— T-Tacho too high
— reduce T-Tacho
— reduce Kp (speed controller)
— Kp (speed controller) too high
— use motor default value for
— Tn (speed controller) too low
drive runs
Tn (speed controller)
roughly
— increase PID-T2
— PID-T2 too low
— increase T-Tacho
— T-Tacho too low
— adjust setpoint-offset (analog
— offset not correctly adjusted for
I/O)
analog setpoint provision
axis drifts at
setpoint = 0V — AGND not joined to the CNC-GND — join AGND and CNC-GND
of the controls
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Expansion Cards
10
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Expansion Cards
Information about availability and order numbers can be found on p. 115
10.1
Guide to installation of expansion cards
l
l
l
l
l
98
Use a suitable screwdriver to unscrew
the cover of the option slot.
Take care that no small items (such as
screws) fall into the open option slot.
Push the expansion card carefully into
the provided guide rails of the main
slot, without twisting it.
Press the expansion card firmly into
the slot, until the front cover touches
the fixing lugs. This ensures that the
connectors make good contact.
Screw the screws on the front cover
into the threads in the fixing lugs.
SERVOSTAR 640/670 Instructions Manual
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10.2
Expansion Cards
07/2016
Expansion card -I/O-14/08This chapter describes the I/O-expansion card -I/O-14/08-. It only describes the additional
features that the expansion card makes available for the SERVOSTAR 640/670.
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 fast.
The -I/O-14/08- provides you with 14 additional digital inputs and 8 digital outputs. The
functions of the inputs and outputs are fixed. They 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.
The functions of the inputs and signal outputs correspond exactly to the functions that can
be assigned to the digital-I/O on connector X3 of the SERVOSTAR 640/670.
All inputs and outputs are electrically isolated from the servo amplifier by optocoupler.
10.2.1
Front view
10.2.2
Technical data
24V / 7mA, PLC-compatible, EN 61131
24V / max. 500mA, PLC-compatible, EN 61131
24V (18 ... 36V) / 100mA plus total current of the
outputs (depends on the input wiring of the controls)
Supply inputs, EN 61131
The 24VDC voltage has to be supplied by an
electrically isolated power supply, e.g. with insulating transformer.
4 AT
Fusing (external)
MiniCombicon, 12-pole, coded on PIN1 and 12 reConnectors
spectively
Data – up to 50m long : 22 x 0.5mm², unshielded,
Cables
Supply – 2 x 1mm², check voltage drop
depends on the response time of the control sysWaiting time between 2 motion
tem
tasks
4ms
Addressing time (min.)
2ms
Starting delay (max.)
Response time of digital outputs max. 10ms
Control inputs
Signal outputs
10.2.3
Light emitting diodes (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, short-circuit).
10.2.4
Select motion task number (sample)
Motion task no.
binary 1010 1110
decimal 174
A7
1
128
SERVOSTAR 640/670 Instructions Manual
A6
0
-
A5
1
32
A4
0
-
A3
1
8
A2
1
4
A1
1
2
A0
0
-
99
Expansion Cards
10.2.5
07/2016
Kollmorgen
Connector assignments
Connector X11A
Terminal
Dir
1
In
2
In
3
In
4
In
5
In
6
In
7
In
8
In
9
In
10
In
11
In
12
In
Function
A0
A1
A2
A3
A4
A5
A6
A7
Description
Motion task no., LSB
1
Motion task no., 2
2
Motion task no., 2
3
Motion task no., 2
4
Motion task no., 2
5
Motion task no., 2
6
Motion task no., 2
Motion task no., MSB
Polls the reference switch. If a digital input on the basic unit
is used as a reference input, then the input on the I/O expanReference
sion card will not be evaluated.
Clear the warning of a following error or the response moniFError_clear
toring.
The following task, that is defined in the motion task by “Start
with I/O” is started. The target position of the present motion
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 basic unit.
Start of the setup mode "Jog Mode" with a defined speed. After selecting the function, you can enter the speed in the auStart_Jog v=x xiliary variable “x”. The sign of the auxiliary variable defines
the direction. A rising edge starts the motion, a falling edge
cancels the motion.
Connector X11B
100
1
In
MT_Restart
2
In
Start_MT I/O
3
Out
InPos
4
Out
5
6
7
8
9
10
11
12
Out
Out
Out
Out
Out
Out
Supply
Supply
Next-InPos
PosReg0
FError
PosReg1
PosReg2
PosReg3
PosReg4
PosReg5
24VDC
I/O-GND
Continues the motion task that was previously interrupted.
The motion task can also be continued by an appropriately
configured digital input on the basic unit.
Start of the motion task that has the number that is presented, bit-coded, at the digital inputs (A0 to A7).
The digital function with the same name, in the basic unit,
starts the motion task with the address from the digital inputs
on the basic unit.
When the target position for a motion task has been reached
(the InPosition window), this is signalled 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 signalled by an inversion of the
output signal. The output produces a Low signal at the start
of the first motion task of the motion task sequence.
The form of the message can be varied by using ASCII commands.
Can only be adjusted by ASCII commands.
Following-error (low-active).
The preset function of the corresponding position register is
indicated by a HIGH-signal.
Can only be adjusted by ASCII commands.
auxiliary supply voltage
Digital-GND for the controls
SERVOSTAR 640/670 Instructions Manual
Kollmorgen
10.2.6
Expansion Cards
07/2016
Connection diagram
Control
X11A
SERVOSTAR 640/670
+24V ref. to I/O-GND
1
-IO14/8-
<
<
<
<
<
<
<
<
2
3
4
5
8
6
7
8
9
10nF
12
A3
A4
A5
A6
A7
}
binary coded
motion task No.
Reference
FError_clear
Start_MT next
Start_Jog v=x
X11B
<
<
2
3
4
5
8
A2
<
<
<
11
1
A1
<
10
I/O-GND
A0
6
7
8
9
10
11
+
12
-
MT_Restart
Start_MT I/O
>
>
>
>
>
>
>
InPos
>
PosReg5
Next-InPos / PosReg0
FError
PosReg1
PosReg2
PosReg3
PosReg4
4AT
+ 24V
I/O-GND
I/O-GND
X3
18
DGND
10
AGND
AGND and DGND (connector X3) must be joined together !
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Expansion Cards
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07/2016
Expansion cards -PROFIBUSThis chapter describes the PROFIBUS expansion card for the SERVOSTAR 640/670.
Information on the range of functions and the software protocol can be found in the manual "Communication profile PROFIBUS DP". The PROFIBUS expansion card has two
9-pin Sub-D sockets wired in parallel. The supply voltage for the expansion card is provided by the servo amplifier.
10.3.1
Front view
10.3.2
Connection technology
Cable selection, cable routing, shielding, bus connector, bus termination and transmission times are described in the “Installation guidelines for PROFIBUS-DP/FMS” from
PNO, the PROFIBUS User Organization.
10.3.3
Connection diagram
SERVOSTAR 640/670
X12A
PROFIBUS
1
1
5
5
GND1
390Ù
8
390Ù
8
RS485-A
3
220Ù
220Ù
3
RS485-B
390Ù
6
+5V
390Ù
6
+5V
=
=
4
4
X12B
1
8
3
6
5
4
X3
18
DGND
10
AGND
AGND and DGND (connector X3) must be joined together !
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10.4
07/2016
Expansion Cards
Expansion card -SERCOSThis chapter describes the SERCOS expansion card for SERVOSTAR 640/670.
Information on the range of functions and the software protocol can be found in the manual "IDN Reference Guide SERCOS".
10.4.1
Front view
10.4.2
Light emitting diodes (LEDs)
indicates whether SERCOS telegrams are being correctly received. In the final
RT 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.
TT
Check the stations 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
(BAUDRATE) and the fibre-optic connection.
If this LED flickers, this indicates a low level of interference for SERCOS commuERR
nication, or the optical transmitting power is not correctly adjusted to suit 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 DRIVE.EXE on the SERCOS screen page, by altering the parameter for
the cable length.
10.4.3
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 with an F-SMA connector.
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Expansion Cards
10.4.4
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07/2016
Connection diagram
Layout of the SERCOS bus system in ring topology, with optical fibre cables (schematic).
Fibr
Co
ntr
oll
e op
tic c
able
er
AGND and DGND (connector X3) must be joined together !
10.4.5
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. There are various ways to set the station
address:
Keys on the front of the servo amplifier
The SERCOS address can also be modified using the keys on the front (p. 94).
Setup software
The address can also be modified in the setup software. For additional information,
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.
10.4.6
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. For additional
information, please refer to the setup software online help. Alternatively, the commands
SBAUD # and SLEN # can be entered in the “Terminal” screen.
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10.5
Expansion Cards
07/2016
Expansion card -DEVICENETThis section describes the DeviceNet expansion card for SERVOSTAR 640/670.
Information on the range of functions and the software protocol can be found in our manual “DeviceNet Communication Profile”.
10.5.1
Front view
10.5.2
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.
10.5.3
Connection diagram
SERVOSTAR 640/670
X3
10
18
AGND
DeviceNet server/client
DGND
X15
CANH
4
120Ù*
PGND
120Ù*
2
CANL
1
V-
5
3
Shield
11-25V
* according to line impedance
=
=
AGND and DGND (connector X3) must be joined together !
SERVOSTAR 640/670 Instructions Manual
105
Expansion Cards
10.5.4
07/2016
Kollmorgen
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).
10.5.5
Setting the station address (device address)
The station address for the servo amplifier can be set in three different ways:
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.
10.5.6
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.
106
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10.5.7
Expansion Cards
07/2016
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 attached
Min. differential input imstub 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.
X15
X15
1
V-
2
CAN_L
3
4
5
Shield
CAN_H
V+
X15
X15
1
V-
1
2
2
CAN_L
2
3
3
4
4
5
5
1
Shield
CAN_H
V+
3
*
4
5
* according to line impedance about 120
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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Expansion Cards
10.6
Kollmorgen
07/2016
Expansion card -ETHERCATThis section describes the EtherCAT expansion card for SERVOSTAR 640/670. 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 via RJ-45 connectors (IN and OUT ports).
10.6.1
Front view
10.6.2
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)
10.6.3
Connection diagram
Co
ntr
oll
er
AGND and DGND (connector X3) must be joined together !
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10.7
Expansion Cards
07/2016
Expansion card -SYNQNETThis section describes the SynqNet expansion card for SERVOSTAR 640/670.
Information on the range of functions and the software protocol can be found in the
SynqNet documentation..
10.7.1
Front view
10.7.2
NODE ID Switch
LED2
LED1
LED4
LED3
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.
10.7.3
Node LED table
LED#
Name
LED1, green
LINK_IN
LED2, yellow CYCLIC
LED3, green
LINK_OUT
LED4, yellow REPEATER
10.7.4
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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Expansion Cards
10.7.5
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07/2016
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
Out NODEALARM
Indicates a problem with the node
2
Out OUT_01
Digital output
3
In IN_00 (fast)
Capture input (fast)
4
In IN_04
Digital input
5
In IN_01
Digital input
6
In HOME
Reference switch
7
In POSLIM
Limit switch, positive direction
8
In GND
Power supply
9
Out OUT_00
Digital output
10
Out OUT_02
Digital output
11
In IN_02
Digital input
12
In IN_03
Digital input
13
In NEGLIM
Limit switch, negative direction
14
In NODEDISABLE
Disables Node
15
10.7.6
Connection diagram digital inputs/outputs, connector X21A
8
DGND
SERVOSTAR
Control
5
IN 04
6
IN 01
7
HOME
8
POSLIM
12
IN 02
13
IN 03
14
NEGLIM
15
NODEDISABLE
4
IN 00 (Fast)
DGND
1
+24V
2
NODEALARM
3
OUT 01
10
OUT 00
11
OUT 02
DGND
9
GND
AGND and DGND (connector X3) must be joined together !
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10.8
07/2016
Expansion Cards
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.
10.8.1
Installation
The modul must be placed onto the option slot after levering off the cover of the option
slot:
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
10.8.2
Front View
10.8.3
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).
SERVOSTAR 640/670 Instructions Manual
111
Expansion Cards
10.8.4
Connector assignments
RS232
X6A Pin
1
2
3
4
5
6
7
8
9
10.8.5
Kollmorgen
07/2016
CAN1=CAN2
X6B=X6C Pin
1
2
3
4
5
6
7
8
9
Signal
Vcc
RxD
TxD
GND
CAN-Low
CAN-GND
CAN-High
Connection diagram
OFF
ON
X6
X5
X2
X1
X6
X5
ON
X1
ON
OFF
OFF
X6A
RS232
RS232
X3
X3
AGND
AGND
Analog-In 1+
Analog-In 1Analog-In 2+
Analog-In 2-
Analog-In 2-
Analog-Out 1
Analog-Out 1
Analog-Out 2
Analog-Out 2
AGND
AGND
NSTOP
ENABLE
DGND
2-CAN
2-CAN
DGND
PSTOP
CAN2
CAN2
NSTOP
X6C
X6C
PSTOP
ENABLE
CAN
Master
BTB / RTO
CAN1
Analog-In 2+
BTB / RTO
X6B
Analog-In 1-
CAN1
Analog-In 1+
X6B
BTB / RTO
X6A
X2
BTB / RTO
112
Signal
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11
Appendix
11.1
Glossary
B
Brake circuit
C
Clock
Common-mode voltage
Continuous power of brake circuit
Counts
Current controller
D
E
F
G
H
I
DC bus link
Disable
Enable
Final speed
Fieldbus interface
GRAY-code
Holding brake
I²t threshold
Input drift
Incremental encoder interface
K
L
Ipeak, peak current
Irms, effective current
Kp, P-gain
Limit-switch
M
Machine
Monitor output
Motion-block
N
O
Multi-axis system
Natural convection
Optocoupler
Appendix
Converts superfluous energy, which is fed back
during braking, into heat in the brake resistor
Clock signal
The maximum amplitude of a disturbance (on both
inputs) which a differential input can eliminate
Mean power which can be dissipated in the brake
circuit
Internal count pulses, 1 pulse = 1/220 turn-1
Regulates the difference between the current
setpoint and the actual value to 0
Output: power output voltage
Rectified and smoothed power voltage
Removal of the enable signal (0V or open)
Enable signal for the servo amplifier (+24V)
Maximum value for speed normalization at ±10V
CANopen, PROFIBUS, SERCOS etc.
Special method of representing binary numbers
Brake in the motor, which can only be used when
the motor is at a standstill
Monitoring of the actually required r.m.s. current
Temperature and age-dependent alteration of an
analog input
Position signaling by 2 signals with 90° phase
difference, not an absolute position output
The effective value of the peak current
The r.m.s. value of the continuous current
Proportional gain of a control loop
Switch limiting the traverse path of the machine;
implemented as n.c. (break) contact
The complete assembly of all connected parts or
devices, of which at least one is movable
Output of an analog measurement
Data packet with all the position control parameters which are required for a motion task
Machine with several independently driven axes
Free movement of air for cooling
Optical connection between two electrically
independent systems
SERVOSTAR 640/670 Instructions Manual
113
Appendix
P
07/2016
P-controller
Phase shift
PID-controller
PID-T2
Position controller
Potential isolation
Power contactor
Pulse power of the brake circuit
R
S
Regen circuit
Reset
Resolver-digital converter
Reversing mode
Ring core
ROD-Interface
Servo amplifier
Setpoint ramps
Short to ground
Short-circuit
Speed controller
SSI-interface
Supply filter
T
T-tacho, tachometer time constant
Tachometer voltage
Thermal control
Z
114
Tn, I-integration time
Zero pulse
Kollmorgen
Control loop with purely proportional behavior
Compensation for the lag between the electromagnetic and magnetic fields in the motor
Control loop with proportional, integral and
differential behavior
Filter time constant for the speed controller output
Regulates the difference between the position
setpoint and the actual position to 0
Output : speed setpoint
Electrically decoupled
System protection device with phase monitoring
Maximum power which can be dissipated in the
brake circuit
see Brake Circuit
New start of the microprocessor
Conversion of the analog resolver signals into
digital information
Operation with a periodic change of direction
Ferrite rings for interference suppression
Incremental position output
Control device for regulating the position of a
servomotor
Limits for the rate of change of the speed setpoint
Electrically conductive connection between a
phase and PE (protective earth (ground))
here: electrically conductive connection between
two phases
Regulates the difference between the speed
setpoint and the actual value to 0
Output : current setpoint
Cyclic-absolute, serial position output
Device to divert interference on the power supply
cables to PE
Filter time constant in the speed feedback
of the control loop
Voltage proportional to the actual speed
Temperature-sensitive device built into the
motor winding (usually a PTC)
Integral section of a control loop
Output once per turn from incremental encoders,
used to zero the machine
SERVOSTAR 640/670 Instructions Manual
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11.2
Appendix
07/2016
Order codes
The order numbers of accessories such as cables, brake resistors, mains supplies, etc.,
can be found in the accessories manual.
11.2.1
Servo amplifiers
Article
SERVOSTAR 640
SERVOSTAR 670
EU order code
DE-91419
DE-91955
US order code
S64001-NA
S67001-NA
EU order code
DE-103571
DE-90056
DE-90879
DE-90057
DE-108350
DE-200073
DE-101174
US order code
OPT-DN
OPT-PB
OPT-SE
OPT-EI
OPT-EC
OPT-SN
not available
EU order code
DE-101695
DE-92143
DE-101696
DE-106368
US order code
CON-S6X3a
CON-S6X4a
CON-S6X10
CON-S6X15
*= NA means without built-in expansion card
11.2.2
Expansion cards
Article
Expansion card DeviceNet
Expansion card PROFIBUS DP
Expansion card SERCOS
Expansion card -I/0-14/08Expansion card EtherCAT
Expansion card SynqNet
Expansion module 2CAN
11.2.3
Connectors
Article
Connectors X3
Connectors X4
Connectors X10
Connectors X15
(I/O)
(24V)
(AS)
(DeviceNet)
SERVOSTAR 640/670 Instructions Manual
115
Appendix
07/2016
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This page has been deliberately left blank.
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11.3
07/2016
Index
!
24Vaux. supply, interface . . . . . . . . . . . 46
A
A quad B interface . . . . . . . . . . . . . . . 63
Abbreviations . . . . . . . . . . . . . . . . . . 9
Address . . . . . . . . . . . . . . . . . . . . 91
Ambient conditions . . . . . . . . . . . . . . . 24
Ambient temperature. . . . . . . . . . . . . . 24
Analog outputs . . . . . . . . . . . . . . . . . 66
Assembly. . . . . . . . . . . . . . . . . . . . 35
BISS interface . . . . . . . . . . . . . . . . . 52
BTB/RTO. . . . . . . . . . . . . . . . . . . . 68
Baudrate . . . . . . . . . . . . . . . . . . . . 91
Block diagram . . . . . . . . . . . . . . . . . 42
Brake. . . . . . . . . . . . . . . . . . . . . . 26
Brake circuit . . . . . . . . . . . . . . . . . . 27
Brake resistor, interface . . . . . . . . . . . . 47
CANopen-Interface. . . . . . . . . . . . . . . 70
CE-conformance . . . . . . . . . . . . . . . . 18
Capacitor Module . . . . . . . . . . . . . . . 47
Cleaning . . . . . . . . . . . . . . . . . . . . 15
ComCoder, interface . . . . . . . . . . . . . . 56
Conductor cross-sections . . . . . . . . . . . 25
Connection diagram . . . . . . . . . . . . . . 44
DC-link interface . . . . . . . . . . . . . . . . 46
Decommissioning . . . . . . . . . . . . . . . 15
DeviceNet bus cable . . . . . . . . . . . . . 107
Disassemble . . . . . . . . . . . . . . . . . . 15
Disposal . . . . . . . . . . . . . . . . . . . . 16
Emergency Off . . . . . . . . . . . . . . . . . 32
Enclosure protection . . . . . . . . . . . . . . 24
Encoder
Emulations . . . . . . . . . . . . . . . . . 63
Interface . . . . . . . . . . . . . . . . . . 53
Master-Slave interface . . . . . . . . . . . 58
Error messages . . . . . . . . . . . . . . . . 95
Expansion card
-2CAN- . . . . . . . . . . . . . . . . . . 111
-DeviceNet- . . . . . . . . . . . . . . . . 105
-EtherCat- . . . . . . . . . . . . . . . . . 108
-I/O-14/08- . . . . . . . . . . . . . . . . . 99
-PROFIBUS- . . . . . . . . . . . . . . . 102
-SERCOS- . . . . . . . . . . . . . . . . 103
-SynqNet- . . . . . . . . . . . . . . . . . 109
Guide to installation . . . . . . . . . . . . 98
External fusing . . . . . . . . . . . . . . . . . 24
Forming . . . . . . . . . . . . . . . . . . . . 78
B
C
D
E
F
G
H
I
K
L
Appendix
Glossary . . . . . . . . . . . . . . . . . . . 113
Ground symbol . . . . . . . . . . . . . . . . . 39
Grounding
Connection diagram . . . . . . . . . . . . 44
Installation . . . . . . . . . . . . . . . . . 38
Hall, interface . . . . . . . . . . . . . . . . . 55
Hardware requirements . . . . . . . . . . . . 80
Holding brake . . . . . . . . . . . . . . . . . 26
Incremental encoder, interface . . . . . . . . . 57
Inputs
Analog setpoints . . . . . . . . . . . . . . 65
DIGI-IN 1/2 . . . . . . . . . . . . . . . . . 67
Enable . . . . . . . . . . . . . . . . . . . 67
NSTOP . . . . . . . . . . . . . . . . . . . 67
PSTOP . . . . . . . . . . . . . . . . . . . 67
Installation
Electrical . . . . . . . . . . . . . . . . . . 37
Expansion cards . . . . . . . . . . . . . . 98
Mechanical . . . . . . . . . . . . . . . . . 34
Software . . . . . . . . . . . . . . . . . . 80
Key operation . . . . . . . . . . . . . . . . . 93
M
N
O
P
Q
R
S
T
U
V
W
Mains supply connection, interface. . . . . . . 46
Mains supply networks . . . . . . . . . . . . . 45
Maintenance . . . . . . . . . . . . . . . . . . 15
Master-Slave . . . . . . . . . . . . . . . . . . 58
Motor holding brake . . . . . . . . . . . . . . 26
Motor, interface . . . . . . . . . . . . . . . . 49
Mounting position . . . . . . . . . . . . . . . 24
Multi-axis systems
Address / Baud Rate . . . . . . . . . . . . 91
Connection example . . . . . . . . . . . . 92
NSTOP . . . . . . . . . . . . . . . . . . . . . 67
Nameplate . . . . . . . . . . . . . . . . . . . 19
Noise emission . . . . . . . . . . . . . . . . . 24
Operating systems . . . . . . . . . . . . . . . 80
Options . . . . . . . . . . . . . . . . . . . . . 22
Order codes. . . . . . . . . . . . . . . . . . 115
Outputs
Analog out 1/2 . . . . . . . . . . . . . . . 66
BTB/RTO . . . . . . . . . . . . . . . . . . 68
DIGI-OUT 1/2 . . . . . . . . . . . . . . . 68
PC cable . . . . . . . . . . . . . . . . . . . . 69
PC connection . . . . . . . . . . . . . . . . . 69
PSTOP . . . . . . . . . . . . . . . . . . . . . 67
Package supplied . . . . . . . . . . . . . . . 19
Packaging . . . . . . . . . . . . . . . . . . . 14
Part number scheme . . . . . . . . . . . . . . 20
Pin assignments . . . . . . . . . . . . . . . . 43
Pollution level . . . . . . . . . . . . . . . . . 24
Pulse-direction, interface . . . . . . . . . . . . 61
Quickstart . . . . . . . . . . . . . . . . . . . 81
RS232/PC, interface . . . . . . . . . . . . . . 69
Repair . . . . . . . . . . . . . . . . . . . . . 16
Residual-current circuit breaker (FI) . . . . . . 33
Resolver, interface . . . . . . . . . . . . . . . 51
Restart lock -AS- . . . . . . . . . . . . . . . . 71
SSI, interface. . . . . . . . . . . . . . . . . . 64
Safety instructions . . . . . . . . . . . . . . . 10
Setpoint inputs . . . . . . . . . . . . . . . . . 65
Setup. . . . . . . . . . . . . . . . . . . . . . 78
Shielding
Connection diagram . . . . . . . . . . . . 44
Connection techniques . . . . . . . . . . . 40
Installation . . . . . . . . . . . . . . . . . 38
Shock-hazard protection . . . . . . . . . . . . 33
Sine-cosine encoder, interface . . . . . . . . . 54
Site . . . . . . . . . . . . . . . . . . . . . . . 34
Site altitude. . . . . . . . . . . . . . . . . . . 24
Standards . . . . . . . . . . . . . . . . . . . . 8
Storage. . . . . . . . . . . . . . . . . . . . . 14
Supply voltage . . . . . . . . . . . . . . . . . 24
Switch-on and switch-off behaviour . . . . . . 28
System components, overview. . . . . . . . . 41
Target group . . . . . . . . . . . . . . . . . . 10
Technical data . . . . . . . . . . . . . . . . . 23
Torque, connectors . . . . . . . . . . . . . . 24
Transport . . . . . . . . . . . . . . . . . . . . 14
Trouble shooting . . . . . . . . . . . . . . . . 97
Use as directed
Hardware . . . . . . . . . . . . . . . . . . 12
Setup software . . . . . . . . . . . . . . . 79
Ventilation
Installation . . . . . . . . . . . . . . . . . 34
Tech.Data . . . . . . . . . . . . . . . . . 24
Vibrations . . . . . . . . . . . . . . . . . . . 24
Warning messages. . . . . . . . . . . . . . . 96
Wiring . . . . . . . . . . . . . . . . . . . . . 39
LC-Display . . . . . . . . . . . . . . . . . . . 93
Leakage current . . . . . . . . . . . . . . . . 33
Limit Switch Inputs . . . . . . . . . . . . . . . 67
SERVOSTAR 640/670 Instructions Manual
117
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 the Customer Support.
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