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Product Manual

Edition 09/2006

Valid for Hardware Revision 02.01

SERVOSTAR

300

Digital Servo Amplifier

Keep all manuals as a product component

during the life span of the servo amplifier.

Pass all manuals to future users / owners

of the servo amplifier.

File sr300_e.xxx

Summary of content (110 pages)

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SERVOSTAR® 300 Digital Servo Amplifier Product Manual Edition 09/2006 Valid for Hardware Revision 02.01 Keep all manuals as a product component during the life span of the servo amplifier. Pass all manuals to future users / owners of the servo amplifier. File sr300_e.
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Record of Document Revisions: Revision 06/04 04/05 04/05a 11/05 12/05 02/06 05/06 09/06 Remarks First edition Restart lock -AS-, UL-listing, new pinning for X8, several corrections order numbers 400V types for NA updated Chapter 1 updated, ComCoder wiring corrected, Acuro(BISS)-Interface new, max.
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Kollmorgen 09/2006 Contents page 1 General 1.1 1.2 1.3 1.4 2 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hints for the online edition (PDF format) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Contents 09/2006 Kollmorgen page 8.10 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.1 Resolver (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.2 ComCoder (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Kollmorgen 09/2006 Contents page 10 Expansions and Accessories 10.1 Expansion Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 10.1.1 Guide to installation of expansion cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 10.1.2 Expansion card -I/O-14/08- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Kollmorgen 09/2006 This page has been deliberately left blank.
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Kollmorgen General 09/2006 1 General 1.1 About this manual This manual describes the SERVOSTAR® 300 series of digital servo amplifiers (standard version: 1.5A ...10A rated current). A more detailed description of the expansion cards that are currently available and the digital connection to automation systems can be found, together with our applications notes, in Acrobat-Reader format on the accompanying CD-ROM (system requirements: WINDOWS, Internet Browser, Acrobat Reader) in different languages.
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General 1.4 Kollmorgen 09/2006 Abbreviations used The abbreviations used in this manual are explained in the table below. Abbrev.
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Kollmorgen 09/2006 2 Safety 2.1 Safety Instructions Safety l Only properly qualified personnel are permitted to carry out activities such as transport, installation, commissioning and maintenance. Properly qualified persons are those who are familiar with the transport, assembly, installation, commissioning and operation of the product, and who have the appropriate qualifications for their job.
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Safety 2.2 09/2006 Kollmorgen Use as directed Servo amplifiers are components that are built into electrical plant or machines, and can only be operated as integral components of such plant or machines. The manufacturer of the machine must generate a hazard analysis for the machine, and take appropriate measures to ensure that unforeseen movements cannot cause injury or damage to any person or property.
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Kollmorgen 09/2006 3 Standards 3.1 European Directives and Standards Standards Servo amplifiers are components that are intended to be incorporated into electrical plant and machines for industrial use. When the servo amplifiers are built into machines or plant, the amplifier must not be used until it has been established that the machine or equipment fulfills the requirements of the EC Machinery Directive (98/37/EC), the EC EMC Directive (89/336/EEC) and the EC Low Voltage Directive 73/23/EEC.
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Standards Kollmorgen 09/2006 3.4 Approvals 3.4.1 CE conformance Conformance with the EC EMC Directive 89/336/EEC and the Low Voltage Directive 73/23/EEC is mandatory for the supply of servo amplifiers within the European Community. Product standard EN 61800-3 is applied to ensure conformance with the EMC Directive. The Declaration of Conformity form can be found on our website (download area).
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Kollmorgen 09/2006 4 Handling 4.1 Transport 4.2 4.3 4.4 Handling l Transport by qualified personnel in the manufacturer’s original recyclable packaging l Avoid shocks while transporting l Transport temperature: -25 to +70°C, max. rate of change 20°C / hour l Transport humidity: max. 95% relative humidity, no condensation l The servo amplifiers contain electrostatically sensitive components, that can be damaged by incorrect handling.
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Package Kollmorgen 09/2006 5 Package 5.1 Package supplied When you order an amplifier from the SERVOSTAR 300 series (order numbers ð p.106), you will receive: — — SERVOSTAR 3xx mating connectors X0, X3, X4, X8, X9 only with SERVOSTAR 303-310 (S3xx6) The mating SubD connectors are not part of the package! — — — Assembly, Installation and Setup instructions (product manual) Online documentation on CD-ROM Setup software DRIVEGUI.
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Kollmorgen 09/2006 Technical description 6 Technical description 6.1 The SERVOSTAR 300 family of digital servo amplifiers Standard version l Two voltage classes with large nominal voltage range 1 x 110V-10% ... 3 x 230V+10% (SERVOSTAR 303-310, S3xx6) 3 x 208V-10% ...
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Technical description Kollmorgen 09/2006 Integrated safety l Appropriate insulation/creepage distances and electrical isolation ensure safe electrical separation, as per EN 50178, between the power input / motor connections and the signal electronics. l Soft-start, overvoltage detection, short-circuit protection, phase-failure monitoring. l Temperature monitoring of the servo amplifier and motor (if our motors and prefabricated cables are used).
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Kollmorgen 6.2 09/2006 Technical description Connection to various electrical supply networks This page illustrates all the possible connection variations for different electrical supply networks. An isolating transformer is always required for 400 … 480V networks that are asymmetrically grounded or not grounded. 110V : SERVOSTAR 303-310* 230V : all types 400V / 480V : SERVOSTAR 341-346* * Order code reference see p.
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Technical description 6.
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Kollmorgen Technical description 09/2006 6.4 Technical data 6.4.1 Technical data for 110/230 V (types S3_ _6_) Rated data Order Code DIM — Rated supply voltage (grounded supply, phase to phase) V~ SERVOSTAR 303 306 310 S30361 S30661 S31061 1 x 110V-10% … 1 x 230V+10% 3 x 110V-10% … 3 x 230V+10% 50/60 Hz 1.1 2,4 4 450 Rated input power for S1 operation kVA Max.
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Technical description 6.4.2 Kollmorgen 09/2006 Technical data for 400/480 V (types S3_ _0_) Rated data Order Code Rated supply voltage (grounded supply, phase to phase) Rated input power for S1 operation Max. DC bus link voltage Rated output current (rms value, ± 3%) at 3x208V at 3x230V at 3x400V at 3x480V Peak output current (max. approx.
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Kollmorgen 6.4.3 09/2006 Technical description Inputs / outputs V ±10 V ±10 V as per EN 61131-2 Type 1, max. 30VDC V open Emitter, max. 30VDC, 10mA V DC max. 30, AC max 42 BTB/RTO output, relay contacts mA 500 Auxiliary supply voltage, electrically isoV 20 - 30 A 1 lated, without brake/fan V 24 (-0% +15%) Auxiliary supply voltage, electrically iso2.5 lated, with brake/fan (check voltage drop !) A Max. output current to brake A 1.
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Technical description 6.4.6 Kollmorgen 09/2006 Permissible ambient conditions, ventilation, mounting position Storage hints Transport hints Supply voltage ð p.13 ð p.13 303-310*: 341-346*: 1x110V-10% …1x230V+10%, 50/60 Hz 3x110V-10% …3x230V+10%, 50/60 Hz 3x208V-10% - 3x 480V+10%, 50/60 Hz Auxiliary voltage without brake and fan with brake or fan 20 V DC ... 30 V DC 24 V DC (-0% +15%), check voltage drop ! 0...+40°C under rated conditions Ambient temperature in operation +40...
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Kollmorgen 6.6 09/2006 Technical description Control circuit for motor-holding brake A 24V / max.1.5A holding brake in the motor can be controlled directly by the amplifier. Check voltage drop, measure the voltage at brake input and check brake function (brake and no brake). This function does not ensure personnel safety! The brake function must be enabled through the BRAKE parameter (screen page: Motor, setting: WITH).
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Technical description 6.7 Kollmorgen 09/2006 Grounding system AGND — analog inputs, internal analog ground, encoder emulation, RS232, CAN DGND — digital inputs/outputs and the 24V supply, optically isolated. 6.8 Regen circuit During braking with the aid of the motor, energy is fed back into the servo amplifier. This regenerative energy (hence the term “regen” circuit) is dissipated as heat in the regen resistor. The regen resistor is switched in by the regen circuit.
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Kollmorgen 09/2006 Technical description Technical Data: 343 / 346 (S30301/S30601) 341 (S30101) 306 / 310 (S30661/S31061) 303 (S30361) Regen circuit Rated data Switch-on (upper) threshold of regen circuit Overvoltage F02 Regen resistor (internal) Continuous power in regen circuit (RBint) Pulse power in regen circuit (RBint max. 1s) Regen resistor (external)* Continuous power in regen circuit (RBext) max. Pulse power in regen circuit (RBext max.
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Technical description 6.9 Kollmorgen 09/2006 Switch-on and switch-off behavior The diagram below illustrates the correct functional sequence for switching the servo amplifier on and off. DC bus link 6.9.1 Stop function as per EN 60204 (VDE 0113) If a fault occurs (ð p.80) then the output stage of the servo amplifier is switched off and the BTB/RTO contact is opened.
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Kollmorgen 6.9.2 09/2006 Technical description Emergency Stop strategies The Emergency Stop function is defined in EN 60204 (VDE 0113), Para. 9.2.5.4. Implementation of the Emergency Stop function : Wiring recommendation can be found in the Application Note “Stop and Emergency Stop Functions". Category 0: The controller enable is switched to “disable”, the electrical supply is disconnected. The drive must be held by an electromechanical holding device (brake).
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Mechanical Installation 7 Mechanical Installation 7.1 Important notes 7.2 Kollmorgen 09/2006 l Protect the servo amplifier from impermissible stresses. In particular, do not let any components become bent or any insulation distances altered during transport and handling. Avoid contact with electronic components and contacts. l Ensure that there is an adequate flow of cool, filtered air into the bottom of the control cabinet, or use a heat exchanger. Please refer to page 22.
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Kollmorgen 7.
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Mechanical Installation 7.4 Kollmorgen 09/2006 Dimensions n Fa . nly so e typ 1 0A 1 xx6 nd S3 x01 a A x S3 h6 wit 0 .31 3.. 0 46 R3 ...
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Kollmorgen 09/2006 8 Electrical installation 8.1 Important notes Electrical installation l Check the combination of servo amplifier and motor. Compare the rated voltage and current of the units. Implement the wiring according to the connection diagram on page 33. l Make sure that the maximum permissible rated voltage at the terminals L1, L2, L3 or +DC, –DC is not exceeded by more than 10% even in the most unfavorable circumstances (see EN 60204-1 Section 4.3.1).
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Electrical installation 8.2 Kollmorgen 09/2006 Guide to electrical installation The following notes should help you to carry out the electrical installation in a sensible sequence, without overlooking anything important. Cable selection Select cables in accordance with EN 60204 ð p.22. Grounding Shielding Wiring Final check 32 For EMC-compliant shielding and grounding ð p.38. Ground the mounting plate, motor housing and CNC-GND of the control system. Notes on connection techniques ð p.34.
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Kollmorgen Electrical installation 09/2006 8.3 Wiring 8.3.1 Important Notes Only professional staff who are qualified in electrical engineering are allowed to install the servo amplifier. The installation procedure is described as an example. A different procedure may be appropriate or necessary, depending on the application of the equipments. We provide further know-how through training courses (on request). Warning ! Only install and wire up the equipment when it is not live, i.e.
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Electrical installation 8.3.2 Kollmorgen 09/2006 Shielding connection to the front panel Remove the outside shroud of the cable and the shielding braid on the desired core length. Secure the cores with a cable tie. Remove the outside shroud of the line on a length from for instance 30mm without damaging the shielding braid. Pull a cable tie by the slot in the shielding rail on the front panel of the servo amplifier. Press the shielding of the cable firmly against the front panel with the cable tie.
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Kollmorgen 8.3.3 09/2006 Electrical installation Technical data for connecting cables Further information on the chemical, mechanical and electrical characteristics of the cables can be obtained from our customer service. Observe the rules in the section "Conductor cross-sections" on page 22. To reach the max. permitted cable length, you must use cable material that matches the capacitance requirements listed below.
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Electrical installation 8.4 Kollmorgen 09/2006 Block diagram The block diagram below just provides an overview.
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Kollmorgen 8.5 09/2006 Electrical installation Connector assignments Þ p. 42 Þ p. 43 Þ p. 45 Þ p. 45 Þ p. 46 The connectors of the expansion card depend on used expansion card (see pages 86 ff).
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Electrical installation 8.6 Kollmorgen 09/2006 Connection diagram (Overview) Refer to the Safety Instructions (ð p.9) and Use as Directed (ð p.10) ! SERVOSTAR 300 ð p.43 ð p.45 ð p.49 ð p.45 ð p.46 ð p.42 ð p.50 ð p.41 ð p.41 ð p.39 ð p.51 ð p.50 ð p.60 ð p.52 ð p.53 ð p.54 ð p.56 ð p.59 ð p.40 ð p.58 ð p.86 ð p.89 ð p.90 ð p.92 ð p.95 ð p.
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Kollmorgen 09/2006 8.7 Electrical supply 8.7.1 Mains electrical supply connection (X0) 8.7.1.1 Three phase — — Electrical installation Directly to 3-phase supply network, filter is integrated Fusing (e.g. fusible cut-outs) to be provided by the user ð p.21 SERVOSTAR 300 8.7.1.2 Two phase without neutral SERVOSTAR 300 8.7.1.
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Electrical installation 8.7.2 Kollmorgen 09/2006 24V auxiliary supply (X4) — External 24V DC power supply, electrically isolated, e.g. via an isolating transformer — Required current rating ð p.19 — Integrated EMC filter for the 24V auxiliary supply SERVOSTAR 300 8.7.3 DC bus link (X8) Terminals X8/1 (-DC) and X8/3 (+RBext). Can be connected in parallel, whereby the regen power is divided between all the amplifiers that are connected to the same DC bus link circuit.
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Kollmorgen 8.8 09/2006 Electrical installation Motor connection with brake (X9) Cable length £ 25 meters SERVOSTAR 300 Cable length >25 meters For cable lengths above 25m up to max. 50m, the motor choke 3YLN (ð S.103) must be wired into the motor cable, close to the amplifier. SERVOSTAR 300 8.9 External regen resistor (X8) Remove the plug-in link between the terminals X8/5 (-RB) and X8/4 (+Rbint).
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Electrical installation 8.10 Kollmorgen 09/2006 Feedback Feedback system Resolver ComCoder 8.10.1 Conn. X2 X1 See p. 42 p. 43 Incremental or Sine Encoder with Hall X1 p. 44 Sine Encoder with EnDat/HIPERFACE ACURO Encoder Incremental Encoder (A quad B) Sine Encoder without Data channel X1 X1 X5 X1 p. 45 p. 46 p. 47 p.
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Kollmorgen 8.10.2 09/2006 Electrical installation ComCoder (X1) As an option our motors can be equipped with a ComCoder as feedback unit. For the commutation hall sensors are used and for the resolution an incremental encoder. The thermostat contact in the motor is connected via the ComCoder cable to X1 and evaluated there. If cable lengths of more than 25m are planned, please consult our customer service.
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Electrical installation 8.10.3 Kollmorgen 09/2006 Incremental or Sine Encoder with hall sensors (X1) Feedback devices (incremental or sine-cosine), which don't deliver an absolute information for commutation, can be used as complete feedback system combined with an additional Hall encoder. All signals are connected to X1. If cable lengths of more than 25m are planned, please consult our customer service.
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Kollmorgen 8.10.4 Electrical installation 09/2006 Sine Encoder with EnDat 2.1 or HIPERFACE (X1) As an option, our servomotors can be fitted with a single-turn or multi-turn sine-cosine encoder. Preferred types are the ECN1313 and EQN1325 encoders. The encoder is used by the SERVOSTAR 300 as a feedback device for drive tasks that require highly precise positioning or extremely smooth running. The thermostat contact in the motor is connected via the encoder cable to X1 and evaluated there.
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Electrical installation 8.10.5 Kollmorgen 09/2006 ACURO encoder, BISS interface (X1) As an option, our servomotors can be fitted with a single-turn or multi-turn ACURO encoder with BISS interface. The encoder is used by the SERVOSTAR 300 as a feedback device for drive tasks that require highly precise positioning or extremely smooth running. The thermostat contact in the motor is connected via the encoder cable to X1 and evaluated there.
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Kollmorgen 8.10.6 09/2006 Electrical installation Incremental Encoder (X5) An incremental encoder can be used as standard motor feedback. Select feedback type 19 "ROD 5V with W&S". Drive executes wake&shake to calculate the necessary start-up information for the position controller every time the 24V auxiliary voltage is switched on. If lead lengths of more than 50m are planned and for questions concerning the power supply of the encoder, please consult our customer service.
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Electrical installation 8.10.7 Kollmorgen 09/2006 Sine Encoder without data channel (X1) An sine-cosine encoder without data channel can be used as standard motor feedback. Select feedback type 7 "SinCos 5V with W&S". Drive executes wake&shake to calculate the necessary start-up information for the position controller every time the 24V auxiliary voltage is switched on. The thermostat contact in the motor is connected via the encoder cable to X1 and evaluated there.
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Kollmorgen 09/2006 8.11 Digital and analog inputs and outputs 8.11.1 Analog inputs (X3) Electrical installation The servo amplifier is fitted with two programmable differential inputs for analog setpoints. AGND (X3/7) must always be joined to the GND of the controls as a ground reference. Technical characteristics — — — — — Differential-input voltage max. ± 10 V Ground reference AGND, terminal X3/7 Input resistance 2.
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Electrical installation 8.11.2 Kollmorgen 09/2006 Digital inputs (X3/X4) All digital inputs are electrically isolated via optocouplers. Technical characteristics — — — Ground reference is Digital-GND (DGND, terminals X4/3 and X4/4) The inputs at X3 are PLC-compatible (IEC 61131-2 Type 1) High: 11...30 V / 2...11 mA , Low: -3...
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Kollmorgen 8.11.3 09/2006 Electrical installation Digital outputs (X3) Technical characteristics — — — — Ground reference is Digital-GND (DGND, terminals X4/3 and X4/4) All digital outputs are floating DIGITAL-OUT1 and 2 : Open Emitter, max. 30 V DC, 10 mA BTB/RTO : Relay output, max. 30 V DC or 42 V AC, 0.5 A Update rate 250 µs SERVOSTAR 300 Ready-to-operate contact BTB/RTO Operational readiness (terminals X3/1 and X3/2 ) is signaled by a floating relay contact.
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Electrical installation Kollmorgen 09/2006 8.12 Encoder emulation 8.12.1 Incremental encoder output - A quad B (X5) The incremental-encoder interface is part of the standard package. Select encoder function ROD (A Quad B) Encoder (“Encoder Emulation” screen page). The servo amplifier calculates the motor shaft position from the cyclic- absolute signals of the resolver or encoder, generating incremental-encoder compatible pulses from this information.
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Kollmorgen 8.12.2 Electrical installation 09/2006 SSI output (X5) The SSI interface (synchronous serial absolute-encoder emulation) is part of the standard package. Select encoder function SSI (“Encoder Emulation” screen page). The servo amplifier calculates the motor shaft position from the cyclic-absolute signals of the resolver or encoder. From this information a SSI date (Stegmann patent specification DE 3445617C2) is provided. Max 32 bits are transferred.
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Electrical installation 8.13 Kollmorgen 09/2006 Master-slave operation, encoder master control This interface can be used to link several SERVOSTAR 300 amplifiers together in master-slave operation. Parameter setting for the slave amplifier is carried out with the aid of the setup software (electrical gearing). The resolution (no. of pulses/turn) can be adjusted, and the analog setpoint inputs are out of action. Signal diagram (for encoders with RS422 or 24 V output) 8.13.
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Kollmorgen 8.13.2 09/2006 Electrical installation Connection to incremental encoder master with 24 V signal level (X3) This interface can be used to operate the SERVOSTAR as a slave, mastered by an encoder with a 24 V signal level (master-slave operation). This uses the digital inputs DIGITAL-IN 1 and 2 on connector X3. Frequency limit: 100 kHz, transition time tv £ 0.1 µs SERVOSTAR 300 8.13.
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Electrical installation 8.14 Kollmorgen 09/2006 Interface for stepper motor controllers (step and direction) This interface can be used to connect the servo amplifier to a third-party stepper-motor controller. Parameter setting for the slave amplifier is carried out with the aid of the setup software (electrical gearing). The number of steps can be adjusted, so that the servo amplifier can be adapted to match the step-direction signals of any stepper controller.
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Kollmorgen 8.14.1 09/2006 Electrical installation Connection to a stepper controller with 5 V signal level (X5) This interface can be used to connect the servo amplifier to a stepper-motor controller with a 5 V signal level. It uses the SubD connector X5. Frequency limit: 1.5 MHz SERVOSTAR 300 8.14.2 Connection to a stepper controller with 24 V signal level (X3) This interface can be used to connect the servo amplifier to a stepper-motor controller with a 24 V signal level.
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Electrical installation 8.15 Kollmorgen 09/2006 RS232 interface, PC connection (X6) Operating, position control, and motion-block parameters can be set up by using the setup software on an ordinary commercial PC. Connect the PC interface (X6) of the servo amplifier to a serial interface on the PC via a null-modem cable, while the supply to the equipment is switched off. Do not use a null-modem power link cable! This interface has the same electrical potential as the CANopen interface.
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Kollmorgen 8.16 09/2006 Electrical installation CANopen interface (X6) The interface for connection to the CAN-bus (default : 500 kBaud). The integrated profile is based on the CANopen DS301 communication profile and the DS402 drive profile. The following functions are available in connection with the position controller: Jogging with variable speed, homing run (zeroing to reference), start motion task, start direct task, digital setpoint provision, data transmission functions and many others.
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Electrical installation 8.17 Kollmorgen 09/2006 Personnel safe restart lock -ASA frequently required application task is the protection of personnel against the restarting of drives. This can be achieved by an electronic inhibit or with mechanical elements (positively driven relay contacts). When positively driven relay contacts where used, either the net contactor in the mains supply circuit switched off or the motor was disconnected from the servo amplifier by an additional contactor.
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Kollmorgen 8.17.4 09/2006 Electrical installation Functional description If the restart lock -AS- is not needed, then the input AS-ENABLE must be connected directly with +24VDC. The restart lock is then passed by and cannot not be used. In case of use of the restart lock the input AS Enable must be connected to the exit of a security control or a safety relay, which meets at least to the requirements of the category 3 after EN 954-1 (see the connection diagram on page 63).
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Electrical installation 8.17.4.1 Kollmorgen 09/2006 Signal diagram (sequence) The diagram shows how to use restart lock -AS- to ensure a safe stop of the drive and error free operation of the servo amplifier. 1. 2. 3.
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Kollmorgen 8.17.4.2 09/2006 Electrical installation Control circuit Emergency-stop circuit acc. to EN 954-1 category 4 Safe stop acc. to EN954-1 category 3 for 3 drives Safe stop acc. to EN 954-1 category 3 for 2 drives The example shows a circuit diagram with two separated work areas connected to one emergency stop circuit. For each work area individually "safe stop" of the drives is switched by a protective screen.
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Electrical installation 8.17.4.3 09/2006 Kollmorgen Functional test With initial starting and after each interference into the wiring of the drive or after exchange of one or several components of the drive the function of the restart lock must be tested. 1. Method: 1. Stop drive, with setpoint 0V, keep servo amplifier enabled. Do not enter hazardous area! 2. Activate the restart lock -AS- e.g. by opening protective screen.
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Kollmorgen 09/2006 9 Setup 9.1 Important notes Setup Only professional personnel with extensive knowledge in the fields of electrical engineering and drive technology are allowed to setup the servo amplifier. The procedure for setup is described as an example. Depending on the application, a different procedure may be appropriate or necessary. In multi-axis systems, set up each servo amplifier individually.
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Setup Kollmorgen 09/2006 9.2 Setup software 9.2.1 General This chapter describes the installation of the setup software DRIVEGUI.EXE for the SERVOSTAR 300 digital servo amplifiers. We offer training and familiarization courses on request. 9.2.1.1 Use as directed The setup software is intended to be used for altering and saving the operating parameters for the SERVOSTAR 300 series of servo amplifiers.
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Kollmorgen 9.2.1.3 09/2006 Setup Hardware requirements The PC interface (X6, RS232) of the servo amplifier is connected to the serial interface of the PC by a null-modem cable (not a null-modem link cable!) (ð p.58). Connect / disconnect the interface cable only when the electrical supply is switched off for both the PC and the servo amplifier. The interface in the servo amplifier has the same potential level as the CANopen interface. Minimum requirements for the PC: 9.2.1.
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Setup Kollmorgen 09/2006 9.3 Quickstart 9.3.1 Preparation 9.3.1.1 Unpacking, Mounting and Wiring the Servo Amplifier 1. Unpack servo amplifier and accessories 2. Observe safety instructions in the manuals 3. Mount the servo amplifier as described in chapter 7.3 4. Wire the servo amplifier as described in chapter 8.3 or apply the minimum wiring for drive testing as described in chapter 9.3.1.3 5. Install the software as described in chapter 9.2 9.3.1.
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Kollmorgen 9.3.1.3 Setup 09/2006 Minimum Wiring for Drive Test This wiring does not fulfill any requirements to safety or functionality of your application, it just shows the required wiring for drive testing without load.
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Setup 9.3.2 Kollmorgen 09/2006 Connect l Connect the interface cable to a serial interface on your PC and to the serial interface X6 of the servo amplifier. USB to serial converter can be used optionally. l Switch on the 24 V power supply for the servo amplifier. l Wait about 30 seconds, until the front display of the servo amplifier displays the current class (e.g. for 3 A). If the power supply voltage is switched on, too, a lea- ding P is displayed (e.g. for Power, 3 A).
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Kollmorgen 09/2006 Setup If communication works, you see the start screen. Select "Setup Wizard" in the navigation frame. Make sure, that the amplifier is disabled (Input Enable connector X3 pin 12 must be 0 V or open)! 9.3.3 Important Screen Elements Help Function The Online-Help gives detailed information to all parameters the servo amplifier can work with. Key F1 Menu bar ? Starts Online Help for the actual screen page. Starts Online Help with the first page. Context Help.
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Setup 9.3.4 09/2006 Kollmorgen Setup Wizard The Setup Wizard leads you through the necessary steps for configuring your servo amplifier. Depending on the selected application, only the active screen pages are necessary. For a quick setup / drive test, select the setup type "Quick Motor/Drive Setup". Start the Wizard. 9.3.4.1 Basic Setup Basic parameters are setup here. Response to Loss of Input Phase: Select Single-Phase or Three-Phase operation.
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Kollmorgen 9.3.4.2 09/2006 Setup Units/Mechanical The user units for all input fields in the setup software can be preselected here. Position, Velocity, Acceleration Select usable units for your application referring to the moved load. Mechanical Conversion The relationship between motor shaft revolution (pole pait pitch with linear motors) and motion distance of the load is specified here. Gear ratio can be calculated here as well. Detailed information can be found in the online help.
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Setup 9.3.4.3 Kollmorgen 09/2006 Motor (rotary) / Feedback Simplified setting of the motor related parameters. Feedback: Select the feedback system used in the motor. Attention: Resolver is fixed to 2 pole in the Quick Motor/Drive Setup. Change "pole n°" on feedback screen in Complete Setup later, if required. Motor type: Click the button "Select from Database...". Open the database file (mdb_ _ _.csv) and select the used motor out of the list. Special motors must be defined in the "Complete Setup".
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Kollmorgen 9.3.4.5 Setup 09/2006 Save Parameters and Restart You are going to finish the Setup Wizard and you have changed several basic parameters. Depending on the parameters you changed, two possible reactions will occure now: Configuration parameters changed A warning appears, that you have to restart the amplifier, this is called "coldstart". Click "YES". The parameters are saved to the amplifier's EEPROM automatically and a reset command restarts the amplifier (takes some seconds).
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Setup 9.3.6 Kollmorgen 09/2006 More Setup Screens Observe the safety instructions in the manuals and in the online help before you change parameters in the additional setup screens. For all setup functions detailed information can be found in the Online Help system and the integrated command reference. Select "Complete Setup" in the Setup-Wizard.
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Kollmorgen Setup 09/2006 9.4 Multi-axis systems 9.4.1 Station address for CAN-bus During setup it makes sense to use the keypad on the front panel to preset the station addresses for the individual amplifiers and the baud rate for communication (ð p.79). 9.4.2 Baud rate for CAN-bus After changing the station address and baud rate you must turn the 24V auxiliary supply for the servo amplifier off and on again. Coding of the Baud rate in the LED display : Coding 1 2 5 10 12 9.
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Setup 9.5.2 Kollmorgen 09/2006 Status display ð p.77 9.5.
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Kollmorgen 9.5.4 Setup 09/2006 Advanced menu To operate the amplifier via the detailed menu, you must keep the right key pressed while switching on the 24 V supply. ð p.77 ð p.
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Setup 9.6 09/2006 Kollmorgen Error messages Any errors that occur are shown in coded form by an error number in the LED display on the front panel. All error messages result in the BTB/RTO contact being opened, the output stage being switched off (motor loses all torque), and the holding brake is activated. Number E/P ... -SF01* Explanation Status Messages Status Message Status Message AS-Enable Heat Sink Temperature Status messages, no error, see p.
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Kollmorgen 9.7 09/2006 Setup Warning messages Faults which occur, but which do not cause a switch-off of the amplifier output stage (BTB/RTO contact remains closed), are indicated in the LED display on the front panel by a coded warning number. Detailled description see "ASCII command reference". Number E/P ...
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Setup 9.8 Kollmorgen 09/2006 Trouble Shooting The table below should be regarded as a “First-aid” box. There may be a wide variety of reasons for the fault, depending on the conditions in your installation. In multi-axis systems there may be further hidden causes of a fault. Our customer service can give you further assistance with problems.
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Kollmorgen Setup 09/2006 Fault Possible causes F13 message: — permissible internal temperature has been exceeded Internal temp.
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Setup Fault Drive runs roughly Axis drifts at setpoint = 0V n12 message: Motor default values loaded n14 message: SinCos feedback 84 Kollmorgen 09/2006 Possible causes — Kp (speed controller) too high — Tn (speed controller) too low — ARLPF / ARHPF too low — ARLP2 too low — offset not correctly adjusted for analog setpoint provision — AGND not joined to the controller-GND of the controls — Motor numbers stored in the encoder and amplifier do not match the parameters that have been set — SinCos commutat
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Kollmorgen 10 09/2006 Expansions and Accessories Expansions and Accessories You can find information about availability and order numbers on page 106. 10.1 Expansion Cards 10.1.1 Guide to installation of expansion cards l Use a suitable screwdriver to lever off the cover of the option slot. l Take care that no small items (such as screws) fall into the open option slot. l Lever off the small metall sheet and push it back to the small slot. Dispose the big metall sheet.
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Expansions and Accessories 10.1.2 Kollmorgen 09/2006 Expansion card -I/O-14/08This section describes the additional features that the expansion card -I/O-14/08- provides for the SERVOSTAR 300. If you ordered the expansion card together with the servo amplifier, then it will be delivered already inserted into the expansion slot of the servo amplifier and screwed in place. The -I/O-14/08- provides you with 14 additional digital inputs and 8 digital outputs.
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Kollmorgen 10.1.2.5 09/2006 Expansions and Accessories Connector assignments The functions are adjustable with the setup software. In the table below the default values are described.
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Expansions and Accessories 10.1.2.
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Kollmorgen 10.1.3 09/2006 Expansions and Accessories Expansion card -PROFIBUSThis section describes the PROFIBUS expansion card for the SERVOSTAR 300. Information on the range of functions and the software protocol can be found in our manual “Communication Profile PROFIBUS DP”.. The PROFIBUS expansion card has two 9-pin SubD sockets wired in parallel. The supply voltage for the expansion card is provided by the servo amplifier. 10.1.3.1 Front view 10.1.3.
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Expansions and Accessories 10.1.4 09/2006 Kollmorgen Expansion card -SERCOSThis section describes the SERCOS expansion card for SERVOSTAR 300. Information on the range of functions and the software protocol can be found in our manual “IDN Reference Guide SERCOS”. 10.1.4.1 Front view 10.1.4.2 LEDs RT TT Indicates whether SERCOS telegrams are being correctly received. In the final Communication Phase 4 this LED should flicker, since cyclical telegrams are being received.
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Kollmorgen 10.1.4.4 09/2006 Expansions and Accessories Connection diagram Layout of the SERCOS bus system in ring topology, with optical fiber cables (schematic). 10.1.4.5 Modifying the station address The drive address can be set to a value between 0 and 63. With address 0, the drive is assigned as an amplifier in the SERCOS ring. Set the station address with the: Keys on the front of the servo amplifier The SERCOS address can be modified using the keys on the front of the amplifier (p. 78).
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Expansions and Accessories 10.1.5 09/2006 Kollmorgen Expansion card -DEVICENETThis section describes the DeviceNet expansion card for SERVOSTAR 300. Information on the range of functions and the software protocol can be found in our manual “DeviceNet Communication Profile”. 10.1.5.1 Front view 10.1.5.
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Kollmorgen 10.1.5.4 09/2006 Expansions and Accessories Combined module/network status-LED LED Meaning The device is not online. - The device has not yet finished the Dup_MAC_ID test. off - The device is possibly not yet switched on. The device is operating as normal, is online, and the connections have been green established. The device has been assigned to a master. The device is operating as normal, is online, but the connections have not been established.
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Expansions and Accessories 10.1.5.7 09/2006 Kollmorgen Bus cable To meet ISO 898, a bus cable with a characteristic impedance of 120 W should be used. The maximum usable cable length for reliable communication decreases with increasing transmission speed. As a guide, you can use the following values which we have measured, but they are not to be taken as assured limits.
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Kollmorgen 10.1.6 09/2006 Expansions and Accessories Expansion card -ETHERCATThis section describes the EtherCat expansion card for SERVOSTAR 300. Information on the range of functions and the software protocol can be found in the EtherCat documentation. This expansion cards enables the servo amplifier to be connected to the EtherCat network. 10.1.6.1 Front view 10.1.6.
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Expansions and Accessories 10.1.7 Kollmorgen 09/2006 Expansion card -SYNQNETThis section describes the SynqNet expansion card for SERVOSTAR 300. Information on the range of functions and the software protocol can be found in the SynqNet documentation. 10.1.7.1 Front view LED2 LED1 10.1.7.2 LED4 LED3 NODE ID Switch With these hexadecimal switches you can set the main and low significant bytes of the Node ID seperately.
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Kollmorgen 10.1.7.5 Expansions and Accessories 09/2006 Digital inputs/outputs, connector X21A (SubD 15-pin, socket) Inputs (In): 24V (20...28V), opto-isolated, one high-speed input (Pin 4) Outputs (Out): 24V, opto-isolated, Darlington driver Pinout connector X21A (SubD 15 pin) Pin Type Description In +24V power supply 1 NODEA indicates a problem Out 2 LARM with the node Out OUT_01 digital output 3 In IN_00 capture input (fast) 4 In IN_04 digital input 5 10.1.7.
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Expansions and Accessories 10.1.8 Kollmorgen 09/2006 Expansion module -2CANConnector X6 of the SERVOSTAR is assigned to the signals for the RS232 interface and the CAN interface. It is therefore not the standard pin assignment for these interfaces, and a special cable is required to be able to use both interfaces simultaneously. The -2CAN- expansion module provides the interfaces on separate Sub-D connectors. The two CAN connectors are wired in parallel.
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Kollmorgen 10.1.8.4 09/2006 Connector assignments RS232 X6A Pin 1 2 3 4 5 6 7 8 9 10.1.8.
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Expansions and Accessories Kollmorgen 09/2006 10.2 Accessories 10.2.1 External power supply 24 V DC / 5 A Technical data Input voltage Input current Frequency Primary fusing Output voltage Max. output current Residual ripple Switching peaks Output fusing Temperature range Mounting method Weight 100 (not available in North America) 120 / 230 V 0.9 / 0.6 A 50/60 Hz 3.
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Kollmorgen 10.2.2 09/2006 Expansions and Accessories External power supply 24 V DC / 20 A Mounting Plate (not available in North America) Input voltage 3 x 400 V AC ± 10% Input current approx. 1.1 A Frequency 50/60 Hz Primary fusing none Output voltage 24 V ± 1% Max. output current 20 A Residual ripple <0.1% Output fusing short-circuit proof Test voltage as per VDE 0550 Temperature range -20 to +60°C on mounting plate (supMounting method plied) keep necessary space clear Weight 3.
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Expansions and Accessories 10.2.3 09/2006 Kollmorgen External regen resistor BAR(U) Caution: The surface temperature can exceed 200°C. Make sure that the necessary space is kept clear.
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Kollmorgen 10.2.4 09/2006 Expansions and Accessories Motor chokes 3YLN To use with motor cables longer than 25 m up to 50 m max. to reduce velocity ripple and to protect the output power stage of the amplifier. The terminals BR are used to connect the motor holding brake. Beside the terminal are block two shield connection terminals for safe connection of the cables's shielding braid. Mount the choke nearby the servo amplifier. The cable length between amplifier and choke must never exceed 2 m.
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Appendix Kollmorgen 09/2006 11 Appendix 11.1 Glossary C Clock Clock signal Common-mode voltage The maximum amplitude of a disturbance (on both inputs) which a differential input can eliminate CONNECT modules Modules built into the servo amplifier, with integrated position control, that provide special versions of the interface for the connection to the higherlevel control.
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Kollmorgen 09/2006 Appendix O Optocoupler Optical connection between two electrically independent systems P P-controller Control loop with purely proportional behavior Phase shift Compensation for the lag between the electromagnetic and magnetic fields in the motor PI-controller Control loop with proportional and differential behavior Position controller Regulates the difference between the position setpoint and the actual position to 0 Output: speed setpoint Potential isolation electrically
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Appendix Kollmorgen 09/2006 11.2 Order codes 11.2.
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Kollmorgen 11.2.4 Appendix 09/2006 Feedback cables with connectors Article Resolver cable 5m Resolver cable 10m Resolver cable 15m Resolver cable 20m Resolver cable 25m Encoder cable 5m Encoder cable 10m Encoder cable 15m Encoder cable 20m Encoder cable 25m Comcoder cable 5m Comcoder cable 10m Comcoder cable 15m Comcoder cable 20m Comcoder cable 25m (4x(2x0.25)) (4x(2x0.25)) (4x(2x0.25)) (4x(2x0.25)) (4x(2x0.25)) (7x(2x0.25)) (7x(2x0.25)) (7x(2x0.25)) (7x(2x0.25)) (7x(2x0.25)) (8x(2x0.25)) (8x(2x0.
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Appendix 11.3 09/2006 Index ! 24V aux. supply, interface . . . . . . . . 40 A K ACURO (BISS), interface . . . . . . . . 46 AGND . . . . . . . . . . . . . . . . . . 24 ambient temperature . . . . . . . . . . . 22 AS ENABLE . . . . . . . . . . . . . . . 50 assembly . . . . . . . . . . . . . . . . . 29 baud rate . . . . . . . . . . . . . . . . . 77 block diagram (overview). . . . . . . . . 36 brake, see also motor-holding brake . . . 23 BTB/RTO. . . . . . . . . . . . . . . . . 51 CAN-bus cable . . . . .
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Kollmorgen 09/2006 Appendix This page has been deliberately left blank.
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Sales and Service We are committed to quality customer service. In order to serve in the most effective way, please contact your local sales representative for assistance. If you are unaware of your local sales representative, please contact us. Europe Danaher Motion Customer Support Europa Internet E-Mail Phone: Fax: www.DanaherMotion.net support@danahermotion.net +49(0)203 - 99 79 - 0 +49(0)203 - 99 79 - 155 North America Danaher Motion Customer Support North America Internet www.DanaherMotion.