KOLLMORGEN 640,670 Installation Manual

Assembly, Installation, Setup

Edition 06/02

file 640670hw.xxx

EU order.No.: 91978

NA: M-SS-015-0107

Digital servo amplifier

®

SERVOSTAR

640/670

Previous versions :

Edition Remarks

07/99 First edition
11/99 technical data, encoder connection diagram
12/99 encoder cable length

10/00

05/01 some UL/cUL related hints

01/02

06/02

Dimensions mains filter, setup software on CD-ROM only, wiring diagrams electr. gearing, warning and error messages,
recommended torque, various corrections

-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

PC-AT is a registered trademark of International Business Machines Corp.

MS-DOS is a registered trademark of Microsoft Corp.

WINDOWS is a registered trademark of Microsoft Corp.

HIPERFACE is a registered trademark of Max Stegmann GmbH

EnDat is a registered trademark of Dr. Johannes Heidenhain GmbH

SERVOSTAR is a registered trademark of Kollmorgen Corporation.

Manufactured under one or more of the following US patents:

4,434,389 4,447,771 4,456,934 4,463,299 4,479,078
4,490,661 4,504,755 4,508,988 4,532,461 4,538,080

4,541,575 4,543,520 4,551,646 4,559,485 4,562,399
4,572,999 4,579,012 4,633,151 4,644,199 4,647,824
4,661,756 4,670,696 4,675,547 4,679,313 4,682,093
4,686,437 4,698,537 4,729,160 4,763,049 4,763,056
4,763,057 4,733,149 4,782,272 4,797,592 4,857,816

4,868,475 4,868,970 4,912,381 4,926,063 4,935,080
4,943,760 4,954,739 4,992,716 5,051,634 5,144,183
5,173,651 5,194,786 5,399,908 5,435,517 5,530,396
5,574,636 5,606,791 5,625,265 5,633,793 5,646,467
5,715,590 5,736,916 5,739,648 5,754,732 5,789,841

5,829,118 5,912,638 5,949,202 5,949,359 5,998,905
6,002,234

Technical changes which improve the performance of the equipment may be made without prior notice !

Printed in the Federal Republic of Germany

All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm or any other method)

or stored, processed, copied or distributed by electronic means without the written permission of Kollmorgen Seidel Corporation.

Seidel

Contents

06/02 Contents

Drawing Page

Contents ...............................................3

Safety instructions ........................................6

European directives and standards .............................7

- / UL- conformance ......................................7

Abbreviations and symbols...................................8

I General

I.1 About this manual ...................................................................................9

I.2 Prescribed use (Use as directed) of the servo amplifier .....................................................10

I.3 Nameplate........................................................................................11

I.4 Instrument description...............................................................................11

I.4.1 Package supplied ............................................................................11

I.4.2 The digital servo amplifiers of the series SERVOSTAR 640/670 ........................................12

I.4.3 Operation directly from supply...................................................................12

I.4.4 Digital servo amplifier concept...................................................................13

I.5 Connection to different mains supply networks ...........................................................14

I.6 Components of a servo system .......................................................................15

I.7 Technical data of the SERVOSTAR 640/670 .............................................................16

I.7.1 External fusing...............................................................................16

I.7.2 Allowable ambient conditions, ventilation, mounting position ...........................................17

I.7.3 Conductor cross-sections ......................................................................17

I.7.4 Recommended torques ........................................................................17

I.7.5 LED display .................................................................................17

I.8 Grounding system..................................................................................18

I.9 Control for motor-holding brake .......................................................................18

I.10 Regen circuit ......................................................................................19

I.11 Switch-on and switch-off behavior .....................................................................20

I.11.1 Stop function to EN 60204 (VDE 0113)............................................................20

I.11.2 Emergency Stop strategies .....................................................................21

I.12 Restart lock -AS-...................................................................................22

I.12.1 Advantages of the restart lock ...................................................................22

I.12.2 Functional description .........................................................................22

I.12.3 Block diagram ...............................................................................23

I.12.4 Signal diagram (sequence) .....................................................................23

I.12.5 Installation / Setup ............................................................................24

I.12.5.1 Safety instructions ........................................................................24

I.12.5.2 Functional test ...........................................................................24

I.12.5.3 Connection diagram.......................................................................24

I.12.6 Application examples..........................................................................25

I.12.6.1 Moving single axes or axis-groups in setting-up operation .........................................25

I.12.6.2 Switching off grouped axes with separate working areas ..........................................25

I.12.6.2.1 Control circuit.......................................................................25

I.12.6.2.2 Mains supply circuit ..................................................................26

- A.4.028.6/10

- A.4.038.1/12

- A.4.031.3/01, A.4.038.1/10

- A.4.038.3/01

- A.4.031.1/32,30

- A.4.031.1/30

- A.4.031.1/31

- A.4.031.3/05

II Installation

II.1 Important instructions ...............................................................................27

II.2 Assembly ........................................................................................28

II.2.1 Dimensions of SERVOSTAR 640/670.............................................................29

II.3 Wiring ...........................................................................................30

II.3.1 Connection diagram for SERVOSTAR 640/670 .....................................................32

II.3.2 Example of connections for multi-axis system ......................................................33

II.3.3 Pin assignments for SERVOSTAR 640/670 ........................................................34

II.3.4 Notes on connection techniques .................................................................35

II.3.4.1 Shielding connection to the front panel ........................................................35

II.3.4.2 Technical data for connecting cables..........................................................36

II.4 Setup software ....................................................................................37

II.4.1 General ....................................................................................37

II.4.1.1 Use as directed ..........................................................................37

II.4.1.2 Software description ......................................................................37

II.4.1.3 Hardware requirements ....................................................................38

II.4.1.4 Operating systems ........................................................................38

II.4.2 Installation under WINDOWS 95 / 98 / 2000 / ME / NT ................................................38

- A.4.038.4/12

- A.4.038.4/07

- A.4.038.1/03

- A.4.038.1/04

- A.4.038.4/13

- A.4.029.4/25

SERVOSTAR®640 / 670 Installation Manual 3

Contents

06/02 Seidel

Drawing Page

III Interfaces

Contents

- A.4.038.1/09

III.1 Power supply .....................................................................................40

III.1.1 Mains supply connection (X0) ..................................................................40

III.1.2 24V auxiliary supply (X4).......................................................................40

III.1.3 DC-link (X7) .................................................................................40

- A.4.038.1/ 05, 06

III.2 Motor connection with brake (X0, X4) ...................................................................41

III.3 External regen resistor (X0) ..........................................................................41

- A.4.038.1/07, 08

III.4 Feedback ........................................................................................ 42

III.4.1 Resolver connection (X2) ......................................................................42

III.4.2 Encoder (X1) ................................................................................43

- A.4.031.1/26

- A.4.031.1/27

III.5 Control signals, monitor signals .......................................................................44

III.5.1 Analog setpoint inputs (X3) .....................................................................44

III.5.2 Monitor outputs (X3) ..........................................................................45

III.5.3 Digital control inputs (X3) ......................................................................46

III.5.4 Digital control outputs (X3) .....................................................................47

- A.4.031.1/23

- A.4.031.1/22

- A.4.031.1/24

- A.4.031.1/20

III.6 Encoder simulations ................................................................................48

III.6.1 Incremental encoder simulation - A quad B position output (X5) ........................................48

III.6.2 SSI encoder simulation - position output (X5) .......................................................49

- A.4.031.1/11

- A.4.031.1/12

III.6.3 Interface for master-slave operation, encoder input ..................................................50

III.6.3.1 Connection to a SERVOSTAR master, 5V signal level (X5) ........................................50

III.6.3.2 Connection to encoders with 24V signal level (X3) ...............................................51

III.6.3.3 Connection to a sine-cosine encoder (X1) ......................................................51

III.7 Interface for stepper-motor controls (pulse-direction) .......................................................52

- A.4.031.1/44,43

- A.4.031.3/02

III.7.1 Connection to stepper-motor controller with 5V signal level (X5)........................................53

III.7.2 Connection to stepper-motor controller with 24V signal level (X3).......................................53

III.8 RS232 interface, PC connection (X6) ...................................................................54

III.9 CANopen Interface (X6) .............................................................................55

- A.4.031.1/10,4

- A.4.031.1/13,1

- A.4.031.1/15, 36

IV Setup

IV.1 Important notes ....................................................................................57

IV.2 Parameter setting ..................................................................................59

IV.2.1 Multi-axis systems ............................................................................59

IV.2.1.1 Node address for CAN-bus .................................................................59

IV.2.1.2 Baud rate for CAN-bus.....................................................................59

IV.2.2 Key operation / LED display ....................................................................60

IV.2.2.1 Key operation............................................................................60

IV.2.2.2 Status display............................................................................60

IV.2.2.3 Standard menu structure ...................................................................61

IV.2.2.4 Extended menu structure...................................................................61

IV.3 Error messages....................................................................................62

IV.4 Warning messages .................................................................................63

- A.4.038.4/11

- A.4.031.3/04, 09

- A.4.031.3/03, 08

4 SERVOSTAR®640 / 670 Installation Manual

Seidel

06/02 Contents

Drawing Page

V Extensions / Accessories

Contents

V.1 Expansion card -I/O-14/08- ...........................................................................65

V.1.1 Fitting the expansion card ......................................................................65

V.1.2 Technical data ...............................................................................65

V.1.3 Light emitting diodes (LEDs) ....................................................................65

V.1.4 Position of the connectors ......................................................................66

- A.4.038.4/27

V.1.5 Connector assignments ........................................................................67

V.1.6 Select motion task number (Sample) .............................................................67

V.1.7 Connection diagram ..........................................................................68

A.4.031.1/39

V.2 Expansion card -PROFIBUS- .........................................................................69

V.2.1 Position of the connectors ......................................................................69

V.2.2 Fitting the expansion card ......................................................................69

- A.4.038.4/26

V.2.3 Connection technology ........................................................................70

V.2.4 Connection diagram ..........................................................................70

- A.4.031.1/41

V.3 Expansion card -SERCOS-...........................................................................71

V.3.1 Position of the connectors ......................................................................71

V.3.2 Fitting the expansion card ......................................................................71

- A.4.038.4/25

V.3.3 Light emitting diodes (LEDs) ....................................................................72

V.3.4 Connection technology ........................................................................72

V.3.5 Connection diagram ..........................................................................72

- A.4.038.4/24

V.4 Expansion module -2CAN- ...........................................................................73

V.4.1 Position of the connectors ......................................................................73

V.4.2 Fitting the expansion module ....................................................................73

- A.4.038.4/22

V.4.3 Connection technology ........................................................................74

V.4.4 Connector assignments ........................................................................74

V.4.5 Connection diagram ..........................................................................74

- A.4.038.4/23

V.5 Accessories.......................................................................................75

V.5.1 External 24VDC / 5A supply ....................................................................75

V.5.2 External 24VDC / 20A supply ...................................................................76

V.5.3 External regen resistor BAS ....................................................................77

V.5.4 Mains filters .................................................................................78

V.5.5 Mains chokes................................................................................79

- A.4.037.4/07

- A.4.012.4/33

- A.4.947.4/24

- A.4.038.4/14

- A.4.030.4/12

VI Appendix

VI.1 Transport, storage, maintenance, disposal...............................................................81

VI.2 Removing faults/warnings............................................................................82

VI.3 Glossary .........................................................................................84

VI.4 Order numbers ....................................................................................86

VI.5 Index ............................................................................................87

SERVOSTAR®640 / 670 Installation Manual 5

Safety instructions

Safety Instructions

06/02 Seidel

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Only properly qualified personnel are permitted to perform activities such as
transport, installation, setup and maintenance. Properly qualified persons
are those who are familiar with the transport, assembly, installation, setup

and operation of the product, and who have the appropriate qualifications
for their job. The qualified personnel must know and observe:

IEC 364 and CENELEC HD 384 or DIN VDE 0100
IEC-Report 664 or DIN VDE 0110

national accident prevention regulations or BGV A2

Read this documentation before carrying out installation and setup.
Incorrect handling of the servo amplifier can lead to personal injury or

material damage. It is vital that you keep to the technical data and
information on connection requirements (on the nameplate and in the
documentation).

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.

The servo amplifiers contain electrostatically sensitive components which
may be damaged by incorrect handling. Ground yourself before touching the

servo amplifier by touching any unpainted metal surface. Avoid contact with
highly insulating materials (artificial fabrics, plastic film etc.). Place the

servo amplifier on a conductive surface.

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Do not open the units. Keep all covers and switchgear cabinet doors closed
during operation. Otherwise there are deadly hazards, with the possibility of
severe danger to health or material damage.

During operation, servo amplifiers, according to their degree of enclosure
protection, may have uncovered live components. Control and power
connections may be live, even if the motor is not rotating.

Servo amplifiers may have hot surfaces during operation.

Never undo the electrical connections to the servo amplifier while it is live.
There is a danger of electric arcing with damage to contacts and danger to
persons.

Wait at least five minutes after disconnecting the servo amplifier from the
mains supply voltage before touching live sections of the equipment (e.g.

contacts) or undoing connections. Capacitors can still have dangerous
voltages present up to five minutes after switching off the supply voltages.

To be sure, measure the voltage in the DC-link circuit and wait until it has
fallen below 40V.

Safety instructions

6 SERVOSTAR®640 / 670 Installation Manual

Seidel

European directives and standards

Servo amplifiers are components which are intended to be incorporated into electrical plant and machines for
industrial use.
When the servo amplifiers are built into machines or plant, the intended operation of the amplifier is forbidden
until it has been established that the machine or plant fulfills the requirements of the EC Directive on Machines

98/37/EC and the EC Directive on EMC (89/336/EEC). EN 60204 and EN 292 must also be observed.

06/02 Directives and standards

The manufacturer of the machine must generate a hazard analysis for the machine, and take appropri
ate measures to ensure that unforeseen movements cannot cause injury or damage to any person or

property.

In connection with the Low Voltage Directive 73/23/EEC , the harmonized standards of the EN 50178 series
are applied to the amplifiers, together with EN 60439-1, EN 60146 and EN 60204.
The manufacturer of the machine or plant is responsible for ensuring that they meet the limits which are

required by the EMC regulations. Advice on the correct installation for EMC - such as shielding, grounding,
arrangement of filters, treatment of connectors and the laying out of cabling - can be found in this documenta
tion.

- conformance

Conformance with the EC Directive on EMC 89/336/EEC and the Low Voltage Directive 73/23/EEC is manda
tory for the supply of servo amplifiers within the European Community.
The servo amplifiers of the SERVOSTAR 640/670 series have been tested by an authorized testing laboratory
in a defined configuration with the system components which are described in this documentation. Any diver

gence from the configuration and installation described in this documentation means that you will be responsi
ble for the performance of new measurements to ensure that the regulatory requirements are met.

UL and cUL- Conformance

UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S. and Canadian stan
dard (in this case UL 840 and UL 508C).

This standard describes the fulfilment by design of minimum requirements for electrically operated power con
version 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 fulfilment by design of minimum requirements for electrically operated power conver
sion equipment, such as frequency converters and servo amplifiers, which is intended to eliminate the risk of
fire being caused by such equipment.

UL 840

UL 840 describes the fulfilment by design of air and insulation creepage spacings for electrical equipment and
printed circuit boards.

Directives and standards

-

SERVOSTAR®640 / 670 Installation Manual 7

Abbreviations / symbols

Abbreviations used in this manual

The abbreviations used in this manual are explained in the table below.

06/02 Seidel

Abbrev. 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

IEC International Electrotechnical Commission

IGBT Insulated Gate Bipolar Transistor

INC Incremental Interface

ISO International Standardization Organization

LED Light-emitting diode

MB Megabyte

MS-DOS Operating system for PC-AT

Abbrev Meaning

NI Zero pulse

NSTOP Limit-switch input for CCW rotation (left)

PC-AT Personal computer with 80x86 Processor

PELV Protected low voltage

PGND Ground for the interface

PSTOP Limit-switch input for CW rotation (right)

PWM Pulse-width modulation

RAM Volatile memory

Rregen Regen resistor

RBext External regen resistor

RBint Internal regen resistor

RES Resolver

ROD 426 (EEO) A quad B encoder

PLC Programmable logic controller

SRAM Static RAM

SSI Synchronous serial interface

SW/SETP. setpoint

UL Underwriters Laboratory

VAC AC voltage

VDC DC voltage

VDE Verein deutscher Elektrotechniker

XGND Ground for the 24V supply

Symbols used in this manual

danger to personnel from elec
tricity and its effects

ð

Keys on the servo amplifier panel :

U

U

see page (cross-ref.) l special emphasis

press once : move up one menu item, increase number by one

U

press twice in rapid succession : increase number by ten
press once : move down one menu item, decrease number by one
press twice in rapid succession : decrease number by ten

U

hold right key pressed, and then press left key as well :
to enter number, “Return” function

Abbreviations / symbols

-

general warning
general instructions

mechanical hazard

8 SERVOSTAR®640 / 670 Installation Manual

Seidel

I General

I.1 About this manual

This manual describes the digital servo amplifiers of the SERVOSTAR®640/670 series
(standard version). You can find information about:

Technical data of the servo amplifiers Chapter I

l

Assembly / installation Chapter II

l

Interfaces Chapter III

l

Setup the servo amplifier Chapter IV

l

Accessories Chapter V

l

Transport, storage, maintenance, disposal of the servo amplifiers Chapter VI

l

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 95 with Internet browser) in English, German and French
versions.

You can print this documentation on any standard printer. A printed copy of the documentation is
available from us at extra cost.

06/02 General

This manual makes the following demands on qualified personnel :

Transport : only by personnel with knowledge in handling electrostatically

sensitive components.

Installation : only by electrically qualified personnel

Setup : only by personnel with extensive knowledge of electrical

engineering / drive technology

SERVOSTAR®640 / 670 Installation Manual 9

General

06/02 Seidel

I.2 Prescribed use (Use as directed) of the servo amplifier

The servo amplifiers are components which are built into electrical equipment or machines, and can
only be used as integral components of such equipment. The manufacturer of the machine must

generate a hazard analysis for the machine, and take appropriate measures to ensure that unfore
seen movements cannot cause injury or damage to any person or property.

The SERVOSTAR 640/670 family of servo amplifiers 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 5000rms symmetrical amperes, 480VAC maximum]
when protected by fuses type Fusetron FRS-R-50 forSERVOSTAR 640 or FRS-R-80 class RK5

for SERVOSTAR 670, manufactured by Bussman, or equivalent, 480VAC min.
The servo amplifiers must not be operated directly on power supply networks >230V without an

earth (ground) or with an asymmetrical earth (ground).
Connection to other mains supply networks ð p. 14.

The use of external mains chokes and mains filters is required.

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.

The regen resistors have to be protected by fuses type Limitron KLM, rated for 500VAC/DC

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 volt

age of the motors must be at least as high as the DC-link voltage of the servo amplifier. The motor
must have integral thermal protection.

The servo amplifiers may only be operated in a closed switchgear cabinet, taking into account the
ambient conditions defined on page 17 and the dimensions shown on page 28. Ventilation or cool

ing may be necessary to prevent enclosure ambient from exceeding 45°C (113°F).

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).

We only guarantee the conformance of the servo amplifiers with the standards for industrial areas
(page 7), if the components (motors, cables, amplifiers etc) are delivered by Seidel.

-

-

-

Restart lock -AS-

The restart lock -AS- is exclusively intended to provide safety for personnel, by preventing the
restart of a system. To achieve this personnel safety, the wiring of the safety circuits must meet the

safety requirements of EN60204, EN292 and VDI 2853.

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 and BTB/RTO) for all servo amplifiers are wired into

the control signal loop (to recognize a cable break).

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 :

1. - cleaning, maintenance and repair operations

- long inoperative periods
In such cases, the entire system should be disconnected from the supply by the personnel,

and secured (main switch).

2. - emergency-stop situations
In an emergency-stop situation, the main contactor is switched off (by the emergency-stop

button or the BTB-contact in the safety circuit).

10 SERVOSTAR®640 / 670 Installation Manual

Seidel

I.3 Nameplate

The nameplate depicted below is attached to the side of the servo amplifier.
The information described below is printed in the individual fields.

Typenbezeichnung

06/02 General

Customer Service
Europe Tel. +49 (0)203 / 9979 0
Italy Tel. +39 (0)362 / 594260
North America Tel. [phone]

Model Number

Ser. Nr

Ser. No.

Bemerkung

CommentsSerial numberServo amplifier type

Comment

Spannungsversorgung

Power Supply

Electrical supply

Installed load

I.4 Instrument description

I.4.1 Package supplied

When you order a SERVOSTAR 640/670 series amplifier, you will receive:

— SERVOSTAR 6xx
— mating connectors X3, X4

The mating SubD connectors are not part of the package!

Nennstrom

Output current

in S1 operation

Nom. Current

Schutzart

Encl.Rating

Enclosure Rating

— Assembly and Installation Instructions
— Online documentation on CD-ROM

— Setup software DRIVE.EXE on CD-ROM

Accessories:

(must be ordered separately)

— Mains filter 3EF-xx (ð p.78) required
— Mains choke 3Lxx-yy (ð p.79) required

— AC Servomotor (linear or rotary)
— motor cable as a cut-off length

— brake cable as a cut-off length
— feedback cable (pre-assembled, see application note “Cables and connectors”) or both

feedback connectors separately, with feedback cable as length

— external regen resistor (ð p.77)
— communications cable to the PC(ð p.54) or Y-adapter (ð p.59) for parameter setting of up

to 4 or 6 servo amplifiers from one PC

— power cable, control cables, fieldbus cables (as lengths)

- A.4.028.6/10

SERVOSTAR®640 / 670 Installation Manual 11

General

06/02 Seidel

I.4.2 The digital servo amplifiers of the series SERVOSTAR 640/670

Standard version

2 current ratings (40 A, 70 A)

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wide range of rated voltage (3x208V

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shield connection directly at the servo amplifier

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two analog setpoint inputs

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integrated CANopen (default 500 kBaud), for integration into CANbus systems and for

l

setting parameters for several amplifiers via the PC-interface of one amplifier

integrated RS232, electrically isolated, integrated pulse-direction interface

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-AS- built-in safety relay (personnel-safety starting lock-out), (ð p.22)

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Open architecture

open hardware and software architecture

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slot for an expansion card

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integrated macro language, including compiler

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prepared for all conceivable customer-specific extensions

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–10%

to 3x480V

+10%

)

Options

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-I/O-14/08- expansion card, ð p. 65

PROFIBUS DP expansion card, ð p. 69

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SERCOS expansion card, ð p. 71

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-2CAN- Expansion module, separated connectors for CAN bus and RS232, ð p. 73

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Third party expansion cards (ModBus, FireWire, LightBus etc. - contact distributors for fur

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ther information)

I.4.3 Operation directly from supply

Electrical supply

Directly off grounded 3~ system,

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230V
208V

TN-system, TT-system with earthed (grounded) neutral point, not more than 5000 rms sym
metrical 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. 14

Fusing (e.g. fusible cutout) provided by the user

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Auxiliary supply voltage 24VDC

Electrically isolated, internal fusing (4 AT), from an external 24VDC psu, e.g. with insulating

l

transformer

-10%

-10%

... 480V
... 480V

+10%

+10%

,50Hz,
,60Hz,

-

-

Power input filter

External interference suppression filter for the supply input (to Class A) required

l

Interference suppression filter for the 24V aux. supply (to Class A) is integrated

l

Mains choke

l

External mains choke required

12 SERVOSTAR®640 / 670 Installation Manual

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06/02 General

I.4.4 Digital servo amplifier concept

Operation and parameter setting

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

l

for status display in case of no PC available

Fully programmable via RS232 interface

l

Power section

Power supply: B6 rectifier bridge, off 3-phase earthed (grounded) supply,

l

integral inrush circuit

All shielding connections directly on the amplifier

l

Output stage: IGBT- module with isolated current measurement

l

Regen circuit: with dynamic distribution of the regen power between several

l

amplifiers on the same DC-link circuit, external regen resistor

DC-link voltage 260 — 900 VDC, can be switched in parallel

l

Completely digital control

l

Digital current controller (space vector pulse-width modulation, 62.5 µs)

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

l

control

Evaluation of the resolver signals and sine-cosine signals of a high-resolution encoder

l

Encoder simulation (incremental or SSI)

l

Comfort functions

Adjustable setpoint ramps

l

2 analog monitor outputs

l

4 programmable digital inputs (normally, two are defined as limit-switch inputs)

l

l

2 programmable digital outputs

Freely programmable combinations of all digital signals

l

Integrated safety

Safe electrical separation to EN 50178 between the power input / motor connections and the

l

signal electronics, provided by appropriate insulation/creepage distances and complete elec
trical isolation

Soft-start, overvoltage recognition, short-circuit protection, phase-failure monitoring

l

Temperature monitoring of servo amplifier and motor

l

(when using our motors with our pre-assembled cables)

-

SERVOSTAR®640 / 670 Installation Manual 13

General

06/02 Seidel

I.5 Connection to different mains supply networks

On this page you'll find all possible connection variations to different mains supply networks.

An isolating transformer is always required for 400...480V mains networks without
earth(ground) and for networks with asymmetrical earth(ground).

- A.4.038.1/12

SERVOSTAR

208V with 60Hz only

230...480V with 50Hz or 60Hz

SERVOSTAR

SERVOSTAR

SERVOSTAR

SERVOSTAR

SERVOSTAR

SERVOSTAR

SERVOSTAR

SERVOSTAR

SERVOSTAR

SERVOSTAR

14 SERVOSTAR®640 / 670 Installation Manual

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06/02 General

I.6 Components of a servo system

PC

Control / PLC

SERVOSTAR 640/670

restart lock -AS-

24V-power
supply

Mains filter

Mains choke

Drive contactor

Fuses

Fuses

Regen resistor

Motor

Terminals

Cables drawn bold are shielded.

SERVOSTAR®640 / 670 Installation Manual 15

General

06/02 Seidel

I.7 Technical data of the SERVOSTAR 640/670

Rated data DIM SERVOSTAR 640 SERVOSTAR 670

Rated-supply voltage (grounded system)

Rated installed load for S1 operation kVA 30 50
Rated DC-link voltage V= 260 - 675
Supply voltage range for output current V~ 230 ... 480 230 400 480
Rated output current (rms value, ± 3%) Arms 40 85 80 70

Peak output current (max. ca. 5s, ± 3%)
Clock frequency of the output stage kHz 8
Technical data for regen circuit — ð p.19
Overvoltage protection threshold V 450...900
Form factor of the output current

(at rated data and min. load inductance)
Bandwidth of subordinate current controller kHz > 1,2
Residual voltage drop at rated current V 5
Quiescent dissipation, output stage disabled W 40
Dissipation at rated current (incl. power
supply losses, without regen dissipation)

Internal fusing (external fusing ð p.16)

Auxiliary supply 24V — internal 4 AT
Regen resistor — internal, electronic

Inputs

Setpoint ½, resolution 14bit/12bit V ±10

Common-mode voltage max. V ±10
Input resistance to AGND

Digital inputs

Digital outputs, open collector

BTB/RTO output, relay contacts

Aux. power supply, electrically isolated V 24 (-0% +15%)
without brake A 2
Aux. power supply, electrically isolated V 24 (-0% +15%)
with brake (consider voltage loss!) A 4
Max. output current, brake A 2

Connections

Control signals — Combicon 5,08 / 18 pole , 2,5mm²
Power signals — Terminals 10mm² — 50mm²
Resolver input — SubD 9pole (socket)
Sine-cosine encoder input — SubD 15pole (socket)
PC-interface, CAN — SubD 9pole (plug)

Encoder simulation, ROD (EEO) / SSI — SubD 9pole (plug)
Thermal control, Motor — min. 15VDC, 5mA

Mechanical

Weight kg 19,5 21
Height without shield sheet, w/o eyes (w. eyes) mm 345 (375)
Height with shield sheet, w/o eyes (w. eyes) mm 484 (495)
Width mm 250
Depth without connectors mm 300
Depth with connectors mm 325

V~ 3 x 230V-10% ... 480V+10%, 50 Hz
V~ 3 x 208V-10% ... 480V+10%, 60 Hz

Arms

— 1.01

W 400 700

kW

V low 0...7 / high 12...36

mA 7

V max. 30

mA 10

V DC max. 30, AC max. 42

mA 500

80 160 160 140

20

I.7.1 External fusing

Fusible cutouts or similar (Fuse UL time delay) SERVOSTAR 640 SERVOSTAR670

AC supply F

Type of branch circuit fuses: Class RK5, 480V min

Regen resistor F

* (x=SorS-Rfor480V applications x=NorN-Rfor230V applications ð p. 10)

Note: The SERVOSTAR 640/670 drives are suitable for use on a circuit capable of delivering not more

than 5000rms symmetrical amperes, 480VAC max.

N1/2/3

B1/2

50 AT (FRx-50) * 80 AT (FRx-80) *

KLM 20 KLM 30

16 SERVOSTAR®640 / 670 Installation Manual

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06/02 General

I.7.2 Allowable ambient conditions, ventilation, mounting position

Storage temperature/humidity/duration ð p.81
Transport temperature / humidity ð p.81

Supply voltage tolerances

Input power (ð p.14)

min 3x230V
min 3x208V

AC / max 3x 480V

-10%

AC / max 3x 480V

-10%

+10%

+10%

,50Hz
,60Hz

Aux. power supply

Ambient temperature in operation

Humidity in operation rel. humidity 85%, no condensation

Site altitude

Pollution level Pollution level 2 to EN60204/EN50178 Enclosure protection IP 20

Mounting position generally vertical. ð p.28 Ventilation forced convection by built-in fans

Make sure that there is sufficient forced ventilation within the switchgear cabinet.

I.7.3 Conductor cross-sections

Following EN 60204 (for AWG: table 310-16 of the NEC 60°C or 75°C column), we recommend for
single-axis systems:

AC connection 25 mm² (2 awg), shielded between filter and amplifier, 600V,105°C (221°F)
DC-link 25 mm² (2 awg), shielded for lengths > 20 cm, 600V,105°C (221°F)

Motor cables

Resolver, thermostat-motor

Encoder, thermostat-motor

Setpoints, monitors, AGND 0.25 mm² (22awg) twisted pairs, shielded
Control signals, BTB, DGND 0.5 mm² (20 awg)
Holding brake (motor) min. 1.5 mm² (18 awg), 600V,105°C (221°F), shielded, check voltage drop
+24 V / XGND max. 2.5 mm² (14 awg), check voltage drop
Regen resistor ð p.41, min. 10 mm² (6 awg), shielded, 1000V,105°C (221°F)

For multi-axis systems, please note the special operating conditions in your installation

Technical data for connection cables ð p. 36. Observe our application note “Cables and connectors”.

ð p.41, cross section see manual of the used motor series,

capacitance <250pF/m, 600V,105°C (221°F)
4x2x0.25 mm² (22awg) twisted pairs, shielded, max.100m,
capacitance <120pF/m
7x2x0,25 mm² (22awg) twisted pairs, shielded, max.50m,

capacitance <120pF/m

24 VDC (-0% +15%)

o

0to+45
+45 to +55°C (113 to 131 °F) with power derating

up to 1000m a.m.s.l. without restriction
1000 — 2500m a.m.s.l. with power derating

1.5%/100m

C (32 to 113 °F) at rated data

2.5% / K

I.7.4 Recommended torques

Connector Recommended torque

X3, X4 0.3 Nm(2.25 in lb)

X10 0,3 Nm (2.25 in lb)
X0 6...8 Nm (45... 60 in lb)

I.7.5 LED display

A 3-character LED display shows the amplifier status after switching on the 24V supply
(ð p.61). During operation and parameter setting of the amplifier via the keys on the front panel,

the parameter and function numbers (ð p.61) are displayed, as well as the numbers of any errors
which occur (ð p.62).

SERVOSTAR®640 / 670 Installation Manual 17

General

06/02 Seidel

I.8 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. 14).

I.9 Control for motor-holding brake

A 24V / max. 2A holding brake in the motor can be controlled directly by the servo amplifier. This
function does not ensure personnel safety! The brake function must be enabled through the

BRAKE parameter (setting: WITH BRAKE). In the diagram below you can see the time and func
tional relationships between the ENABLE signal, speed setpoint, speed and braking force.

-

During the internal ENABLE delay time of 100ms the speed setpoint of the servo amplifier is
internally driven down a 10ms ramp to 0V. The brake output is switched on when 3% of the final

speed is reached. The rise (tbrH) and fall (tbrL) times of the holding brake which is built into the
motors are different for the various types of motor (see motor manual). A description of the

interface can be found on page 41.
A safe (for personnel) operation of the holding brake requires an additional “make” (n.o.) contact in

the brake circuit and a suppressor device (varistor) for the recommended brake circuit diagram :

- A.4.031.3/01, A.4.038.1/10

SERVOSTAR

18 SERVOSTAR®640 / 670 Installation Manual

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I.10 Regen 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 regen resistor. The regen resistor is switched into circuit by the regen

circuit. The regen 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 regen power which is required. A
description of the interface can be found on page 41 .

Functional description:

1.- Individual amplifiers, not coupled through the DC-link (DC+, DC-)

The circuit starts to respond at a DC-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 regen power, then the servo amplifier will output
the status “regen power exceeded” and the regen circuit will be switched off. At the next

internal check of the DC-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. 62). The
BTB/RTO contact (terminal X3/2,3) will be opened at the same time (ð p. 47).

2.- Several servo amplifiers coupled through the DC-link circuit (DC+, DC-)

Thanks to the built-in regen circuit with its patented power distribution, several amplifiers
(even with different current ratings) can be operated off a common DC-link. This is achieved

by an automatic adjustment of the regen thresholds (which vary, because of tolerances).
The regen 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. 47).

06/02 General

Regen circuit: technical data SERVOSTAR
Supply voltage Rated data DIM 640 670

External regen resistor Ohm 15 10
Upper switch-on level of regen circuit V 400 - 430

3 x 230 V

3 x 400 V

3 x 480 V

Switch-off level of regen circuit V 380 - 410
Overvoltage F02 V 450

Continuous power of regen circuit (R
Pulse power, external (R
External regen resistor Ohm 15 10
Upper switch-on level of regen circuit V 720 - 750
Switch-off level of regen circuit V 680 - 710

Overvoltage F02 V 800
Continuous power of regen circuit (R
Pulse power, external (R
External regen resistor Ohm 15 10
Upper switch-on level of regen circuit V 840 - 870

Switch-off level of regen circuit V 800 - 830
Overvoltage F02 V 900
Continuous power of regen circuit (R
Pulse power, external (R

max. 1s) kW 10 16

Bext

max. 1s) kW 35 50

Bext

max. 1s) kW 45 70

Bext

) max. kW 6

Bext

) max. kW 6

Bext

) max. kW 6

Bext

SERVOSTAR®640 / 670 Installation Manual 19

General

06/02 Seidel

I.11 Switch-on and switch-off behavior

The diagram below illustrates the correct functional sequence for switching the servo amplifier on
and off.

DC-link

I.11.1 Stop function to EN 60204 (VDE 0113)

If a fault occurs (ð p. 62) the output stage of the servo amplifier is switched off and the BTB/RTO
contact is opened. In addition, a global error signal can be given out at one of the digital outputs

(terminals X3/16 and X3/17) (see online help for the setup software). These signals can be used by
the higher-level control to finish the current PLC cycle or to shut down the drive (with additional

brake or similar.).

The built-in restart lock -AS- can be used to switch off the drive via a positive-action (approved by
Trade Liability Association) safety relay, so that personnel safety is ensured at the drive shaft

(ð p. 22).

Instruments which are equipped with a selected “Brake” function use a special sequence for switch
ing off the output stage (ð p. 18).

The Stop functions are defined in EN 60204 (VDE 0113), Para. 9.2.2, 9.2.5.3.

There are three categories of Stop functions:

Category 0: Shut down by immediately switching off the supply of energy to the

drive machinery (i.e an uncontrolled shut-down);

Category 1: A controlled shut-down, during which the supply of energy to the drive

machinery is maintained to perform the shut-down, and where the energy
supply is only interrupted when the shut-down has been completed;

Category 2: A controlled shut-down, where the supply of energy to the drive machinery

is maintained.

Every machine must be equipped with a Stop function to Category 0. Stop functions to Categories 1
and/or 2 must be provided if the safety or functional requirements of the machine make this neces
sary.

You can find additional information and implementation examples in our application note “Stop and
Emergency Stop functions with SERVOSTAR 600”.

-

-

- A.4.038.3/01

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06/02 General

I.11.2 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 :

You can find wiring recommendations in our application note

“Stop and Emergency Stop functions with SERVOSTAR 600”

Category 0:

The controller is switched to “disable”, the electrical supply (208...480VAC) is disconnected.

The drive must be held by an electromagnetic holding device (brake).

In multiaxis systems with connected DC-link bus (intermediate circuit) the motor leads have
to be disconnected by a changeover switch (contactor, e.g. Siemens 3RT1516-1BB40) and
short-circuited by resistors connected in a star configuration.

Category 1:

If hazardous conditions can result from an emergency stop switch-off with an unbraked
run-down, then the drive can be switched off by a controlled shut-down.

Stop Category 1 permits electromotive braking with a switch-off when zero speed has
been reached. Safe shut-down can be achieved, when the loss of the mains supply is not

rated as a fault and the control takes over the disabling of the servoamplifier.
In the normal situation, only the supply power is switched off in a safe manner.

The 24V auxiliary supply remains switched on.

SERVOSTAR®640 / 670 Installation Manual 21

General

06/02 Seidel

I.12 Restart lock -AS-

I.12.1 Advantages of the restart lock

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 ele

ments (positively driven relay contacts).
To get round this problem, up to now either the main contactor in the mains supply line was
switched off, or another contactor was used to disconnect the motor from the servo amplifier.

The disadvantages of this method are :

— the DC-link has to be charged up again at restart
— wear on the contacts of the contactors, caused by switching under load

— extensive wiring required, with additional switching components

The restart lock -AS- avoids these disadvantages. A safety relay in the servo amplifier is activated
either by the PLC or manually. Positively driven contacts provide a safe disconnection of the ampli

fier, the setpoint input of the servo amplifier is inhibited, and a signal is sent to the safety circuit.

The suggested circuits (ð p. 25) fulfills safety category 1 (EN 954-1). You can fulfill safety
category 3, if you use a mains contactor with suited supervision.

Advantages of the restart lock -AS- :

— the DC-link remains charged up, since the mains supply line remains active
— only low voltages are switched, so there is no contact wear

— very little wiring is required
— the functionality and the personnel safety when using the circuit recommendations in

this documentation have been approved by the Trade Liability Association.

-

-

I.12.2 Functional description

The connector (X10) is mounted on the front panel of the SERVOSTAR 640/670.The coil connec
tions and a make (n.o.) contact of a safety relay are made available through 4 terminals on this con

nector.

The 24VDC safety relay in the servo amplifier (approved) is controlled externally. All the relay con
tacts 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.

-

-

-

22 SERVOSTAR®640 / 670 Installation Manual

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I.12.3 Block diagram

06/02 General

I.12.4 Signal diagram (sequence)

- A.4.031.1/32,30

SERVOSTAR®640 / 670 Installation Manual 23

General

I.12.5 Installation / Setup

I.12.5.1 Safety instructions

Observe the prescribed use of the restart lock -AS- (ð p. 10)

l

The monitoring contacts (KSO1/2) for each amplifier must be looped into the control circuit.

l

This is vital, so that a malfunction of the internal safety relay or a cable break can be recog
nized.

If the restart lock -AS- is automatically activated by a control system (KSI1/2), then make

l

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 :

l

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, apply an additional mechanical block to the drive

4. Activate the restart lock -AS-

I.12.5.2 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. Stop all drives, with setpoint 0V, disable drives,
mechanically block any suspended loads

2. Activate the restart lock -AS-.

3. Open protective screens (but do not enter hazardous area)

4. Pull off the X10 connector from an amplifier: the mains contactor must drop out

5. Reconnect X10. Switch on mains contactor again.

6. Repeat steps 4 and 5 for each individual servo amplifier.

06/02 Seidel

-

I.12.5.3 Connection diagram

- A.4.031.1/30

SERVOSTAR

24 SERVOSTAR®640 / 670 Installation Manual

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06/02 General

I.12.6 Application examples

I.12.6.1 Moving single axes or 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.

I.12.6.2 Switching off grouped axes with separate working areas

Even when several SERVOSTAR 640/670 are operating off a common mains supply and DC-link, it
is possible to set up groups for separate working areas. These groups can then be switched off

separately for personnel safety. For this purpose, we have provided you with a suggested circuit
(mains supply circuit and control circuit for 2 separate working groups which have interconnected

DC-links and a common mains supply voltage).

I.12.6.2.1 Control circuit

The suggested circuit fulfills safety category 1 (EN 954-1). You can fulfill safety category 3, if you
use a mains contactor with suited supervision.

- A.4.031.1/31

SERVOSTAR®640 / 670 Installation Manual 25

General

I.12.6.2.2 Mains supply circuit

06/02 Seidel

- A.4.031.3/05

SERVOSTAR

SERVOSTAR SERVOSTAR SERVOSTAR SERVOSTAR

26 SERVOSTAR®640 / 670 Installation Manual

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II Installation

II.1 Important instructions

06/02 Installation

Protect the servo amplifier from impermissible stresses. In particular, do not let any compo

l

nents become bent or any insulation distances altered during transport and handling. Avoid
contact with electronic components and contacts.

Check the combination of servo amplifier and motor. Compare the rated voltage and current

l

of the units. Carry out the wiring according to the connection diagram on page 30.

Make sure that the maximum permissible rated voltage at the terminals L1, L2, L3 or +DC,

l

–DC is not exceeded by more than 10% even in the most unfavourable case
(see EN 60204-1 Section 4.3.1). An excessive voltage on these terminals can lead to

destruction of the regen circuit and the servo amplifier. Use the SERVOSTAR 640/670 servo
amplifiers only on an earthed (grounded) 3-phased supply system, to drive a synchronous

servomotor.

The use of external mains chokes and mains filters is required.

l

The fusing of the AC supply input and the 24V supply is installed by the user (ð p. 16).

l

Take care that the servo amplifier and motor are earthed (grounded) properly. Do not use

l

painted (non-conductive) mounting plates.

Route power and control cables separately. We recommend a separation of at least 200mm.

l

This improves the interference immunity required by EMC regulations.

Install all heavy-current cables with an adequate cross-section, as per EN 60204. (ð p. 17).

l

Wire the BTB/RTO contact in series into the safety circuit of the installation.

l

Only in this way is the monitoring of the servo amplifier assured.

Install all shielding with large areas (low impedance), with metallised connector housings or

l

shield connection clamps where possible.
Earth (ground) the shielding at both ends (ð p. 32).

Notes on connection techniques can be found on page 35 and in the application note
“Cables and connectors”.

l

Ensure that there is an adequate flow of cool, filtered air into the bottom of the switchgear
cabinet. Observe page 17 .

-

It is permissible to alter the servo amplifier settings by using the setup software.

l

Any other alterations will invalidate the warranty.

Caution
Never disconnect the electrical connections to the servoamplifier while it is live. In
unfavourable circumstances this could result in destruction of the electronics.
Residual charges in the capacitors can have dangerous levels up to 300 seconds after
switching off the mains supply voltage. Measure the voltage in the DC-link (+DC/-DC),

and wait until the voltage has fallen below 40V.
Control and power connections can still be live, even when the motor is not rotating.

SERVOSTAR®640 / 670 Installation Manual 27

Installation

II.2 Assembly

Ask our customer service for information for pass through mounting
Material : 4 hexagon socket screws to DIN 912, M6

Tool required : 5 mm Allen key

06/02 Seidel

- A.4.038.4/12

SERVOSTAR

28 SERVOSTAR®640 / 670 Installation Manual

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06/02 Installation

II.2.1 Dimensions of SERVOSTAR 640/670

- A.4.038.4/07

SERVOSTAR®640 / 670 Installation Manual 29

Installation

II.3 Wiring

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 sensible or
necessary, depending on the application of the equipment.

We provide further know-how through training courses (on request).

Caution !
Only install and wire up the equipment when it is not live, i.e. when neither the mains
power supply nor the 24 V auxiliary voltage nor the operating voltages of any other
connected equipment is switched on.
Take care that the cabinet is safely disconnected (with a lock-out, warning signs etc.).
The individual voltages will be switched on for the first time during setup.

Note !

06/02 Seidel

The ground symbol

X, 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 con

fused with the PE- symbol W (a protective measure to EN 60204).

Use the following connection diagrams:

— Restart lock -AS- : page 24
— Power and control connections : page 32
— Multi-axis systems, example : page 33
— Resolver : page 42
— High-resolution encoder : page 43
— Encoder simulation ROD : page 48
— Encoder simulation SSI : page 49
— Master-slave interface : page 50
— Pulse direction interface : page 52
— RS232 / PC : page 54
— CAN-interface : page 55
— Expansion card -I/O-14/08- : Page 68
— Expansion card PROFIBUS : Page 70
— Expansion card SERCOS : Page 72
— Expansion module -2CAN- : Page 74

-

30 SERVOSTAR®640 / 670 Installation Manual

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06/02 Installation

The following notes should assist you to carry out the installation in a sensible sequence, without
overlooking anything important.

Site

Ventilation

In a closed switchgear cabinet. Observe page 17 .
The site must be free from conductive or corrosive materials.
For the mounting position in the cabinet ð p. 28

Check that the ventilation of the servo amplifier is unimpeded
and keep within the permitted ambient temperature ð p. 17 .

Keep the required space clear above and below the servo amplifier
ð p28.

Assembly

Cable selection

Grounding

Shielding

Wiring

Assemble the servo amplifier and power supply, filter and choke close
together on the conductive, grounded mounting plate in the cabinet.

Select cables according to EN 60204 (ð p. 17)

EMC-compliant (EMI) shielding and grounding (ð p. 32)
Earth (ground) the mounting plate, motor housing and CNC-GND

of the controls.
Notes on connection techniques are on page 35

— Route power leads and control cables separately

— Wire the BTB/RTO contact in series into the safety

— loop of the installation

— 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 leads

— 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. 17)

— Connect mains choke and mains filter (shielded lines between filter

— and servo amplifier)

— Connect main power supply

— (for max. permissible voltage values ð p. 17)

— Connect PC (ð p. 54).

— Final check of the implementation of the wiring,

Final check

— according to the wiring diagrams which have been used.

SERVOSTAR®640 / 670 Installation Manual 31

Installation

06/02 Seidel

II.3.1 Connection diagram for SERVOSTAR 640/670

Reference Safety Instructions (ð p.6) and
Use As Directed (ð p.10) !

- A.4.038.1/03

SERVOSTAR 640/670

ð p.44

ð p.43

ð p.45

ð p.42

ð p.41

ð p.46

ð p.40

ð p.41

ð p.40

ð p.47

ð p.22

ð p.48

ð p.49
ð p.50

ð p.52

ð p.55

ð p.54

32 SERVOSTAR®640 / 670 Installation Manual

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06/02 Installation

II.3.2 Example of connections for multi-axis system

Reference Safety Instructions (ð p.6) and
Use As Directed (ð p.10) !

SERVOSTAR

- A.4.038.1/04

SERVOSTAR

SERVOSTAR®640 / 670 Installation Manual 33

Installation

06/02 Seidel

II.3.3 Pin assignments for SERVOSTAR 640/670

- A.4.038.4/13

34 SERVOSTAR®640 / 670 Installation Manual

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06/02 Installation

II.3.4 Notes on connection techniques

Please consider our application note “Cables and connectors”

II.3.4.1 Shielding connection to the front panel

- A.4.029.4/25

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.

Remove the outer covering of the cable
over a length of about 30mm, without
damaging the shielding braid.

Pull a cable tie through the slot in the
shielding rail (front panel) of the servo

amplifier.

SERVOSTAR 640/670

SERVOSTAR 640/670

Use the cable tie to clamp the shielding
braid of the cable firmly to the shielding
rail.

SERVOSTAR®640 / 670 Installation Manual 35

Installation

06/02 Seidel

II.3.4.2 Technical data for connecting 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 17 .

Insulation material

Sheathing - PUR (polyurethane, code 11Y)
Core insulation - PETP (polyesteraphtalate, code 12Y)

Capacitance

Motor cable - £ 4mm² : less than 150 pF /m

>4mm² : less than 250 pF/m

RES-cable - less than 120 pF/m

Technical data

— The brackets in the cable designation indicate the shielding.
— Alle cables are suitable for use as trailing cables.

— The technical data refer to the use as moveable cables.

Operating life : 1 million bending cycles

Operation-

Cores
[mm²]

(4x1,0) color -30 / +80 -22 / 176 10,5 100
(4x1,5) letter -30 / +80 -22 / 176 11,3 105

(4x2,5) number -5 / +70 23 / 158 12,7 125

(4x4) number -5 / +70 23 / 158 12,8 130

(4x10) number -5 / +70 23 / 158 19 190
(4x16) number -5 / +70 23 / 158 23,3 230

(4x25) number -5 / +70 23 / 158 32,7 330
(4x2x0,25) color -30 / +80 -22 / 176 6,9 60
(7x2x0,25) color -30 / +80 -22 / 176 9,9 80

(10x2x0,14) color -30 / +80 -22 / 176 8,8 80

Coretype

Temperature

range

[°C]

Operation-

Temperature

range

[°F]

Outside

diameter

[mm]

Bending

radius

[mm]

Remarks

twisted

pairs

36 SERVOSTAR®640 / 670 Installation Manual

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II.4 Setup software

II.4.1 General

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.

II.4.1.1 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 9 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.

06/02 Installation

II.4.1.2 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. 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 the Danaher Motion web site
in the Kollmorgen Seidel 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 rec
ognized, and the additional parameters which are required for position control or motion-block defi

nition 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.

-

-

SERVOSTAR®640 / 670 Installation Manual 37

Installation

II.4.1.3 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. 54).

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:

Processor : 80486 or higher
Operating system : WINDOWS 95(c) / 98 / 2000 / ME, WINDOWS NT4.0

Graphics adapter : Windows compatible, color
Drives : hard disk with at least 5 MB free space

Main memory : at least 8MB
Interface : one free serial interface (COM1:, :2, :3 or COM4:)

II.4.1.4 Operating systems

06/02 Seidel

CD-ROM drive

WINDOWS 95(c) / WINDOWS 98 / WINDOWS 2000 / WINDOWS ME / WINDOWS NT

DRIVE.EXE is executable under WINDOWS 95(c) / 98 / 2000 / ME and WINDOWS NT 4.0.
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.

II.4.2 Installation under WINDOWS 95 / 98 / 2000 / ME / NT

An installation program called SETUP.EXE can be found on the CD-ROM which makes it easier to install the setup software on your PC.

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. 54).

Switch-on:

Switch on your PC-AT and the monitor.
After the start phase (boot-up) is finished, the Windows user-interface appears on the screen.

Installation:
Click on START (Task bar), then on Run. Enter the program call in the entry window:

x:\setup.exe (x= the correct CD-ROM drive letter).

Click on OK and follow the instructions.

38 SERVOSTAR®640 / 670 Installation Manual

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III Interfaces

All important interfaces are shown in this chapter. The precise location of the connectors and
terminals can be seen on page 34. The block diagram below is just an overview.

06/02 Interfaces

- A.4.038.1/09

SERVOSTAR®640 / 670 Installation Manual 39

Interfaces

06/02 Seidel

III.1 Power supply

III.1.1 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. 16

SERVOSTAR

III.1.2 24V auxiliary supply (X4)

— Electrically isolated, external 24VDC supply, e.g. with insulating transformer

— Required current rating ð p. 16

— Integrated EMI filter for the 24V auxiliary supply

III.1.3 DC-link (X7)

Can be connected in parallel, thanks to patented circuit to distribute the regen power among all the
amplifiers connected to the same DC-link circuit. (Connection example ð p. 33).

SERVOSTAR

- A.4.038.1/ 05, 06

40 SERVOSTAR®640 / 670 Installation Manual

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06/02 Interfaces

III.2 Motor connection with brake (X0, X4)

Cross section see manual of the motor series.

SERVOSTAR

III.3 External regen resistor (X0)

— Fusing and regen resistor provided by the user

- A.4.038.1/07, 08

SERVOSTAR

SERVOSTAR®640 / 670 Installation Manual 41

Interfaces

III.4 Feedback

III.4.1 Resolver connection (X2)

Our rotatory servomotors have 2-pole hollow-shaft resolvers built in as a standard. It is possible to
connect 2...36-pole resolvers to the SERVOSTAR 640/670.

If lead lengths of more than 100m are planned, please contact our customer service .
The thermostat contact in the motor is connected via the resolver cable to the
SERVOSTAR 640/670 and evaluated there.

SERVOSTAR

06/02 Seidel

- A.4.031.1/26

colors for European cables only

42 SERVOSTAR®640 / 670 Installation Manual

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III.4.2 Encoder (X1)

06/02 Interfaces

As an option, our servomotors can be fit with a single-turn or multiturn sine-cosine encoder. Pre
ferred types are ECN1313 and EQN1325.

This encoder is used by the SERVOSTAR 640/670 as a feedback device for drive tasks which
require highly precise positioning or extremely smooth running.

If lead lengths of more than 50m are planned, please consult our customer service .

The thermostat contact in the motor is connected via the resolver cable to the
SERVOSTAR 640/670 and evaluated there.

Max. input frequency: 250KHz

SERVOSTAR

- A.4.031.1/27

SubD15

17pol.round

-

colors for European cables only

SERVOSTAR®640 / 670 Installation Manual 43

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06/02 Seidel

III.5 Control signals, monitor signals

III.5.1 Analog setpoint 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

SERVOSTAR

Input SW/SETP.1 (terminals X3/4-5)

Differential input voltage max. ± 10 V, resolution 14-bit, scalable
Standard setting : speed setpoint

Input SW/SETP.2 (terminals X3/6-7)

Differential input voltage max. ± 10 V, resolution 12-bit, scalable
Standard setting : torque setpoint

Application examples for setpoint input SW/SETP.2:
— 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.

- A.4.031.1/23

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III.5.2 Monitor outputs (X3)

Technical characteristics

— Reference ground is analog-GND (AGND, terminal X3/1 and X3/10)
— Output resistance : 2.2kW

— Output voltage ±10V
— Resolution : 10 bit.

06/02 Interfaces

SERVOSTAR

Programmable analog outputs MONITOR 1 / MONITOR 2

The terminals X3/8 (MONITOR 1) or X3/9 (MONITOR 2) can have the following analog signals
assigned to them:

Standard setting :

Monitor 1 : Tachometer voltage VTA (speed)
The output delivers ±10V at the preset limit speed.

Monitor 2 : Current setpoint IDC (torque)
The IDC-monitor delivers ± 10V at the preset peak current (effective r.m.s. value).

You can use the terminals X3/8 (MONITOR 1) or X3/9 (MONITOR 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.

-A.4.031.1/22

SERVOSTAR®640 / 670 Installation Manual 45

Interfaces

III.5.3 Digital control inputs (X3)

All digital inputs are electrically isolated through optocouplers.

Technical characteristics

— Reference ground is digital-GND (DGND, terminal X3/18)
— The logic is dimensioned for +24V / 7mA (PLC-compatible)
— H-level of +12 .. 36V / 7mA, L-level of 0 .. 7V / 0 mA

SERVOSTAR

06/02 Seidel

ENABLE input

The output stage of the servo amplifier is activated by the enable signal
(terminal X3/15, input 24V, 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 24V 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 logi
cally combined in a pre-programmable function.

- A.4.031.1/24

-

46 SERVOSTAR®640 / 670 Installation Manual

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06/02 Interfaces

III.5.4 Digital control 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 . 30VDC, 10 mA

BTB/RTO : Relay output, max. 30VDC or 42VAC, 0.5A

SERVOSTAR

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 regen threshold.

All faults cause the BTB/RTO contact to open and the switch-off of the output stage.

A list of the error messages can be found on page 62.

Programmable digital outputs DIGITAL-OUT1/2:

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 24V 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 SETUP SOFTWARE manual refers to the output of the
inverting interface relays. Consider the delay of the applied relay !

- A.4.031.1/20

SERVOSTAR®640 / 670 Installation Manual 47

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06/02 Seidel

III.6 Encoder simulations

III.6.1 Incremental encoder simulation - A quad B position output (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 system Resolution Zero position

Resolver 16...1024

ROD (1)

ROD interpolation (3)

EnDat / HIPERFACE

Incremental encoders with
out absolut data channel

16...4096 and

8192...524288 (2

4...128 (2

­TTL lines per sine line

n

)

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 :

- A.4.031.1/11

one per revolution
(only if A=B=1)

one per revolution

n

)

(only if A=B=1)
analog pass through
from X1 to X5

SERVOSTAR

48 SERVOSTAR®640 / 670 Installation Manual

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06/02 Interfaces

III.6.2 SSI encoder simulation - position output (X5)

The SSI interface (synchronous serial absolute-encoder simulation) is part of the delivered pack
age. 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 or 9 bits are fixed to ZERO, the lower 12 or 15 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:
the upper 12 bits are set to 1 (data invalid!) until a homing run is performed.

MULTI TURN selected: The upper 12 or 9 bits contain the number of motor turns, the lower 12 or
15 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-TAKT parameter (200 kHz or 1.5MHz and inverted).

Drivers are supplied from internal supply voltage. PGND must always be connected.

Connection and signal description for SSI interface :

The count direction for the SSI interface is upwards when the motor shaft is rotating clockwise
(looking at the shaft end).

SERVOSTAR

If an encoder with a commutation track is used as the feedback unit, then

- A.4.031.1/12

-

SERVOSTAR®640 / 670 Installation Manual 49

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06/02 Seidel

III.6.3 Interface for master-slave operation, encoder input

This interface can be used to link several SERVOSTAR 640/670 amplifiers together in
master-slave operation.

The parameters for the slave amplifiers are set up with the aid of the setup software.
The resolution (no. of pulses/turn) can be adjusted. The analog setpoint inputs are out of action.

AGND and DGND (connector X3) must be joined together !

Signal diagram (for encoders with RS422 or 24V output)

III.6.3.1 Connection to a SERVOSTAR master, 5V signal level (X5)

This interface can be used to link several SERVOSTAR amplifiers together in master-slave opera
tion. Up to 16 slave amplifiers can be controlled by the master via the encoder output. The connec

tor X5 must be used.

Edge frequency: 1,5MHz, slew rate tv £ 0,1µs

AGND and DGND (connector X3) must be joined together !

SERVOSTAR

SERVOSTAR

-

-

50 SERVOSTAR®640 / 670 Installation Manual

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06/02 Interfaces

III.6.3.2 Connection to encoders with 24V signal level (X3)

This interface can be used to operate the SERVOSTAR 640/670 as a slave, mastered by an
encoder with 24V signal level (master-slave operation). The digital inputs DIGITAL-IN 1 and 2 at

connector X3 must be used.

Edge frequency: 250 kHz, slew rate tv £ 0,1µs

AGND and DGND (connector X3) must be joined together !

SERVOSTAR 640/670

III.6.3.3 Connection to a sine-cosine encoder (X1)

This interface can be used to operate the SERVOSTAR 640/670 as a slave, mastered by a
sine-cosine encoder (master-slave operation). The connector X1 must be used.

Edge frequency: 100 kHz

AGND and DGND (connector X3) must be joined together !

The cable colors in the wiring diagram are valid for the european 4x2x0,25mm² cable.

SERVOSTAR 640/670

-A.4.031.1/44,43

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06/02 Seidel

III.7 Interface for stepper-motor controls (pulse-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 gear

ing). 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.

The analog setpoint inputs are out of action.

AGND and DGND (connector X3) must be joined together !

Speed profile and signal diagram

-

Note:
Encoder Input A quad B offers more EMI supression.

- A.4.031.3/02

52 SERVOSTAR®640 / 670 Installation Manual

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06/02 Interfaces

III.7.1 Connection to stepper-motor controller with 5V signal level (X5)

This interface can be used to connect the servo amplifier to a stepper-motor controller with 5V
signal level. The connector X5 must be used.

Edge frequency: 1,5MHz

AGND and DGND (connector X3) must be joined together !

SERVOSTAR

III.7.2 Connection to stepper-motor controller with 24V signal level (X3)

This interface can be used to connect the servo amplifier to a stepper-motor controller with 24V
signal level. The digital inputs DIGITAL-IN 1 and 2 at connector X3 must be used.
Edge frequency: 100 kHz

AGND and DGND (connector X3) must be joined together !

SERVOSTAR 640/670

- A.4.031.1/10,4

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06/02 Seidel

III.8 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 37.

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. 73).

SERVOSTAR

Interface cable between the PC and servo amplifiers of the

(View : looking at the face of the built-in SubD connectors, this corresponds to the solder side of the
SubD sockets on the cable)

- A.4.031.1/13,1

SERVOSTAR 640/670 series:

54 SERVOSTAR®640 / 670 Installation Manual

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III.9 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. 73).

If the analog setpoint inputs are not used, then AGND and DGND (connector X3) must be
joined together !

SERVOSTAR

06/02 Interfaces

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 max. cable length / m

1000 20

500 70
250 115

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 ± 5WÞterminating resistor 150 ± 5W).
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

-A.4.031.1/15, 36

SERVOSTAR®640 / 670 Installation Manual 55

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06/02 Seidel

This page has been intentionally left blank.

56 SERVOSTAR®640 / 670 Installation Manual

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IV Setup

IV.1 Important notes

Only professional personnel with extensive knowledge in the fields of electrical/ drive
technology are allowed to setup the servo amplifier.

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 hazard analysis for the machine,
and take appropriate measures to ensure that unforeseen movements cannot cause
injury or damage to any person or property.

Caution !
Check that all live connecting elements are protected from accidental contact.
Deadly voltages can be present, up to 900V.
Never disconnect any of the electrical connections to the servo amplifier while it is live.
Capacitors can still have residual charges with dangerous levels up to 300 seconds
after switching off the supply power.
Heat sinks of the amplifier can reach a temperature of up to 80°C (176°F) in opera
tion. Check (measure) the heat sink temperature. Wait until the heat sink has cooled
down below 40°C (104°F) before touching it.

06/02 Setup

-

Warning !
If the servo amplifier has been stored for longer than 1 year, then the DC-link capaci
tors 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 termi
nals 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).

-

-

SERVOSTAR®640 / 670 Installation Manual 57

Setup

06/02 Seidel

The following instructions should help you to carry out the setup in a sensible order, without any
hazards to people or machinery.

Check installation

Inhibit

Enable signal

Switch on 24V

auxiliary voltage

Switch on PC,

start setup software

ð p.27ff. Disconnect the servo amplifier from the supply.

0V on terminal X3/15 (Enable)

24VDC on terminal X4/1, ground on terminal X4/3
After the initialisation procedure (about 0.5 sec.) the status is

shown in the LED display (ð p.61)

Select the interface to which the servo amplifier is connected,
The parameters which are stored in the SRAM of the servo

amplifier are transferred to the PC.

Caution !

Check displayed

parameters,

and correct

if necessary

Supply voltage : set to the actual mains supply voltage
Rated motor voltage : at least as high as the DC-link voltage of the amplifier

Motor pole-no. : must match the motor (see motor manual)
Feedback : must match the feedback unit in the motor

I

RMS

I

PEAK

Limit speed : maximum is the rated motor speed (on nameplate)
Regen power : maximum is the permitted regen resistor dissipation

Station address : unique address (see setup software manual)

It is especially important to check the following parameters.
If you do not keep to them, parts of the system can be
damaged or destroyed.

: maximum is the motor standstill current I0(on nameplate)
: maximum is 4 x motor standstill current I

0

Check

safety devices

Switch on

supply power

Apply 0V setpoint

Enable

Setpoint

Optimization

Setup

the expansion card

Caution !
Make sure that any unintended movement of the drive
cannot cause danger to machinery or personnel.

through the ON/OFF button of the contactor control

0V on terminals X3/4-5 or X3/6-7

(500 ms after switching on the supply power) 24VDC on
terminal X3/15, motor stands with standstill torque M

apply a small analog setpoint, about 0.5V is recommended,
to terminals X3/4-5 or X3/6-7

If the motor oscillates, the parameter Kp in the menu
page “speed controller” must be reduced

- the motor is endangered!

Optimize speed, current and position controllers

see setup instructions in the corresponding
manual on the CD-ROM

0

58 SERVOSTAR®640 / 670 Installation Manual

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IV.2 Parameter setting

A default parameter set is loaded into your servo amplifier by the manufacturer. This contains valid
and safe parameters for the current and speed controllers.

A database for motor parameters is stored in the servo amplifier. During setup you must select the
data set for the motor that is connected and store it in the servo amplifier. For most applications

these settings will already provide good to very good control loop characteristics.
An exact description of all parameters and the possibilities for optimizing the control loop character

istics can be found in the manual “Setup Software DRIVE.EXE”.

IV.2.1 Multi-axis systems

Using a special multilink cable, you can connect up to six servo amplifiers together and to your PC :
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.

06/02 Setup

-

X6
PC/CAN

PC

Cable -SR6Y-

COMx
RS232

Baud rates are the same for all amplifiers,
see table below

Add.:01

X6
CAN

IV.2.1.1 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. 61).

Add.:02

X6
CAN

Add.:03

Add.:04

X6
CAN

IV.2.1.2 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 Baud rate in kbit/s Coding Baud rate in kbit/s

0 10 5 250
1 20 6 333
2 50 7 500
3 100 8 666

4 125 9 800

10 1000

- A.4.038.4/11

SERVOSTAR®640 / 670 Installation Manual 59

Setup

06/02 Seidel

IV.2.2 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.

IV.2.2.1 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

U

U

U

U

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

IV.2.2.2 Status display

- A.4.031.3/04, 09

60 SERVOSTAR®640 / 670 Installation Manual

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IV.2.2.3 Standard menu structure

IV.2.2.4 Extended menu structure

06/02 Setup

p.59
the entry will be stored automatically,

when you exit the input field.

- A.4.031.3/03, 08

p.59

p.59

SERVOSTAR®640 / 670 Installation Manual 61

Setup

IV.3 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 Designation Explanation

F01* heat sink temperature

F02* overvoltage

F03* following error message from the position controller

F04 feedback cable break, short circuit, short to ground

F05* undervoltage

F06 motor temperature

F07 aux. voltage internal aux. voltage not OK

F08* overspeed motor running away, speed is too high

F09 EEPROM checksum error
F10 Flash-EPROM checksum error
F11 brake cable break, short circuit, short to ground
F12 motor phase motor phase missing (cable break or similar)

F13* internal temperature internal temperature too high

F14 output stage fault in the output stage
F15 I²t max I²t max. value exceeded

F16* supply - BTB/RTO 2 or 3 phases missing in the supply feed

F17 A/D converter

F18 regen regen circuit faulty or incorrect setting

F19 supply phase

F20 Slot fault Hardware fault of the expansion card
F21 Handling fault Software fault of the expansion card

F22

F23 CAN Bus off CAN Bus total communication error
F24 Warning Warning displays as error

F25 Commutation error Encoder systems only
F26 Limit switch Homing error (hardware limit switch reached)
F27 restart lock -AS- Operating error for restart lock -AS-
F28 reserved reserved
F29 SERCOS error SERCOS error
F30 Emerg. Stop Timeout Emerg. Stop Timeout
F31 reserved reserved
F32 system error system software not responding correctly

Short circuit to earth
(ground)

06/02 Seidel

heat sink temperature too high
limit is set by manufacturer to 80°C
overvoltage in DC-link

limit depends on the mains supply voltage

undervoltage in DC-link
limit is set by manufacturer to 100V
motor temperature too high

limit is set by manufacturer to145°C

error in the analog-digital conversion, usually caused by excessive
EMI

a supply phase is missing
(can be switched off for 2-phase operation)

short circuit to earth (ground)

* = 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 com
mand is also all that is carried out.

-

62 SERVOSTAR®640 / 670 Installation Manual

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IV.4 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 Designation Explanation

n01 I²t I²t threshold exceeded

n02 regen power preset regen power reached
n03* S_fault exceeded preset contouring error
n04* response monitoring response monitoring (fieldbus) is active

n05 supply phase supply phase missing
n06* Sw limit-switch 1 passed software limit-switch 1
n07* Sw limit-switch 2 passed software limit-switch 2

n08 motion task error a faulty motion task was started

n09 no reference point not reference point set at start of motion task
n10* PSTOP PSTOP limit-switch activated

n11* NSTOP NSTOP limit-switch activated

n12 motor default values loaded

n13* expansion card expansion card not functioning correctly

n14 SinCos feedback

n15 Table error Velocity current table INXMODE 35 error

n16-n31 reserved reserved

n32 Firmware beta version The firmware is an unreleased beta version

A Reset RESET is active at DIGITAL IN x

06/02 Setup

Only sine encoders with ENDAT or HIPERFACE format.
Motor number stored in encoder memory different from number
stored in drive memory, default parameters loaded

Sine encoder “wake & shake mode” , ends if drive is enabled
and wake & shake is done.

* = These warning messages lead to a controlled shut-down of the drive (braking with the emergency ramp)

SERVOSTAR®640 / 670 Installation Manual 63

Setup

06/02 Seidel

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64 SERVOSTAR®640 / 670 Installation Manual

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V Extensions / Accessories

V.1 Expansion card -I/O-14/08-

This 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.

The 24VDC supply for the expansion card is taken from the controller. All inputs and outputs are
electrically isolated from the servo amplifier by optocoupler.

V.1.1 Fitting the expansion card

If you want to retrofit the I/O expansion card into a SERVOSTAR 640/670, proceed as follows:

06/02 Extensions / Accessories

Use a suitable screwdriver to remove the cover of the option slot.

l

l

Take care that no small items (such as screws) fall into the open option slot.

Push the expansion card carefully into the guide rails that are provided, without twisting it.

l

Press the expansion card firmly into the slot, until the front cover touches the fixing lugs.

l

This ensures that the connectors make good contact.

Screw the screws on the front cover into the threads in the fixing lugs.

l

V.1.2 Technical data

Control inputs 24V / 7mA, PLC-compatible

Signal outputs 24V / max. 500mA, PLC-compatible

Supply inputs, to IEC 1131

Fusing (external) 4 AT

Connectors MiniCombicon, 12-pole, coded on PIN1 and 12 respectively

Cables

Waiting time between 2 motion tasks depends on the response time of the control system

Addressing time (min.) 4ms
Starting delay (max.) 2ms

Response time of digital outputs max. 10ms

24V (18 ... 36V) / 100mA plus total current of the outputs (de
pends on the input wiring of the controls)

Data – up to 50m long : 22 x 0.5mm², un
shielded,
Supply – 2 x 1mm², check voltage drop

-

-

The 24VDC voltage has to be supplied by an electrically isolated power supply, e.g. with
insulating transformer.

V.1.3 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 out

puts from the expansion card (overload, short-circuit).

-

SERVOSTAR®640 / 670 Installation Manual 65

Extensions / Accessories

V.1.4 Position of the connectors

06/02 Seidel

Coding

Plan view of the connectors as
built in

- A.4.038.4/27

66 SERVOSTAR®640 / 670 Installation Manual

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V.1.5 Connector assignments

Terminal Function Description

1 In A0 Motion task no., LSB
2 In A1 Motion task no., 2

3 In A2 Motion task no., 2
4 In A3 Motion task no., 2
5 In A4 Motion task no., 2

6 In A5 Motion task no., 2
7 In A6 Motion task no., 2
8 In A7 Motion task no., MSB

9 In Reference

10 In FError_clear Clear the warning of a following error or the response monitoring.

11 In Start_MT Next

12 In Start_Jog v=x

06/02 Extensions / Accessories

Connector X11A

1

2

3

4

5

6

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 expansion card will not be

evaluated.

The following task, that is defined in the motion task by “Start with I/O”
is started. The target position of the present motion task must be

reached before the following task can be started.
The next motion block can also be started by an appropriately config

ured digital input on the basic unit.
Start of the setup mode "Jog Mode" with a defined speed. After select
ing the function, you can enter the speed in the auxiliary variable “x”.

The sign of the auxiliary variable defines the direction. A rising edge
starts the motion, a falling edge cancels the motion.

-

-

Terminal Function Description

1 In MT_Restart

2 In Start_MT I/O

3 Out InPos

4 Out

5 Out FError
6 Out PosReg1

7 Out PosReg2
8 Out PosReg3
9 Out PosReg4

10 Out PosReg5 Can only be adjusted by ASCII commands.

11 Supply 24VDC auxiliary supply voltage

12 Supply I/O-GND Digital-GND for the controls

Next-InPos

PosReg0 Can only be adjusted by ASCII commands.

Connector X11B

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.

Contouring-error (low-active).

The preset function of the corresponding position register is indicated
by a HIGH-signal.

V.1.6 Select motion task number (Sample)

Motion task no.

(decimal

174 10101110

A7 A6 A5 A4 A3 A2 A1 A0

Motion task no. (binary)

SERVOSTAR®640 / 670 Installation Manual 67

Extensions / Accessories

V.1.7 Connection diagram

06/02 Seidel

SERVOSTAR 640/670

-I/O-14/08

A.4.031.1/39

68 SERVOSTAR®640 / 670 Installation Manual

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06/02 Extensions / Accessories

V.2 Expansion card -PROFIBUS-

This 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".
If you ordered the expansion card together with the servo amplifier, then the expansion card is

already fitted and screwed into the slot when the servo amplifier is delivered.
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.

V.2.1 Position of the connectors

V.2.2 Fitting the expansion card

If you want to retrofit the PROFIBUS expansion card into a SERVOSTAR 640/670, proceed as
follows:

Use a suitable screwdriver to remove the cover of the option slot.

l

Take care that no small items (such as screws) fall into the open option slot.

l

Push the expansion card carefully into the guide rails that are provided, without twisting it.

l

l

Press the expansion card firmly into the slot, until the front cover touches the fixing lugs.
This ensures that the connectors make good contact.

Screw the screws on the front cover into the threads in the fixing lugs. - A.4.038.4/26

l

SERVOSTAR®640 / 670 Installation Manual 69

Extensions / Accessories

V.2.3 Connection technology

Cable selection, cable routing, shielding, bus connector, bus termination and transmission times are
all described in the “Installation guidelines for PROFIBUS-DP/”, Order No. 2.111, from PNO, the

PROFIBUS User Organization.

V.2.4 Connection diagram

- A.4.031.1/41

SERVOSTAR 640/670

06/02 Seidel

70 SERVOSTAR®640 / 670 Installation Manual

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V.3 Expansion card -SERCOS-

This 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".
If you ordered the expansion card together with the servo amplifier, then the expansion card is

already fitted and screwed into the slot when the servo amplifier is delivered.

V.3.1 Position of the connectors

06/02 Extensions / Accessories

V.3.2 Fitting the expansion card

The expansion card can be retrofitted from firmware version 4.30. Proceed as follows:

Use a suitable screwdriver to remove the cover of the option slot.

l

Take care that no small items (such as screws) fall into the open option slot.

l

Push the expansion card carefully into the guide rails that are provided, without twisting it.

l

Press the expansion card firmly into the slot, until the front cover touches the fixing lugs.

l

This ensures that the connectors make good contact.

Screw the screws on the front cover into the threads in the fixing lugs. - A.4.038.4/25

l

SERVOSTAR®640 / 670 Installation Manual 71

Extensions / Accessories

06/02 Seidel

V.3.3 Light emitting diodes (LEDs)

RT: indicates whether SERCOS telegrams are being correctly received. In the final Communi-

cation Phase 4 this LED should flicker, since cyclical telegrams are being received.

TT: indicates that SERCOS telegrams are being transmitted.

In the final Communication Phase 4 this LED should flicker,
since cyclical telegrams are being transmitted.

Check the 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.

Err : 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 communication,
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 LWL length parameter for
the cable length.

V.3.4 Connection technology

For the optical fibre (LWL) connection, only use SERCOS components to the SERCOS Standard
IEC 61491.

Receive data: The optical fibre carrying receive data for the drive in the ring structure

is connected to X13 with an FSMA connector.

Transmit data: Connect the optical fibre for the data output to X14 with an FSMA connector.

V.3.5 Connection diagram

Layout of the SERCOS bus system in ring topology, with optical fibre cables (schematic). -A.4.038.4/24

72 SERVOSTAR®640 / 670 Installation Manual

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V.4 Expansion module -2CAN-

Connector 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.

V.4.1 Position of the connectors

06/02 Extensions / Accessories

V.4.2 Fitting the expansion module

If you want to retrofit the -2CAN- expansion module into a SERVOSTAR, proceed as follows:

Use a suitable screwdriver to remove the cover of the option slot.

l

l

Take care that no small items (such as screws) fall into the open option slot.

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 - A.4.038.4/22

l

SERVOSTAR®640 / 670 Installation Manual 73

Extensions / Accessories

V.4.3 Connection technology

Standard shielded cables can be used for the RS232 and CAN interfaces.

06/02 Seidel

If the servo amplifier is the last device on the CAN bus, then the switch for the bus ter
mination must be set to ON.
Otherwise, the switch must be set to OFF (condition as delivered).

V.4.4 Connector assignments

RS232 CAN1=CAN2
X6A Pin Signal X6B=X6C Pin Signal

1 Vcc 1

2 RxD 2 CAN-Low
3 TxD 3 CAN-GND
44
5 GND 5
66

7 7 CAN-High
88
99

V.4.5 Connection diagram

- A.4.038.4/23

-

74 SERVOSTAR®640 / 670 Installation Manual

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06/02 Extensions / Accessories

V.5 Accessories

V.5.1 External 24VDC / 5A supply

Technical data

Input voltage 120 / 230V
Input current 0,9 / 0,6A
Frequency 50/60Hz
Primary fuse 3,15AT
Output voltage 24V ± 1%

Max. output current 5A
Residual ripple <150mVss
Switching peaks <240mVss
Output fuse short circuit proof
Temperature range 0...+60°C

Type of mounting

Weight 0,75kg

- A.4.037.4/07

DIN-rails, vertical mounting

Keep a clear space of 50mm above and below the instrument

SERVOSTAR®640 / 670 Installation Manual 75

Extensions / Accessories

06/02 Seidel

V.5.2 External 24VDC / 20A supply

- A.4.012.4/33

Technical data

Input voltage 3 x 400VAC ± 10%

Input current ca. 1,1A
Frequency 50/60Hz
Primary fuse none
Output voltage 24V ± 1%
Max. output current 20A

Residual ripple <0,1%
Output fuse short circuit proof
Test voltage acc. to VDE 0550
Temperature range -20...+60°C (-4...140°F)

Type of mounting

Weight 3,5kg

on the supplied mounting plate

Keep the required space clear

76 SERVOSTAR®640 / 670 Installation Manual

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06/02 Extensions / Accessories

V.5.3 External regen resistor BAS

Caution:
Surface temperature may exceed 200°C.
Observe the requested free space.
Do not mount to combustible surface.

- A.4.947.4/24

SERVOSTAR®640 / 670 Installation Manual 77

Extensions / Accessories

V.5.4 Mains filters

06/02 Seidel

- A.4.038.4/14

78 SERVOSTAR®640 / 670 Installation Manual

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V.5.5 Mains chokes

06/02 Extensions / Accessories

- A.4.030.4/12

SERVOSTAR®640 / 670 Installation Manual 79

Extensions / Accessories

06/02 Seidel

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80 SERVOSTAR®640 / 670 Installation Manual

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06/02 Appendix

VI Appendix

VI.1 Transport, storage, maintenance, disposal

Transport : — only by qualified personnel

— only 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

— 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.

— if the packaging is damaged, check the unit for visible damage.

— In this case, inform the shipper and the manufacturer.

Packaging: — Cardboard box with foam padding, can be recycled

— Dimensions: (HxWxD) 410x470x490 mm
— Gross weight, accessories included, approx. 25 Kg

Storage : — only in the manufacturer’s original recyclable packaging

— 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.

— max. stacking height for SERVOSTAR 640/670 : 3 cartons
— storage temperature –25 to +55°C(-13...131°F),

max. 20K/hr. rate of change

— humidity relative humidity max. 95%, no condensation
— storage duration < 1 year without restriction

> 1 year : capacitors must be re-formed before
setting up the servo amplifier.

To do this, remove all electrical connections and
supply the servo amplifier for about 30 min. From

230VAC, single-phase, on terminals L1 / L2.

Maintenance : — the instruments do not require any maintenance

— opening the instruments invalidates the warranty

Cleaning : — if the casing is dirty : cleaning with Isopropanol or similar

do not immerse or spray

— if there is dirt inside the unit : to be cleaned by the manufacturer
— dirty protective grill (fan) : clean with a dry brush

Disposal : — the servo amplifier can be reduced to its principal components by unscrewing

— it (aluminium heat sink and front panel steel housing sections, electronics
— boards)

— disposal should be carried out by a certified disposal company.

— We can give you suitable addresses.

SERVOSTAR®640 / 670 Installation Manual 81

Appendix

VI.2 Removing faults/warnings

06/02 Seidel

The table below should be regarded as a “First-aid” box. Depending on the conditions in your instal
lation, there may be a wide variety of reasons for the fault. In multi-axis systems there may be fur

-

ther hidden causes of a fault. Our customer service can give you further assistance with problems.

Fault possible causes

HMI message:
communication

fault

F01 message:
heat sink
temperature

F02 message:
overvoltage

F04 message:
feedback unit

F05 message:
undervoltage

F06 message:
motor temperature

F07 message:
aux. voltage
F08 message:
motor runs away
(overspeed)

F11 message:
brake

F13 message:
internal tempera

ture

F14 message:
output stage fault

F16 message:
mains BTB/RTO

F17 message:
A/D converter

— wrong cable used
— cable plugged into wrong position

in servo amplifier or PC

— wrong PC interface selected

— permissible heat sink temperature

exceeded

— regen power is insufficient. regen power

limit was reached and the regen resistor
was switched off. This causes excessive

voltage in the DC-link circuit.

— supply voltage too high

— feedback connector not properly inserted
— feedback cable is broken, crushed or

otherwise damaged

— supply voltage not present or too low

when servo amplifier is enabled

— motor thermostat has been activated

— feedback connector is loose or break in

feedback cable

— the aux. voltage produced by the servo

amplifier is incorrect

— motor phases swapped
— feedback set up incorrectly

— short-circuit in the supply cable for the

motor-holding brake
— motor-holding brake is faulty
— fault in brake cable

— no brake connected, although the

brake parameter is set to "WITH"

— permissible internal temperature exceeded — improve ventilation

-

— motor cable has short-circuit/ground short
— motor has short-circuit / ground short

— output module is overheated
— output stage is faulty

— short-circuit / short to ground in the

external regen resistor
— enable was applied, although the

supply voltage was not present.

— at least 2 supply phases are missing
— error in the analog-digital conversion,

usually caused by excessive EMI

Measures to remove the cause of
the fault

— use null-modem cable
— plug cable into the correct sockets

on the servo amplifier and PC

— select correct interface

— improve ventilation

— shorten the braking time RAMP or

use an external regen resistor
with a higher power rating and

adjust the regen power parameter

— use mains transformer

— check connector
— check cable

— only enable the servo amplifier

when the mains supply voltage
has been switched on

delay > 500 ms

— wait until motor has cooled down,

then check why it became so hot

— tighten connector or use

new feedback cable

— return the servo amplifier to the

manufacturer for repair

— correct motor phase sequence
— set up correct offset angle

— remove short-circuit

— replace motor
— check shielding of brake cable

— brake parameter set to "WITHOUT"

— replace cable
— replace motor

— improve ventilation
— return the servo amplifier to the

manufacturer for repair

— remove short-circuit / ground short

— only enable the servo amplifier

when the mains supply voltage

has been switched on
— check electrical supply
— reduce EMI,

check screening and grounding

-

82 SERVOSTAR®640 / 670 Installation Manual

Seidel

06/02 Appendix

Fault possible causes

F25 message:
Commutation error

F27 message:
error AS-option

— wrong cable
— wrong phasing

— -AS-24V relay AND hardware enable AND

software enable are active
— servo amplifier not enabled
— break in setpoint cable
— motor phases swapped

motor does not rotate

— brake not released
— drive is mechanically blocked
— no. of motor poles set incorrectly

— feedback set up incorrectly
— gain too high (speed controller)

motor oscillates

— shielding in feedback cable has a break
— AGND not wired up
—I

or I

rms

drive reports
following error

— setpoint ramp is too long

motor overheating —I

peak

set too high — reduce I

rms/Ipeak

— Kp (speed controller) too low
— Tn (speed controller) too high

drive too soft

— PID-T2 too high
— T-Tacho too high
— Kp (speed controller) too high

drive runs
roughly

— Tn (speed controller) too low

— PID-T2 too low
— T-Tacho too low
— offset not correctly adjusted for analog

axis drifts at
setpoint = 0V

setpoint provision
— AGND not joined to the CNC-GND of the

controls

n12 message:
Motor default values

loaded

n14 message:
Wake & shake active

— Motor number stored in sine encoders

EEPROM different than what drive is

configured for

— Wake & shake not executed — Enable the drive

is set to low

measures to remove the cause of
the fault

— check wiring
— check resolver poles (RESPOLES)

check motor poles (MPOLES)
check offset (MPHASE)

— check PLC programming and

wiring
— apply enable signal
— check setpoint cable
— correct motor phase sequence

— check brake control
— check mechanism
— set no. of motor poles

— set up feedback correctly
— reduce Kp (speed controller)
— replace feedback cable
— join AGND to CNC-GND
— increase I

rms

or I

peak

(keep within motor data !)
— shorten setpoint ramp +/-

rms/Ipeak

— increase Kp (speed controller)
— use motor default value for

Tn (speed controller)
— reduce PID-T2

— reduce T-Tacho
— reduce Kp (speed controller)
— use motor default value for

Tn (speed controller)
— increase PID-T2

— increase T-Tacho
— adjust setpoint-offset (analog I/O)

— join AGND and CNC-GND

— If n12 is displayed, default values

for the motor are loaded.

Motor number will be automatically

stored in EEPROM with SAVE.

SERVOSTAR®640 / 670 Installation Manual 83

Appendix

06/02 Seidel

VI.3 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

Continuous power of regen circuit Mean power which can be dissipated in the regen circuit

Counts Internal count pulses, 1 pulse = 1/2

Current controller Regulates the difference between the current setpoint

D DC-link Rectified and smoothed power voltage

Disable Removal of the enable signal (0V or open)

E Enable Enable signal for the servo amplifier (+24V)

F Final speed Maximum value for speed normalization at ±10V

Fieldbus interface CANopen, PROFIBUS, SERCOS

G GRAY-code Special method of representing binary numbers

H Holding brake Brake in the motor, which can only be used when the

I I²t threshold Monitoring of the actually required r.m.s. current

Input drift Temperature and age-dependent alteration of an analog

Incremental encoder interface Position signalling by 2 signals with 90° phase

Ipeak, peak current The effective value of the peak current

Irms, effective current The r.m.s. value of the continuous current

K Kp, P-gain Proportional gain of a control loop

L Limit-switch Switch limiting the traverse path of the machine;

M Machine The complete assembly of all connected parts or

Monitor output Output of an analog measurement

Motion-block Data packet with all the position control parameters

Multi-axis system Machine with several independently driven axes

N Natural convection Free movement of air for cooling

O Optocoupler Optical connection between two electrically

position control, which provide special versions of the
interface for the connection to the higher-level control

20

-1

turn

and the actual value to 0
Output : power output voltage

motor is at stillstand

input

difference, not an absolute position output

implemented as n.c. (break) contact

devices, of which at least one is movable

which are required for a motion task

independent systems

84 SERVOSTAR®640 / 670 Installation Manual

Seidel

06/02 Appendix

P P-controller Control loop with purely proportional behavior

Phase shift Compensation for the lag between the electromagnetic

and magnetic fields in the motor

PID-controller Control loop with proportional, integral and

differential behavior

PID-T2 Filter time constant for the speed controller output

Position controller Regulates the difference between the position setpoint

and the actual position to 0
Output : speed setpoint

Potential isolation Electrically decoupled

Power contactor System protection device with phase monitoring

Pulse power of the regen circuit Maximum power which can be dissipated in the

regen circuit

R Regen circuit Converts superfluous energy, which is fed back

during braking, into heat in the regen resistor

Reset New start of the microprocessor

Resolver-digital converter Conversion of the analog resolver signals into

Reversing mode Operation with a periodic change of direction

Ring core Ferrite rings for interference suppression

ROD-Interface Incremental position output

digital information

S Servo amplifier Control device for regulating the position of a

servomotor

Setpoint ramps Limits for the rate of change of the speed setpoint

Short to ground Electrically conductive connection between a

Short-circuit here: electrically conductive connection between

Speed controller Regulates the difference between the speed setpoint

SSI-interface Cyclic-absolute, serial position output

Supply filter Device to divert interference on the power supply

phase and PE (protective earth)

two phases

and the actual value to 0
Output : current setpoint

cables to PE

T T-tacho, tachometer time constant Filter time constant in the speed feedback

of the control loop

Tachometer voltage Voltage proportional to the actual speed

Thermostat Temperature-sensitive switch built into the

motor winding

Tn, I-integration time Integral section of a control loop

Z Zero pulse Output once per turn from incremental encoders,

used to zero the machine

SERVOSTAR®640 / 670 Installation Manual 85

Appendix

VI.4 Order numbers

In the table below you'll find the order numbers for the servo amplifiers, options and accessories.

Type European order number North America order code
SERVOSTAR 640 91419 S64001-NA
SERVOSTAR 670 91955 S67001-NA

Expansion card PROFIBUS DP 90056 OPT-PB
Expansion card SERCOS 90879 OPT-SE
Expansion card -I/0-14/08- 90057 OPT-EI
Expansion module -2CAN- 101174 Not available in North America

Mains filter 3EF-42 92102 LF-42
Mains filter 3EF-75 92103 LF-75
Mains filter 3EF-100 92104 LF-100
Mains filter 3EF-130 92105 LF-130

Mains choke 3L0.5-60 95289 LC-60
Mains choke 3L0.4-75 92100 LC-75
Mains choke 3L0.3-100 92098 LC-100

Mains choke 3L0.2-130 92099 LC-130

06/02 Seidel

RS232 cable 90067 A-97251-004
RS232 multilink cable -SR6Y- 90060 A-SR6Y
RS232 multilink cable -SR6Y6- 92042 Not available in North America

Power supply 24V/5A 83034 Not available in North America
Power supply 24V/20A 81279 Not available in North America

Regen resistor BAS 2000-15 103871 BAS-2000-15

Regen resistor BAS 3000-15 103872 BAS-3000-15
Regen resistor BAS 6000-15 103873 BAS-6000-15
Regen resistor BAS 2000-10 103874 BAS-2000-10
Regen resistor BAS 3000-10 103875 BAS-3000-10

Regen resistor BAS 6000-10 103876 BAS-6000-10

Product CD-ROM 90079 KOL-1270

86 SERVOSTAR®640 / 670 Installation Manual

Seidel

VI.5 Index

06/02 Appendix

! 24V supply

20A.....................76

5A.....................75

24Vaux. supply, interface ........... 40

A abbreviations ..................8

AGND ..................... 18

ambient temperature ..............17

assembly ....................28

Assignment ...................86

B Baudrate ....................59

Block diagram

overview .................. 39

brake ......................18

BTB/RTO ....................47

C CANopen-Interface............... 55

CE-conformance .................7

conductor cross-sections............ 17

connection diagram .............. 32

connection techniques .............35

D DC-link interface ................40

DGND .....................18

disposal ....................81

E EMC ......................27

Emergency Stop strategies ..........21

encoder

emulations .................48

interface ..................43

interface master-slave ...........50

error messages................. 62

external fusing ................. 16

F forming ..................... 57

G Glossary ....................84

ground symbol .................30

grounding

connection diagram ............32

installation .................31

H hardware requirements.............38

holding brake ..................18

humidity .................... 81

I inputs

analog setpoints .............. 44

DIGI-IN 1/2................. 46

enable ...................46

NSTOP...................46

PSTOP...................46

installation

hardware.................. 30

restart lock -AS- ..............24

software .................. 38

K key operation .................. 60

L LC-Display ...................60

Limit Switch Inputs ............... 46

M mains supply connection, interface ......40

mains supply networks .............14

maintenance ..................81

master-slave ..................50

monitor outputs.................45

motor

interface ..................41

motor holding brake ..............18

mounting position ...............17

multi-axis systems

connection example ............ 33

N nameplate ...................11

NSTOP..................... 46

O options .....................12

other operating systems ............38

outputs

BTB/RTO.................. 47

DIGI-OUT 1/2 ...............47

Monitor1/2 .................45

P Package supplied ...............11

Packaging ...................81

Parameter setting ...............59

PC cable ....................54

PC connection ................. 54

PGND ..................... 18

pin assignments ................34

pollution level..................17

protection....................17

PSTOP.....................46

pulse-direction, interface ............52

R resolver

interface ..................42

restart lock

block diagram ...............23

Installation/setup ..............24

signal diagram ...............23

restart lock -AS- ................22

ROD interface .................48

RS232/PC, interface ..............54

S safety instructions ................6

setpoint inputs .................44

Setup ......................57

SETUP.EXE ..................38

shielding

connection diagram ............32

installation .................31

site .......................31

site altitude ...................17

SSI, interface..................49

stacking height .................81

standards ....................7

storage ..................... 81

storage duration ................81

storage temperature .............. 81

supply voltage ................. 17

Switch-on and switch-off behaviour ......20

system components, overview .........15

T technical data .................16

torque, connectors ...............17

transport ....................81

U use as directed .................10

servo amplifier ...............10

setup software ...............37

V ventilation

Installation ................. 31

Tech.Data .................17

W Warning messages ...............63

wiring ......................31

X XGND .....................18

SERVOSTAR®640 / 670 Installation Manual 87

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please contact your local sales representative for assistance.

If you are unaware of your local sales representative, please contact us.

Europe

Visit the European Danaher Motion web site at www.DanaherMotion.de for Setup Software upgrades,
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upgrades, application notes, technical publications and the most recent version of our product manuals.

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