Kollmorgen MMC-SD-6.0-460, MMC-SD-1.3-460, MMC-SD-2.4-460, MMC-SD-4.0-460, MMC-SD-8.0-460 Hardware Manual

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MMC© Smart DriveTMand Digital MMC Control

IND. CONT. EQ.

12KP

Hardware Manual

Version 6.3

Catalog No. M.1301.5524 Part No. M.3000.1430

Keep all product manuals as a product component during the life span of the product. Pass all product manuals to future users/owners of the product.

Record of Revisions

Edition Valid for Description

03/2007 PiCPro V16.1 Major Update 10/2007 PiCPro V16.1 SP2 Added MMC-D8 05/2008 PiCPro V16.1 SP3 Added 4 analog drives, various manual updates 09/2008 PiCPro V17.0 Added S200-DLS Drives 12/2008 PiCPro V17.0 Rev 1 fixed various typos 01/2009 PiCPro V17.0 Rev 2 added CE/UL info to S200-DLS 03/2009 PiCPro V17.0 Rev 3 added Aux Feedback Connector to S200DLS 02/2010 PiCPro V18.0 Kollmorgen Branding & S200 BiSS 03/2011 PiCPro V18.0 SP1 Added 230V, 3-Phase Drives 01/05/12 PiCPro V18.0 SP2 Added 460V, 3-Phase NextGen Drives 08/15/12 PiCPro V18.0 SP3 Added SFD on 460V SDN Drives

Added Enhanced Feedback drives to the 230V and

460V Smart Drives 02-15-13 PiCPro V18.0 SP4 Added 230V SDN Drives 06-27-14 PiCPro V18.0 SP6 Added Size 5 & 6 460V Smart Drive

Third party brands and trademarks are the property of their respective owners

Technical changes to improve the performance of the equipment may be made without notice! Printed in USA All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm or any other method) or processed, copied or distributed by electronic means without the written permission of Kollmorgen.

Kollmorgen - June 2014 1

NOTE

These products are being manufactured and sold by G & L Motion Control, Inc., a Kollmorgen company.

Progress is an on-going commitment at Kollmorgen. We contin ually strive to offer the most advanced products in the industry; therefore, information in this document is subject to change without notice. The text and illustrations are not binding in detail. Kollmorgen shall not be liable for any technical or editorial omissions occurring in this document, nor for any consequential or incidental damages resulting from the use of this document.

Kollmorgen makes every attempt to ensure accuracy and reliability of the specifications in this publication. Specifications are subject to change without notice. Kollmorgen provides this information “AS IS” and disclaims all warranties, express or implied, including, but not limited to, implied warranties of merchantability and fitness for a particular purpose. It is the responsibility of the product user to determine the suitability of this product for a specific application.

DO NOT ATTEMPT to use any Kollmorgen product until the use of such product is completely understood. It is the responsibility of the user to make certain proper operation practices are understood. Kollmorgen products should be used only by qualified personnel and for the express purpose for which said products were designed.

Should information not covered in this document be required, contact the Customer Service Department, Kollmorgen, 672 South Military Road, P.O. Box 1960, Fond du Lac, WI 54936-1960. Kollmorgen can be reached by telephone at (920) 921-7100 or (8 00) 558-4 808 in the United States or by e-mail at glmotion.support@kollmorge n .co m .

2 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - TABLE OF CONTENTS

Table of Contents................................................................................................................................3

1 Introduction to the MMC Smart Drive.............................................................................................9

1.1 Overview...................................................................................................................................9

1.2 Contents of This Manual...........................................................................................................9

1.3 Software and Manuals..............................................................................................................9

1.3.1 Required Software and Manuals.....................................................................................9

1.3.2 Suggested Manuals ........................................................................................................9

1.4 Kollmorgen Support Contact ..................................................................................................11

2 Safety Precautions.........................................................................................................................13

2.1 System Safety ........................................................................................................................13

2.1.1 User Responsibility .......................................................................................................13

2.1.2 Safety Instructions.........................................................................................................13

2.2 Safety Signs ...........................................................................................................................14

2.3 Warning Labels.......................................................................................................................14

2.4 Safety First .............................................................................................................................15

2.5 Safety Inspection....................................................................................................................15

2.5.1 Before Starting System.................................................................................................15

2.6 After Shutdown.......................................................................................................................15

2.7 Operating Safely.....................................................................................................................16

2.8 Electrical Service & Maintenance Safety................................................................................16

2.9 Safe Cleaning Practices .........................................................................................................17

3 Installing the MMC Smart Drive ....................................................................................................19

3.1 Storing the Smart Drive Before Installation ...........................................................................19

3.2 Unpacking the Smart Drive.....................................................................................................19

3.3 Handling an MMC Smart Drive...............................................................................................19

3.4 Inspecting the Smart Drive Before Installation .......................................................................19

3.5 Complying with European Directives......................................................................................20

3.6 Conforming with UL and cUL Standards ................................................................................20

3.7 General Installation and Ventilation Requirements ................................................................20

3.8 Controlling Heat Within the System........................................................................................21

3.9 Bonding .................................................................................................................................22

3.9.1 Bonding a Subpanel Using a Stud................................................................................22

3.9.2 Bonding a Ground Bus Using a Stud............................................................................22

3.9.3 Bonding a Ground Bus or Chassis Using a Bolt ................. ... .... ... ................................23

3.9.4 Grounding Multiple Drive Cabinets ...............................................................................23

3.9.5 Bonding Multiple Subpanels..........................................................................................23

3.10 Drive Mounting Guidelines ...................................................................... ... ..........................23

3.11 Drive System Grounding Procedures...................................................................................24

3.11.2 Grounding Multiple Drives in the Same Cabinet.........................................................27

3.12 System Wiring Guidelines ....................................................................................................27

3.12.1 Recommended Signal Separation ..............................................................................28

3.12.2 Building Your Own Cables ..........................................................................................30

3.12.3 Routing Cables............................................................................................................30

3.13 Wiring the Drive....................................................................................................................30

3.13.1 Sizing the 24V Power Supply......................................................................................30

3.13.2 System AC Power Wiring Guidelines ............ ... ... .... ... ...................................... .... ... ...31

3.13.3 Connecting Interface Cables ......................................................................................32

3.13.4 Preparing Motor Connection Wires ............................................................................33

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MMC Smart Drive Hardware Manual - TABLE OF CONTENTS

4 System Power Devices ................................................................................................................. 37

4.1 AC Input Power Requirements............................................................................................... 37

4.2 Protection............................................................................................................................... 40

4.2.1 Motor Overload Protection............................................................................................ 40

4.2.2 Motor Thermal Protection............................................................................................. 40

4.2.3 24VDC Input Power Protection (460V SD Only) .......................................................... 41

4.2.4 S200-DLS Drive Protection Requirements................................................................... 41

4.2.5 230V Smart Drive (SD) Protection Requirements ........................................................ 43

4.2.6 460V Smart Drive (SD & SDN) Protection Requirements ............................................ 45

4.3 Line Reactors......................................................................................................................... 51

4.3.1 Specifications and Dimensions for Required Line Reactors......................................... 52

4.4 Isolation Transformers ........................................................................................................... 59

4.5 External Shunts...................................................................................................................... 60

4.5.1 Choosing External Shunts............................................................................................ 60

4.5.2 Mounting External Shunts ............................................................................................ 62

4.5.3 Connecting Shunt Modules .......................................................................................... 69

4.5.3.1 230V, 1-Phase MMC Smart Drive Shunt Wiring................................................. 69

4.5.3.2 460V, 3-Phase MMC Smart Drive (-SD) Shunt Wiring..................... .... ... ... ... ... ... 71

4.6 Line Filters.............................................................................................................................. 72

4.6.1 Line Filters and CE Compliance................................................................................... 72

4.6.2 Dimensions for 230V Line Filters.................................................................................. 77

4.6.3 Dimensions for 460V Line Filters.................................................................................. 78

5 230V 3 Phase MMC Smart Drive NextGen................................................................................... 79

5.1 Control Section Connectors, Switches, LEDs........................................................................ 82

5.1.1 Status Display............................................................................................................... 82

5.1.2 Node Address Rotary Switches.................................................................................... 82

5.1.3 Digital Link Ports........................................................................................................... 83

5.1.4 Feedback Connectors (F1 & F2) .................................................................................. 85

5.1.4.1 Feedback Connectors (F1 and F2) Details ......................................................... 90

5.1.4.2 Feedback Port (F1/F2) to Motor Cables.............................................................. 95

5.1.5 Drive I/O Connectors (IO1 & IO2)............................................................................... 100

5.2 Power Section Connectors...................................................................................................104

5.2.1 DC Power Connector.................................................................................................. 104

5.2.1.1 "EN" requirements and Safe-off Operation ....................................................... 104

5.2.2 AC Power Connector.................................................................................................. 105

5.2.2.1 Line Fusing........................................................................................................ 105

5.2.3 Motor/Brake Connector .............................................................................................. 106

5.2.3.1 Motor/Brake Cables .......................................................................................... 108

5.2.3.2 Motor Chokes.................................................................................................... 108

5.2.4 DC Bus/Regen Connector.......................................................................................... 109

5.2.4.1 Bus/Regen Connections ................................................................................... 109

5.2.4.2 External Regen Resistors ................................................................................. 110

5.3 Specifications - 230V MMC Smart Drive NextGen............................................................... 111

5.3.1 General Data .............................................................................................................. 111

5.3.2 Physical and Electrical Data....................................................................................... 116

5.4 Dimensions .......................................................................................................................... 117

6 460V 3 Phase MMC Smart Drive NextGen................................................................................. 121

6.1 Control Section Connectors, Switches, LEDs...................................................................... 124

6.1.1 Status Display............................................................................................................. 124

6.1.2 Node Address Rotary Switches.................................................................................. 124

6.1.3 Digital Link Ports......................................................................................................... 125

6.1.4 Feedback Connectors (F1 & F2) ................................................................................ 127

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MMC Smart Drive Hardware Manual - TABLE OF CONTENTS

6.1.4.1 Feedback Connectors (F1 and F2) Details........................................................132

6.1.4.2 Feedback Port (F1/F2) to Motor Cables............................................................137

6.1.5 Drive I/O Connectors (IO1 & IO2) ...............................................................................142

6.2 Power Section Connectors...................................................................................................146

6.2.1 DC Power Connector..................................................................................................146

6.2.1.1 "EN" requirements and Safe-off Operation........................................................146

6.2.2 AC Power Connector ..................................................................................................147

6.2.2.1 Line Fusing........................................................................................................147

6.2.3 Motor/Brake Connector...............................................................................................148

6.2.3.1 Motor/Brake Cables...........................................................................................150

6.2.3.2 Motor Chokes ....................................................................................................150

6.2.4 DC Bus/Regen Connector...........................................................................................151

6.2.4.1 Bus/Regen Connections....................................................................................151

6.2.4.2 External Regen Resistors..................................................................................151

6.3 Specifications - 460V MMC Smart Drive NextGen...............................................................153

6.3.1 General Data...............................................................................................................153

6.3.2 Physical and Electrical Data........................................................................................158

6.4 Dimensions...........................................................................................................................159

7 230V 1/3 Phase MMC Smart Drive ..............................................................................................163

7.1 Control Section Connectors, Switches, LEDs ......................................................................166

7.1.1 LEDs ...........................................................................................................................166

7.1.2 PiCPro Port (Digital Interfaced Drives)........................................................................166

7.1.3 PiCPro Port (Analog Drives) .......................................................................................168

7.1.4 Node Address Rotary Switch (Digital Interfaced MMC-SD Only)................................171

7.1.5 Digital Link Ports (Digital Interfaced MMC-SD Only) .. ... ... ... ... .... ... ..............................172

7.1.6 Feedback Connectors (F1 & F2).................................................................................174

7.1.6.1 Feedback Connectors (F1 and F2) Details........................................................179

7.1.6.2 Feedback Port (F1/F2) to Motor Cables............................................................184

7.1.7 Drive I/O Connector (IO).............................................................................................196

7.2 Power Section Connectors...................................................................................................203

7.2.1 24 VDC IN/Brake Connector.......................................................................................204

7.2.1.1 "EN" requirements and Safe-off Operation........................................................205

7.2.2 Power Connector ........................................................................................................206

7.2.3 DC Bus/Regen Connector (3-phase drive only)..........................................................209

7.3 Specifications - 230V MMC Smart Drive ..............................................................................210

7.3.1 General Data for all 230V Models ......... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... ... .210

7.3.2 Physical and Electrical Data for 230V Drives..............................................................213

7.4 Dimensions for 230V MMC Smart Drive...............................................................................215

8 460V 3-Phase MMC Smart Drive.................................................................................................221

8.1 Control Section Connectors, Switches, LEDs ......................................................................221

8.2 Power Section Connectors...................................................................................................222

8.2.1 Size 1 Power Section Connectors...............................................................................222

8.2.1.1 Shunt/DC Bus Connector .................................................................................224

8.2.1.2 AC Power Connector ........................................................................................225

8.2.1.3 Motor Connector................................................................................................225

8.2.1.4 24V Power Connector (J1) ................................................................................226

8.2.1.5 Motor Brake Connector (X101) .........................................................................227

8.2.2 Size 2 Power Section Connectors...............................................................................227

8.2.2.1 AC Power Connector.........................................................................................229

8.2.2.2 Motor Connector................................................................................................230

8.2.2.3 24V Power Connector (J1) ................................................................................231

8.2.3 Size 3 Power Section Connectors...............................................................................232

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MMC Smart Drive Hardware Manual - TABLE OF CONTENTS

8.2.3.1 AC Power Connector ........................................................................................ 234

8.2.3.2 Motor Connector ............................................................................................... 235

8.2.3.3 24V Power Connector (J1)................................................................................ 236

8.2.3.4 Motor Brake Connector (X101)......................................................................... 237

8.2.4 Size 4 Power Section Connectors.............................................................................. 237

8.2.4.1 AC Power Connector ....................................................................................... 239

8.2.4.2 Motor Connector ............................................................................................... 240

8.2.4.3 24V Power Connector (J1)................................................................................ 241

8.2.4.4 Motor Brake Connector (X101)......................................................................... 242

8.2.4.5 Fan Connector (X36)......................................................................................... 243

8.2.5 Size 5 Power Section Connectors.............................................................................. 243

8.2.5.1 AC Power Connector ....................................................................................... 245

8.2.5.2 24V Power Connector (J1)................................................................................ 247

8.2.5.3 Motor Brake Connector (X101)......................................................................... 248

8.2.5.4 Fan Connector (X36)......................................................................................... 249

8.3 Typical 460V Drive Connection Layout................................................................................ 250

8.4 Specifications - 460V MMC Smart Drive)............................................................................. 251

8.4.1 Common Data for Size 1, 2, 3, 4, 5, 6 (All Models) .................................................... 251

8.4.2 Physical/Electrical Data for 460V Size 1 Smart Drives............................................... 254

8.4.3 Physical/Electrical Data for 460V Size 2 Smart Drives............................................... 256

8.4.4 Physical/Electrical Data for 460V Size 3 Smart Drives............................................... 259

8.4.5 Physical/Electrical Data for 460V Size 4 Smart Drives............................................... 262

8.4.6 Physical/Electrical Data for 460V Size 5 Smart Drives............................................... 265

8.4.7 Physical/Electrical Data for 460V Size 6 Smart Drives............................................... 268

8.5 Dimensions for the 460V Smart Drives ............................................................................... 271

9 S200-DLS Drive............................................................................................................................ 283

9.1 S200-DLS Option Card........................................................................................................ 285

9.1.1 LED Indicators............................................................................................................ 285

9.1.2 Diagnostic Indicator Details........................................................................................ 285

9.1.3 Digital Link LEDs ........................................................................................................285

9.1.4 Node Address Rotary Switches.................................................................................. 286

9.1.5 Digital Link Ports......................................................................................................... 287

9.1.6 Auxiliary Feedback Port.............................................................................................. 289

9.1.7 Drive I/O and I/O Power Ports.................................................................................... 297

9.1.8 Drive I/O Port Details.................................................................................................. 299

9.1.8.1 Drive I/O Port Outputs....................................................................................... 300

9.1.8.2 Drive I/O Port Inputs.......................................................................................... 300

9.1.8.3 Drive I/O Port Wiring Example.......................................................................... 300

9.2 Power Section Wiring Accessories ...................................................................................... 301

9.3 Specifications - S200-DLS Drive.......................................................................................... 303

10 Motor Cables & Connectors............. .... ... ... ... ... .... ... ... ... .... ... ... ... .... ... ... ... ... .... .......................... 305

10.1 Flex Cable Installation Guidelines..... ................................................................................. 305

10.1.1 Bending Radius ........................................................................................................ 305

10.1.2 Cable Tension .......................................................................................................... 306

10.2 Flex Cable Installation... .... ... ... ... .... ... ... ... ... .... ... ... ... .... .......................................... ... .......... 306

10.3 AKM/DDR Motor Power Cables......................................................................................... 308

10.4 LSM/MSM Motor Connector Kits ....................................................................................... 309

10.5 LSM/MSM Motor Power Cables......................................................................................... 310

10.6 LSM/MSM Motor Fan Cables............................................................................................. 313

11 Maintenance and Troubleshooting.......................................................................................... 315

11.1 Maintenance .................................. ... ... ... ....................................... ... ... .... ... ....................... 315

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MMC Smart Drive Hardware Manual - TABLE OF CONTENTS

11.2 Troubleshooting..................................................................................................................316

11.2.1 General Troubleshooting...........................................................................................316

11.2.2 Power LED................................................................................................................316

11.2.3 Power-On Diagnostics ............................ ....................................... ... .... ... ... ... ... .... ....316

11.2.4 Run-Time Diagnostics...............................................................................................316

11.2.4.1 Troubleshooting with the Diagnostic LED (D1) .. ... ... ... .... ... ... ... .... ... ... ... ... .... ... .317

11.2.4.2 Troubleshooting with the 7-Segment Display..................................................317

11.2.4.3 Troubleshooting using the Status LED (STATUS)...........................................325

12 Resolver Interface Option Module............................................................................................329

12.1 Theory of Operation............................................................................................................329

12.2 Installing the Resolver Module ...........................................................................................329

13 Drive Resident Digital MMC Control................................. ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... ... .333

13.1 Introduction.........................................................................................................................333

13.1.1 Overview...................................................................................................................333

13.1.2 Major Components....................................................................................................333

13.2 Installing the Drive Resident Digital MMC Control......... .... ... ... ... ... .... ... ..............................335

13.2.1 Installing into a 230V MMC-SD Drive........................................................................335

13.2.2 Installing into a 460V MMC-SD Drive........................................................................335

13.3 System Wiring Guidelines ..................................................................................................336

13.4 Starting an Operation .........................................................................................................337

13.4.1 Connecting the Drive Resident Digital MMC Control to the Application....................337

13.4.2 Basic Setup and Maintenance Procedures...............................................................337

13.4.3 Start-up Diagnostics..................................................................................................338

13.4.3.1 Power LED ......................................................................................................338

13.4.3.2 Scan LED ........................................................................................................338

13.4.3.3 Drive Resident Digital MMC Control Start-Up Diagnostic LEDs......................339

13.4.4 MMC Run-Time Diagnostics.....................................................................................340

13.5 Connectors & Operation................................... .... ... ... ... ....................................... ... ... .... ....341

13.5.1 PiCPro Port (P1) .......................................................................................................341

13.5.2 Block I/O Port (C1)............................................ ... ....................................... ... ... .... ... .341

13.5.3 User Port. ... ... .... ... ... ... .... ... ... ... ....................................... ... ... .... ... ... ... .... ....................345

13.5.4 Ethernet Port. .... ... ... ... .... ... ... ... ... .... ...................................... .... ... ... ... .... ... ... ..............351

13.5.5 General I/O Port (C5)................................................................................................353

13.5.5.1 DC Output Operation.......................................................................................358

13.5.5.2 DC Input Operation..........................................................................................360

13.6 Specifications ....................................................................................................................362

14 Declarations of Conformity............................................... ... .......................................... ... ........365

A 460V MMC Smart Drive DC Bus Sharing...................................................................................371

A.1 Introduction ..........................................................................................................................371

A.2 DC Bus Sharing with AC Power to All Drives.......................................................................371

A.3 DC Bus Sharing with AC Power to One Drive......................................................................373

Index.................................................................................................................................................377

Sales and Service............................................................................................................................383

Kollmorgen - June 2014 7

MMC Smart Drive Hardware Manual - TABLE OF CONTENTS

8 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - INTRODUCTION TO THE MMC SMART DRIVE

1 Introduction to the MMC Smart Drive

1.1 Overview

This manual covers four distinct products:

• The Analog and Digital Interfaced 230V MMC Smart Drive (MMC-SD). The 230V

Smart Drive is detailed exclusively in Chapter 7 on page 163

• The Digital 460V Smart Drive NextGen. The 460V Smart Drive NextGen is

detailed exclusively in Chapter 6 on page 121

• The Analog and Digital Interfaced 460V MMC Smart Drive (MMC-SD). The 460V

Smart Drive is detailed exclusively in Chapter 8 on page 221

• The S200-DLS Digital Link Drive which receives motion commands via a digital

connection (Digital Link)

1.2 Contents of This Manual

This manual includes the following major topics:

• Information to safely operate and maintain the equipment in a safe manner.

• User responsibilities for product acceptance and storage.

• Power and environmental information for general power, control cabinet, ground-

ing, heat control and handling.

• Procedures for mounting, wiring, and connecting the MMC Smart Drive and stan-

dard Kollmorgen motors recommended for use with the MMC Smart Drive.

• Recommended drive system wiring guidelines for signal separation and differen-

tial devices. Methods to ensure ElectroMagnetic Compatibility.

• The location of connectors on the drive and descriptions of their functionality

including I/O, encoder, serial interface and motor/brake connector locations and signal descriptions.

• Physical, electrical, environmental and functional specifications/dimensions.

• Description of the minimal maintenance necessary.

• A troubleshooting chart of potential problems and possible solutions.

• Part numbers and descriptions for the drive and related equipment.

1.3 Software and Manuals

1.3.1 Required Software and Manuals

PiCPro (one of the following)

• Professional Edition

• MMC Limited Edition

• Monitor Edition

1.3.2 Suggested Manuals

• Function/Function Block Reference Guide

• Motion Application Specific Function Block Manual

Kollmorgen - June 2014 9

MMC Smart Drive Hardware Manual - INTRODUCTION TO THE MMC SMART DRIVE

• Ethernet Application Specific Function Block Manual

• General Purpose Application Specific Function Block

Manual

10 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - INTRODUCTION TO THE MMC SMART DRIVE

1.4 Kollmorgen Support Contact

Contact your local Kollmorgen representative for:

• Sales and order support

• Product technical training

• Warranty support

• Support service agreements

Kollmorgen Technical Support can be reached:

• In the United States, telephone (800) 558-4808

• Outside the United States, telephone (920) 921-7100

• E-mail address: glmotion.support@kollmorgen.com

• Web site: www.kollmorgen.com

Kollmorgen - June 2014 11

MMC Smart Drive Hardware Manual - INTRODUCTION TO THE MMC SMART DRIVE

12 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - SAFETY PRECAUTIONS

2 Safety Precautions

READ AND UNDERSTAND THIS SECTION IN ITS ENTIRETY BEFORE UNDERTAKING INSTALLATION OR ADJUSTMENT OF THE MMC SMART DRIVE AND ANY ASSOCIATED SYSTEMS OR EQUIPMENT

The instructions contained in this section will help users to operate and maintain the equipment in a safe manner.

PLEASE REMEMBER THAT SAFETY IS EVERYONE'S RESPONSIBILITY

2.1 System Safety

The basic rules of safety set forth in this section are intended as a guide for the safe operation of equipment. This general safety information, along with explicit service, maintenance and operational materials, make up the complete instruction set. All personnel who operate, service or are involved with this equipment in any way should become totally familiar with this information prior to operating.

2.1.1 User Responsibility

It is the responsibility of the user to ensure that the procedures set forth here are followed and, should any major deviation or change in use from the original specifications be required, appropriate procedures should be established for the continued safe operation of the system. It is strongly recommended that you contact your OEM to ensure that the system can be safely converted for its new use and continue to operate in a safe manner.

2.1.2 Safety Instructions

• Do not operate your equipment with safety devices bypassed or covers removed.

• Only qualified personnel should operate the equipment.

• Never perform service or maintenance while automatic control sequences are in

operation.

• To avoid shock or serious injury, only qualified personnel should perform mainte-

nance on the system.

Kollmorgen - June 2014 13

MMC Smart Drive Hardware Manual - SAFETY PRECAUTIONS

Danger Electric Shock Risk

ATTENTION

Do not touch the main power supply fuses or any components internal to the power modules while the main power supply switch is ON. Note that when the main power switch is OFF, the incoming supply cable may be live.

• GROUNDING (Protective Earth)

The equipment must be grounded (connected to the protective earth connection) according to OEM recommendations and to the latest local regulations for electrical safety. The grounding (protective earth) conductor must not be interrupted inside or outside the equipment enclosures. The wire used for equipment grounding (connection to protective earth) should be green with a yellow stripe.

2.2 Safety Signs

The purpose of a system of safety signs is to draw attention to objects and situations which could affect personal or plant safety. It should be noted that the use of safety signs does not replace the need for appropriate accident prevention measures. Always read and follow the instructions based upon the level of hazard or potential danger.

2.3 Warning Labels

Hazard warning

When you see this safety sign on a system, it gives a warning of a hazard or possibility of a hazard existing. The type of warning is given by the pictorial representation on the sign plus text if used.

To ignore such a caution could lead to severe injury or death arising from an unsafe practice.

14 Kollmorgen - June 2014

Danger, Warning, or Caution warning

Symbol plus DANGER, WARNING or CAUTION: These notices provide information intended to prevent potential sonal injury and equipment damage.

Symbol plus HOT SURFACE: These notices provide information intended to prevent potential pe sonal injury.

Hot Surface warning

2.4 Safety First

MMC Smart Drive Hardware Manual - SAFETY PRECAUTIONS

Kollmorgen equipment is designed and manufactured with consideration and care to generally accepted safety standards. However, the proper and safe performance of the equipment depends upon the use of sound and prudent operating, maintenance and servicing procedures by trained personnel under adequate supervision.

For your protection, and the protection of other s, lear n and al ways follow these safety rules. Observe warnings on machines and act accordingly. Form safe working habits by reading the rules and abiding by them. Keep these safety rules handy and review them from time to time to refresh your understanding of them.

2.5 Safety Inspection

2.5.1 Before Starting System

• Ensure that all guards and safety devices are installe d and operative and all doors

which carry warning labels are closed and locked.

• Ensure that all personnel are clear of those areas indicated as potentially hazard-

ous.

• Remove (from the operating zone) any materials, tools or other object s that could

cause injury to personnel or damage the system.

• Make sure that the control system is in an operational condition.

• Make certain that all indicating lights, horns, pressure gauges or other safety

devices or indicators are in working order.

2.6 After Shutdown

Make certain all controlled equipment in the pl ant is safe and the associated electrical, pneumatic or hydraulic power is turned off. It is permissible for the control equipment contained in enclosures to remain energized provided this does not conflict with the safety instructions found in this section.

Kollmorgen - June 2014 15

MMC Smart Drive Hardware Manual - SAFETY PRECAUTIONS

2.7 Operating Safely

• Do not operate the control system until you read and understand the operating

instructions and become thoroughly familiar with the system and the controls.

• Never operate the control system while a safety device or guard is removed or

disconnected

• Where access to the control system is permitted for manual operation, only those

doors which provide that access should be unlocked. They should be locked immediately after the particular operation is completed.

• Never remove warnings that are displayed on the equipment. Torn or worn labels

should be replaced.

• Do not start the control system until all personnel in the area have been warned.

• Never sit or stand on anything that might cause you to fall onto the control equip-

ment or its peripheral equipment.

• Horseplay around the control system and its associated equipment is dangerous

and should be prohibited.

ATTENTION

Know the emergency stop procedures for the system.

• Never operate the equipment outside specification limits.

• Keep alert and observe indicator lights, system messages and warnings that are

displayed on the system.

• Do not operate faulty or damaged equipment. Make certain proper service and

maintenance procedures have been performed.

2.8 Electrical Service & Maintenance Safety

• ALL ELECTRICAL OR ELECTRONIC MAINTENANCE AND SERVICE

SHOULD BE PERFORMED BY TRAINED AND AUTHORIZED PERSONNEL ONLY.

• It should be assumed at all times that the POWER is ON and all conditions treated

as live. This practice assures a cautious approach which may prevent accident or injury.

• To remove power:

LOCK THE SUPPLY CIRCUIT DISCONNECTING MEANS IN THE OPEN POSITION. APPLY LOCKOUT/TAGOUT DEVICES IN ACCORDANCE WITH A DOCUMENTED AND ESTABLISHED POLICY.

16 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - SAFETY PRECAUTIONS

• Make sure the circuit is safe by using the proper test equipment. Check test equip-

ment regularly.

ATTENTION

Care should be taken if you are manually discharging the bus capacitors.

WARNING

Even after power to the drive is removed, it may take up to 10 minutes for bus capacitors to discharge to a level below 50 VDC. To be sure the capacitors are discharged, measure the voltage across the + and - terminals for the DC bus.

• There may be circumstances where troubleshooting on live eq uipment is required.

Under such conditions, special precautions must be taken:

• Make sure your tools and body ar e clear of the areas of equipment which may

be live.

• Extra safety measures should be taken in damp areas.

• Be alert and avoid any outside distractions.

• Make certain another qualified person is in attendance.

• Before applying power to any equipment, make cert ain that all personnel ar e clear

of associated equipment.

• Control panel doors should be unlocked only when checking out electrical equip-

ment or wiring. On completion, close and lock panel doors.

• All covers on junction panels should be fastened closed before leaving any job.

• Never operate any controls while others are performing maintenance on the sys-

tem.

• Do not bypass a safety device.

• Always use the proper tool for the job.

• Replace the main supply fuses only when electrical power is OFF (locked out).

2.9 Safe Cleaning Practices

• Do not use toxic or flammable solvents to clean control system hardware.

• Turn off electrical power (lock out) before cleaning control system assemblies.

• Keep electrical panel covers closed and power off when cleaning an en closure.

Kollmorgen - June 2014 17

MMC Smart Drive Hardware Manual - SAFETY PRECAUTIONS

• Always clean up spills around the equipment immediately after they occur.

• Never attempt to clean a control system while it is operating.

• Never use water to clean control equipment unless you are certain that the equip-

ment has been certified as sealed against water ingress. Water is a very good conductor of electricity and the single largest cause of death by electrocution.

18 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

3 Installing the MMC Smart Drive

NOTE

The National Electrical Code and any other governing regional or local codes overrule the information in this manual. Kollmorgen does n ot assume responsibility for the user’s compliance or non-compliance with any code, national, local or otherwise, for the proper installation of this drive and associated systems or equipment. Failure to abide by applicable codes creates the hazard of personal injury and/or equipment damage.

3.1 Storing the Smart Drive Before Installation

The drive should remain in the shipping contain er prior to inst allation. If the equipment is not to be used for a period of time, store it as follows:

• Use a clean, dry location

• Maintain the storage temperature and humidity as shown in the specifications

section of this manual.

• Store it where it cannot be exposed to a corrosive atmosphere

• Store it in a non-construction area

3.2 Unpacking the Smart Drive

Remove all packing material, wedges, and braces from within and around the components. After unpacking, check the name plate Material Number against the purchase order of the item(s) against the packing list. The model number, serial number and manufacturing date code are located on the side of the unit.

3.3 Handling an MMC Smart Drive

The case protects the MMC Smart Drive’s internal circuitry against mechanical damage in shipping and handling.

However, like any electronic device, the circuitry can be destroyed by:

• Conditions exceeding those detailed in the specifications tables shown in the

Specifications sections in this manual.

• moisture condensing inside the module

• static discharge

• exposure to a magnetic field strong enough to induce a current in the circuitry

• vibration, and other hazards

3.4 Inspecting the Smart Drive Before Installation

Inspect the unit for any physical damage that may have been sustained during shipment.

If you find damage, either concealed or visible, contact your buyer to make a claim with the shipper. If degraded performance is detected when testing the unit, contact your distributor or Kollmorgen. Do this as soon as possible after receipt of the unit.

Kollmorgen - June 2014 19

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

3.5 Complying with European Directives

For industrial products installed within the European Union or EEC region s, ce rtain directives and standards apply. See “Conformity” in the Specifications sections of Chapters 5 and 6 for applicable directives.

Servo amplifiers are considered to be subsystems when incorporated into electrical plants and machines for industrial use. The Kollmorgen servo amplifiers have been designed and tested as such. They bear the CE mark and are provided with a Declaration of Conformance. However, it is the overall machine or system design that must meet European Directives and standards. To help the manufacturer of the machine or plant meet these directives and standards, specific guidelines are provided in this documentation. These include such things as shielding, grounding, filters, treatment of connectors and cable layout.

3.6 Conforming with UL and cUL Standards

Kollmorgen drives meet safety and fire hazard requirements as outlined in “Conformity” in the Specifications sections of Chapter 14, Declarations of Conformity.

3.7 General Installation and Ventilation Requirements

• The drive must be enclosed in a grounded NEMA12 e nclosure offering protection

to IP55 such that they are not accessible to an operator or unskilled person, in order to comply with UL

these requirements providing protec tio n to IP6 6.



and CE requirements. A NEMA 4X enclosure exceeds

• The environmental conditions must not exceed those det ailed in the specifications

tables shown in the Specifications sections in this manual.

• Install the panel on a properly bonded, flat, rigid, non-painted galvanized steel,

vertical surface that won’t be subjected to shock, vibration, moisture, oil mist, dust, or corrosive vapors.

• Maintain minimum clearances for proper airflow, easy module access, and proper

cable bend radius.

• Plan the installation of your system so that you can perform all cutting, drilling,

tapping, and welding with the drive removed from the enclosure. Because the drive is of the open type construction, be careful to keep any metal debris from falling into it. Metal debris or other foreign matter can become lodged in the circuitry, which can result in damage to components.

The MMC Smart Drive is suitable for operation in a pollution degree 2 environment (i.e., normally, only non-conductive pollution occurs). Install the drive away from all sources of strong electromagnetic noise. Such noise can interfere with MMC Smart Drive operation.

Protect the MMC Smart Drive system from all the following:

• conductive fluids and particles

• corrosive atmosphere

• explosive atmosphere

Diagrams included with this manual and recommendations may be modified if necessary so the wiring conforms to current NEC standards or government regulations.

20 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

Table 3-1: Cabinet Clearance Dimensions

Minimum Clearance

230VSD

Location

Above Drive Body

Below Drive Body

Each Side of Drive

In Front of Drive (for cabling)

a. For S200 Drive Clearance Dimensions, refer to the S200 Drive Manual found at

www.kollmorgen.com

Use filtered or conditioned air in ventilated cabinets. The ai r should be free of contaminants, including but not limited to oil, corrosives, and electrically conductive material.

Drive

2.0 in. (50.8 mm)

.50 in. (12.7 mm)

3.0 in. (76.2 mm)

460V SD Drive

4.0 in. (100 mm)

None

3.0 in. (76.2 mm)

NOTE

230V SDN Drive

2.25 in. (57 mm)

.50 in. (12.7 mm)

3.0 in. (76.2 mm)

460V SDN Drive

2.25 in. (57 mm)

0.25 in. (6.35 mm)

3.0 in. (76.2 mm)

3.8 Controlling Heat Within the System

The MMC Smart Drive hardware case is designed to promote air circulation and dissipate heat. Normally no fans or air conditioners are needed. However, if the environment outside the control cabinet is hot or humid, you may need to use a fan, heat exchanger, dehumidifier or air conditioner to provide the correct operating environment.

Make sure that the temperature and humidity within the drive cabinet does n ot exceed that which is shown in the specifications sections of this manual.

Make sure that components installed in th e cabinet with the MMC Smart Drive do not raise the temperature above system limits and that any hot spots do not exceed specifications. For example, when heat-generating compon ents such as transformers, other drives or motor controls are installed, separate them from the drive by doing one of the following:

• Place them near the top of the control cabi net so their heat outp ut rises away from

the MMC Smart Drive.

• Put them in another control cabinet above or to one side of the cabinet with the

MMC Smart Drive. This protects the MMC Smart Drive from both heat and electrical noise.

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MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

The MMC Smart Drive itself is a source of heat, though in most installations its heat dissipates without harmful effects. System heat is generate d from power dissipated by:

• the drive

• field side input/output components

• other drives in the cabinet

• the logic power supply

• external shunt resistors

• line reactors

CAUTION

If the MMC Smart Drive is operated outside the recommended environmental limits, it may be damaged. This will void the warranty.

3.9 Bonding

Connecting metal chassis, assemblies, frames, shields and enclosures to reduce the effects of electromagnetic interference (EMI) is the process of bonding.

Most paints act as insulators. To achieve a good bond between system components, surfaces need to be paint-free or metal plated. Bonding metal surfaces creates a lowimpedance exit path for high-frequency energy. Improper bonding blocks this direct exit path and allows high-frequency energy to travel elsewhere in the cabinet. Excessive high-frequency energy can negatively affect the operation of the drive.

3.9.1 Bonding a Subpanel Using a Stud

1. Weld threaded mounting studs to the back of the enclosure.

2. Brush off any non-conductive materials (e.g. paint) from the studs.

3. Remove any non-conductive materials from the front of the subpanel.

4. Position the mounting holes on the subp anel over the mountin g studs on the back of the enclosure and slide the subpanel onto the studs.

5. Attach the subpanel to the mounting stud by sliding a star washer over the stud and then turn and tighten a nut onto the stud.

3.9.2 Bonding a Ground Bus Using a Stud

1. Weld threaded mounting studs to the back of the subpanel.

2. Brush off any non-conductive materials (e.g. paint) from the studs.

3. Slide a flat washer over the studs.

4. Remove any non-conductive materials from around the mounting hole on the chassis mounting bracket or ground bus.

5. Position the mounting hole of the chassis or ground bus over th e studs on the back of the subpanel and slide the mounting bracket or ground bus onto the stud.

6. Attach the subpanel to the subpanel stud by sliding a star washer and then a flat washer over the stud. Turn and tighten a nut onto the stud.

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MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

3.9.3 Bonding a Ground Bus or Chassis Using a Bolt

1. Brush off any non-conductive materials (e.g. paint) from the threaded bolt (s).

2. Slide a star washer over the threaded bolt (s).

3. Use a subpanel having tapped mounting holes. Remove any non-conductive

materials from around the mounting holes on both sides of the subpanel.

4. Turn the threaded bolts into the subpanel mounting holes.

5. Slide a star washer onto the threaded end of the bolt.

6. Turn and tighten a nut onto the stud.

7. Slide a flat washer onto the threaded end of the bolt.

8. Position the mounting holes on the groundbus or mounting bracket over the

threaded bolts and turn the bolts until they come through the grounding bus or mounting bracket.

9. Slide a star washer onto the threaded end of the bolt.

10. Slide a flat washer onto the threaded end of the bolt.

11. Turn and tighten a nut onto the bolt.

3.9.4 Grounding Multiple Drive Cabinets

1. Mount one bonded ground bus in each cabinet.

2. Designate the cabinet ground bus in one and only one of the ca binet s as the com-

mon ground bus for all of the cabinets in the system.

3. Connect the ground wires from the ground bus in each individual cabinet ground

bus to the designated common ground bus (moun ted in only o ne of the cabinets).

4. Connect the common cabinet ground bus to an external ground system that is

connected to a single point ground.

3.9.5 Bonding Multiple Subpanels

Kollmorgen recommends bonding both the top and bottom of subpanels sharing the same enclosure. Use a 25.4 mm (1.0 in.) x 6.35 mm (0.25) wire braid. Be sure the area around each wire braid fastener is clear of any non-conductive materials. Bond the cabinet ground bus to at least one of the subpanels.

NOTE

Subpanels that are not bonded together may not share a common low impedance path. This difference in impedance may affect networks and other devices that span multiple panels.

3.10 Drive Mounting Guidelines

• A control cabinet for the MMC Smart Drive should have a NEMA-12 rating or bet-

ter. A cabinet with this rating protects its contents from dust and mechanical damage.

• The cabinet must be large enough to provide adequate air circulation for the MMC

Smart Drive and other components. Always allow for adequate air flow through the MMC Smart Drive vents.

Kollmorgen - June 2014 23

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

• The cabinet must have a rigid non-painted galvanized metal su rface to mo unt th e

MMC Smart Drive on.

• The cabinet door should open fully for easy access.

IMPORTANT

Post warnings according to National, State, or local codes for the voltage present in the control cabinet. Diagrams included with this manual and re commendations may be modif ied if nece ssar y so t he w iring confo rms to c urrent NEC standards or government regulations.

NOTE

This drive contains parts and assemblies that are sensitive to ESD (Electrostatic Discharge). Follow static control precautions during installation, testing, service, or repair of this assembly. Parts and assemblies can be damaged if proper precautions ar e no t tak en .

1. Lay out the positions for the drive and accessories in th e en clo su re .

2. Attach the drive to the cabinet, first using the upper mounting slots of the drive and then the lower. The recommended mounting hardware is M5 metric(#10-32).

3. Tighten all mounting fasteners.

3.1 1 Drive System Grounding Procedures

The ground of the MMC Smart Drive power source must be connected directly to a Single Point Ground (SPG) tie block. The tie block should be made of brass or copper, bolted or brazed to the control cabinet. If the tie block is bolted rather than brazed, scrape away paint or grease at the p oint of cont act. Put st ar washers between the tie block and the cabinet to ensure good electrical contact.

Metal enclosures of power supplies, drives, etc., should also have good electrical contact with the SPG.

CAUTION

The Single Point Ground should be the only common point for all the ground lines. If not, ground loops may cause current flow among components of the system which can interfere with proper operation of the MMC Smart Drive.

Devices to be connected directly to the Single Point Ground include:

• Plant safety ground.

• Protective earth ground(s) from the MMC Smart Drive power terminals.

• The metal panel or cabinet on which the MMC Smart Drive is mounted.

24 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

• “Common” or “0 V” lines from power supplies that provid e +2 4 powe r to de vice s

and external power to the I/O modules and the devices to which they are connected.

• Protective grounds from the devices themselves, such as device drivers, machin-

ery, and operator interface devices.

• Protective earth ground from line and load sides of any AC line filters.

• The ground of the power source of the computer workst ation or laptop, if any, from

which you monitor the system operation. An AC outlet in the control cabinet is recommended.

• Single point grounds from other control cabinets, if any, in the system.

IMPORTANT

You must ensure that the “0V” or “Common” of all devices connected to the MMC Smart Drive are connected to Single Point Ground (SPG). Failure to do so may result in erratic operation or damage to the MMC Smart Drive and devices connected to it. Examples of devices connected to the MMC Smart Drive include the power source that supplies power to the MMC Smart Drive and devices connected to the MMC Smart Drive PiCPro Port. Note that some devices (for example, a Personal Computer) may have their “0V” and “Protective Earth Ground” connected together internally, in which case only one connection has to be made to SPG for that device. Also note that the AC/DC converter for some portable PCs have chassis connected from the wall plug to the PC. The ground for the AC outlet must be connected to the SPG.

Also, you must ensure that the MMC Smart Drive “Protective Earth Ground” connection is connected to SPG, and that the MMC Smart Drive is mounted to a metal panel or enclosure that is connected to SPG.

Kollmorgen - June 2014 25

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

+24V COM

BR+ BR-

B-

B+

CAUTION - Risk of Elect ric Shock

High Voltage may exist up to 10 minutes after removing power

P 1

O U T

DC BUS

F 1

F 2

In-coming

Single Point

Drive I/O

Ground (SPG)*

Supply

Ground

ENCLOSURE

Terminal

24V Power

Supply

Supply Circuit Disconnecting Means

SCPD

M M

AC Line Filter

Motor Feedback

Grounding Clamp

Motor Power

* Equipment Ground, AC Common, and DC Common are

tied together at one point only, Single Point Ground (SPG).

In-coming

AC Power (Mains)

Machine Base

Auxiliary

Power

To Workstation

or other Device

3.11.1 Grounding Requirements

Figure 3-1: Example of Grounding Required for CE Compliant Single Phase

230V Drive System

• Mount the filter as close to the Drive as possible. If the dist an ce exceeds 60 0 mm

(2.0 ft), use shielded cable between the Drive and the filter, strapping the shield to chassis at each end of the cable. This is particularly important for attenuation of higher frequency emissions (5-30 MHz).

26 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

• Shield or separate the wires connecting the AC power to the filter from other

power cables (e.g., connections between the Drive and the filter, motor power cable, etc.). If the connections are not separated from each other, the EMI on the Drive side of the filter can couple over to the source side of the filter, thereby reducing or eliminating the filter’s effectiveness. The coupling mechanism can radiate or allow stray capacitance between the wires.

• Bond the filter and the Drive to a grounded conductive surface (the enclosure) to

establish a high frequency (HF) connection. To achieve the HF ground, the contact surface interface between the filter, Drive, and the enclosure should be free from paint or any other type of insulator.

• Size the filter following manufacturer recommendations.

• Provide a large enough ground bar to connect all wires with no more than two

wires per connection.

• Clamp motor power cable shield for EMC termination.

IMPORTANT

Filter AC power to the drives to be compliant to CE emission requirements.

WARNING

High voltage exists in AC line filters. The filter must be grounded properly before applying power. Filter capacitors retain high voltages after power removal. Before handling the equipment, voltages should be measured to determine safe levels. Failure to observe this precaution could result in personal injury.

3.11.2 Grounding Multiple Drives in the Same Cabinet

1. Mount a common bonded ground bus in the cabinet.

2. Connect the ground wires for all drives to the common bonded cabinet ground

bus.

3. Connect the common bonded cabinet ground bus to an external ground system

that is connected to a single point ground.

3.12 System Wiring Guidelines

The MMC Smart Drive relies on electrical signals to report what is going on in the application and to send commands to it. In addition, signals are constantly being

Kollmorgen - June 2014 27

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

exchanged within the system. The MMC Smart Drive is designed for use in industrial environments, but some guidelines should be followed.

This section contains common system wiring configurations, size, and practices that can be used in a majority of applications. National Electrical Code, local electrical codes, special operating temperatures, duty cycles, or system configurations take precedence over the values and methods provided.

Wherever possible, install wiring and related components in the following order:

1. main power line disconnecting means

2. transformer (optional)

3. fuses (SCPD)

4. motor control

5. line reactor (as required)

6. line filter (optional)

7. device protection fuses (as required )

8. drive

9. shunt resistors (optional)

3.12.1 Recommended Signal Separation

Kollmorgen recommends separation of low level signals (encoder, analog, communications, fast DC inputs) from high voltage or high current lines. Maintain at least two inches of separation.

Inside a control cabinet, connect the shields of shielded cables at the MMC Smart Drive. It is recommended that factory cables (from Kollmorgen) are used between MMC drives, controls, and motors to ensure CE compliance.

WARNING

Use care when wiring I/O devices to the MMC Smart Drive and when plugging in cables. Wiring the wrong device to the connector or plugging a connector into the wrong location could cause intermittent or incorrect machine operation or damage to equipment.

28 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

MMC

PICPRO COMMUNICATIONS CABLE

MOTOR POWER CABLE

Drive I/O CABLE

24V

COM

INCOMING AC POWER

GND

SINGLE-POINT GROUND

DC POWER SUPPLY

Power Connector

Capacitor

Smart Drive

MOTOR FEEDBACK CABLE

(MAINS)

SINGLE POINT GROUND (SPG)

(.001 uF)

WARNING: FEEDBACK DEVICE DAMAGE

Feedback Cable Installation and Removal

All power to the Smart Drive (24 Vdc and main AC power) must be removed before connecting/disconnecting feedback cable connectors at the Smart Drive (F1 and F2 connector) or at the motor feedback device. Also, all connections must be secure when power is applied. Failure to follow these precautions may result in damage to the feedback device or Smart Drive.

Figure 3-2: Recommended Signal Separation

To prevent excessive conducted emissions from a DC power source (typically 24V) used for digital I/O, a .001 micro farad capacitor should be used. Connect the capacitor from the +24V DC to COMMON at the distribution terminals.

Kollmorgen - June 2014 29

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

3.12.2 Building Your Own Cables

• Connect the cable shield to the connector shells on both ends of the cable for a

complete 360 degree connection.

• Use a twisted pair cable whenever possible, twisting differential sig nals with each

other, and single-ended signals with the appropriate ground return.

NOTE

Kollmorgen cables are designed t o minimize EMI and are recommended over hand-built cables.

3.12.3 Routing Cables

Guidelines for routing cables in a cabinet include the following:

• Always route power and control cables separately.

• Do not run high and low voltage wires/cable in the same wireway.

• Cross high and low voltage conductors at 90 degree angles.

• On parallel cable runs, maximize the distance between high and low voltage

cables.

• Maintain the least amount of unshielded cable leads.

3.13 Wiring the Drive

These procedures assume you have bonded and mounted your MMC Smart Drive to the subpanel and that there is no power applied to the system.

3.13.1 Sizing the 24V Power Supply

When you size your power supply, you must ensure that t he supply is large enough to handle the total load. Refer to the specification tables for the +24VDC input power requirements.

In most cases, one power supply can be used for an entire control system. However, depending upon the drives and external I/O used in the application, the power distribution may be split into two or more power supplies.

Use of switches in series with the 24VDC power input is not recommended. The drive contains energy storage capacitors at the inputs. While no harm is done to the drive, this much capacitance across the 24VDC source may cause vo ltage dips when the switch in series with the 24VDC power is closed.

30 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

CAUTION

A possible ignition hazard within the MMC Smart Drive ex ists if excessive current is drawn from the 24 VDC powering the MMC Smart Drive. To prevent this possibility (due to improper wiring or 24 VDC supply failure), a fuse should be used in series with the 24 VDC to the MMC Smart Drive. Specifically, a 4 A max. “UL248 Series” fuse should be used. In addition, the 24 VDC shall be supplied by an isolatin g source such th at the maximum op en circuit voltage available to the MMC Smart Drive is not more than 30 VDC.

The +24V power to the MMC Smart Drive is connected through a Phoenix 5-pin connector with a plug-in terminal block. The ground from the power source and the ground from the MMC Smart Drive must be connected to the Single-Point Ground (SPG). Devices connected to the Drive I/O Port may have their own power sources for input or output control signals provided that each one is:

• at the correct voltage and current levels for the module and the device.

• connected to the same Single-Point Ground that the MMC Smart Drive uses.

It is recommended that the same main disconnect switch be used for the MMC Smart Drive and for all devices in the application.

IMPORTANT

No matter how the system is installed, before you connect the MMC Smart Drive to the application, make sure that power is off to the system and to the devices that are wired to the MMC Smart Drive.

3.13.2 System AC Power Wiring Guidelines

NOTE

In addition to the guidelines listed below, follow all national and local electrical codes and regulations.

• Install a supply circuit disconnecting means.

• Install a Short Circuit Protective Device (SCPD).

• Due to high inrush current at power-up, use dual element time dela y fuses for th e

SCPD.

• Install additional device protection fusing (460V models). Only high speed type

fuses provide proper protection.

• Refer to the Specifications sections in Chapter 4 of this manual for device and

conductor requirements.

• Clamp the motor power cable shield to the drive using the Kollmorgen supplied

bracket. Maximum tightening torque for bracket screws is 10 lb-in.

Kollmorgen - June 2014 31

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

• Use shielded cables and AC line filters (for CE Compliance). Make sure that wir-

ing from the drive to the line filter is as short as possible. Locate common grounding bus bars as close as possible to the drive. The braid shield of the cable should be clamped at the drive or mounting panel.

• Power connections for each drive in a system should be separately connected

directly to the AC power supply. Do not daisy chain drive power connections.

• Make sure the phase to neutral ground voltage does not exceed the input ratings

of the drive when using an autotransformer.

3.13.3 Connecting Interface Cables

IMPORTANT

This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Follow static control precautions when installing, testing, servicing, or repairing components in a drive system.

• Plug PiCPro cable into the PiCPro port (9-pin D-shell for the Analog Interfaced

MMC-SD, and 6-pin mini-din for the Digital Interfaced MMC-SD).

• Plug the one 15-pin D-shell, Feedback cable into the FBK1 connector.

• Plug the 26-pin D-shell, Drive I/O cable into the I/O connector.

• Tighten the attachment scre ws for all cables to the drive connectors.

WARNING

To avoid personal injury and/or equipment damage:

•Ensure installation complies with specifications regarding wire

types, conductor sizes, branch circuit protection, and disconnect devices. The National Electrical Code (NEC) and local codes outline provisions for safely installing electrical equipment.

•Ensure motor power connectors are us ed for conn e ctio n pu r-

poses only. Do not use them to turn the unit on and off.

•To avoid personal injury and/or equipment damage, ensure

shielded power cables are grounded to pre ven t po te n tially high voltages on the shield.

32 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

Expose 17 mm (0.68 in.) of braid

(1U2)

Ground

Dimension varies by Drive Model

(1V2)

(1W2)

WARNING: FEEDBACK DEVICE DAMAGE

Feedback Cable Installation and Removal

3.13.4 Preparing Motor Connection Wires

NOTE

It is recommended that Kollmorgen cables be used. Kollmorgen cables are designed to minimize EMI and are recommended over hand-built cables.

1. Strip back cable jacket approximately 152 mm (6.0 in.) from the end of the cable.

2. Strip app roximately 12 mm ( 0.50 in.) of insulation from the end of each conductor.

Do not tin ends after stripping.

IMPORTANT

Do not nick, cut or damage wire strands while removing wire insulation.

3. Strip the cable jacket away from the cable until the shield braid is visible. Expose

17 mm (0.68 in.) of cable shield braid.

Figure 3-3: : Motor Cable

4. Attach the individual wires from the motor cable to their assigned terminal. Refer

5. Tighten each terminal screw.

to Chapters 5 and 6 for front panel connectors and terminal assignments.

Kollmorgen - June 2014 33

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

CAUTION - Risk of Electric Shock

High Volta g e ma y exist u p to 10 minu tes after removing power

Motor Cable Jacket

Shield

Clamp

Clamp Screw

Screw

Motor Cable

6. Gently pull on each wire to make sure it does not come out of its terminal. Reinsert and tighten any loose wires.

7. Attach the plastic cover to terminal block

Factory supplied motor power cables for LSM, MSM, FSM, AKM, DDR, CDDR, and YSM Series motors are shielded, and the power cable is design ed to be termin ated at the drive during installation. A small portion of the cable jacket is removed which exposes the shield braid. The exposed shield braid must be clamped to the drive chassis using the provided clamp and clamp screws

Figure 3-4: Terminating Motor Power Cable for 230V Drive

34 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

Cable Jacket

Shield

Clamp Screw

FROM MAINS

Cable

Jacket

Maximum 10 cm from the Edge of the Drive

TO MOTOR

Cable

Clamp

Shield Clamped to Bottom of Drive

Jacket

MMC-SD 460 DRIVE

Screw

Shield

Shield Clamped to Mounting Panel

Clamp

Figure 3-5: T erminating Incoming AC Power (Mains) Cable for 460V SD Drive

Kollmorgen - June 2014 35

MMC Smart Drive Hardware Manual - INSTALLING THE MMC SMART DRIVE

A C

Shield Bracket

Cable Clamp

Cable

Drive

Note: Shield Bracket, Cable Clamp(s), Cable(s) are installed by User

Figure 3-6: Terminating Power Cables for 460V SDN Drive

36 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

4 System Power Devices

4.1 AC Input Power Requirements

The MMC Smart Drive is powered from an external AC power source. The power required for each 230V drive type is listed in Table 4-1. The power required for each 460V drive type is listed in Table 4-2.

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MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

Table 4-1: 230V Drive AC Input Power Requirements

Requirements

Nominal

Input Current

Drive Model

Amps

1-phase (3-phase)

RMS

Transformer

kVA

1-phase (3-phase)

Input V oltage = 120VAC

MMC-SD-0.5-230 5 (3) 5 (3) .75 (.5) 1.5 (1) MMC-SD-1.0-230 9 (5) 9 (5) 1. 5 (.7 5 ) 2 (1.5) MMC-SD-2.0-230 18 (10) 18 (10) 2.5 (1.5) 4 (2.5) MMC-SD-3.0-230 18 (14) 18 (14) 2.5 (2) 4 (4)

MMC-SDN-1.8-230 tbd (2.7) tbd (2.7) MMC-SDN-3.6-230 tbd (5.4) tbd (5.4) CF CF

MMC-SDN-7.2-230 tbd (9.2) tbd (9.2) CF CF MMC-SDN-14.4-230 tbd 1(8.3) tbd 1(8.3) CF CF S20260-DLS 3.4(N/A) 3.4(2.7) CF CF S20360-DLS 6.5(N/A) 6.5(5.0) CF CF S20660-DLS 12(N/A) 12(9.0) CF CF

Input Voltage = 230VAC

Input Voltage = 120VAC

Input Voltage = 230VAC

S21260-DLS N/A(N/A) 18(16) CF CF S22460-DLS N/A(N/A) 22(24) CF CF S20250-DLS 5(N/A) 3.4(N/A) CF(N/A) CF(N/A) S20350-DLS 10(N/A) 6.5(N/A) CF(N/A) CF(N/A)

a. Smart Drive (SD) Drive Model pertains to Analog (no dash suffix) and digit al (-D

b. Transformer sizes shown are worse-case. For a more accurate determination

c. Consult Factory

38 Kollmorgen - June 2014

& -DN)

of transformer size, see section 4.4 on page 59 for calculating application transformer requirement.

Table 4-2: 460V Drive AC Input Power Requirements

Drive Model

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

Requirements

Nominal

Input Current

Amps

RMS

3-phase

Transformer

kVA

3-phase

Input Voltage = 230VAC

MMC-SD-1.3-460 2.8 2.44 1.2 3.0 MMC-SD-2.4-460 4.8 4.18 2.0 5.0 MMC-SD-4.0-460 8.1 7.0 3.4 8.5 MMC-SD-6.0-460 12.4 10.8 5.2 12.8 MMC-SD-8.0-460 17.0 14.8 7.0 17.6 MMC-SD-12.0-460 19.2 16.7 8.0 19.5 MMC-SD-16.0-460 24.2 21.1 10.0 25.0 MMC-SD-24.0-460 38.0 33.1 16.0 39.5 MMC-SD-30.0-460 53.0 46.0 22.0 55.0 MMC-SD-42.0-460 70.0 70.0 29.0 73.0 MMC-SD-51.0-460 84.0 73.0 35.0 87.0

Input Voltage = 460VAC

Input Voltage = 230VAC

Input Voltage = 460VAC

MMC-SD-65.0-460 105 91.0 44.0 110 MMC-SD-72.0-460 101 101 54 107 MMC-SD-100-460 127 127 67 184 MMC-SD-144-460 185 185 85 170

MMC-SDN-1.8-460 2.7 2.7 MMC-SDN-3.6-460 5.4 5.4 CF CF

MMC-SDN-7.2-460 9.2 9.2 CF CF MMC-SDN-14.4-460 18.3 18.3 CF CF

a. Smart Drive (SD) Model pertains to Analog (no dash suffix) and digital (-D & -DN) b. Transformer sizes shown are worse-case. For a more accurate determination of

transformer size, see section 4.4 on page 59 for calculating application transformer requirement.

c. Consult Factory

Kollmorgen - June 2014 39

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

4.2 Protection

4.2.1 Motor Overload Protection

The Drives described in this manual utilize solid state motor overload protection in accordance with UL508C that operates:

• within 30 minutes at 125% overload

• within 8 minutes at 200% overload

• within 20 seconds at 600% overload

Motor parameters such as maximum motor current can be defined with PiCPro Application Development software. The PiCPro manual can be found at www.glcontrols.com.

4.2.2 Motor Thermal Protection

The Drives described in this manual do not provide motor over-temperature sensing, unless a motor-mounted thermal device is connected to the Drive as described below.

In order to provide Motor Thermal Protection, and to meet the requirements of UL508C, the following must be followed:

• One of the following temperature-sensing devices must be installed in the motor:

• A thermostat (normally closed, contacts rated at 10ma, 3.3VDC or greater).

The thermostat's contact will open when the motor's maximum operating temperature is exceeded. Connect the thermostat between 0V and the Thermostat input of the Drive's Feedback Connector.

• A thermistor (rated at 10ma, 3.3VDC or greater; Philips KTY84-130 PTC or

equivalent recommended). The motor manufacturer will provide the motor's maximum operating temperature. This temperature may be entered into the Motor Temperature Parameters in PiCPro. Connect the thermistor output between 0V and the Thermistor input on the Drive's Feedback Connector.

• The temperature-sensing devi ce m ust be pr op e rly co nn ec te d to th e dr ive , as

described in the MMC Smart Drive Hardware Manual that can be found at www.glcontrols.com.

• The temperature-sensing device must be properly configured in PiCPro (as

described in the PiCPro Manual and/or PiCPro on-line Help)

40 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

4.2.3 24VDC Input Power Protection (460V SD Only)

CAUTION

A possible ignition hazard within the MMC 460V Smart Drives exists if excessive current is drawn from the 24 VDC powering the MMC Smart Drive. To prevent this possibility (due to improper wiring or 24 VDC supply failure), a fuse should be used in series with the 24 VDC to the MMC Smart Drive. Specifically, a 4 A max. “UL248 Series” fuse should be used. In addition, the 24 VDC shall be supplied by an isolating source such that the maximum open circuit voltage available to the MMC Smart Drive is not more than 30 VDC.

4.2.4 S200-DLS Drive Protection Requirements

For installation in the United States, branch circuit protection must be provided in accordance with the National Electrical Code and any applicable local codes.

For installation in Canada, branch circuit protection must be provided in accord ance with the Canada Electrical Code and any applicable provincial codes

NOTE

The S200-DLS Drives are suitable for use on a branch circuit capable of delivering not more than 5,000 RMS symmetrical Amperes, 250 Volts maximum.

Two types of Protection must be provided in case the S200-DLS Drive malfunctions:

• Short Circuit Protection - this protection helps minimize damage to the Smart

Drive in the case of a Short Circuit condition. Short Circuit Protection is required to meet UL508C requirements.

• Branch Circuit Over Current Protection - this protection helps minimize damage to

the Smart Drive and helps protect the wiring between the Smart Drive and the Over Current Protection Device in the case of a sust ained Over Curr ent condition. Over Current Protection must be provided in accordance with NFPA 79 7.2.3 and

7.2.10. Supplemental UL1007 protectors shall not be used to provide Branch Circuit Protection.

When using the S200-DLS Drive, the fuse that provides Short Circu it Prot ec tio n also provides Over Current Circuit Protection, therefore a separate Short Circuit Protection fuse is not required.

Two types of fuses are defined for use with the S200-DLS Drive: Non-restricted - If the Branch Circuit supplying power to the drive is capable of

delivering no more then 5,000 RMS symetrical short circuit amperes (25 0V maximum), the fuse type provided for Protection has no “Clearing I

must meet the following requirements:

t” restrictions, and

• have a current rating no greater than the “Maximum Fuse Size” in Table 4-3

Kollmorgen - June 2014 41

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

• have an interrupt capability no less than the short circuit rating (Prospective Short-

circuit Symetrical Amperes) of the Branch Circuit supplying the drive.

Restricted - If the Branch Circuit supplying power to the drive is capable of delivering between 5,000 and 100,000 RMS symetrical short circuit amperes (250V maximum) ,

the fuse type provided for Protection has “Clearing I following requirements:

• meet both of the requirements for a non-restricted fu se (above)

• be a Class RK1, J, or CC dual element current limiting fuse

The requirements for both restricted and non restricte d fuses may be meet by using a single fuse that meets all requirement s. The easie st way to accomplish this is to use a “Current Limiting Fuse” from Table 4-3. These fuses meet all of the requirements for both Short Circuit Protection and Over Current Protection, and may be used on Branch Circuits that supply up to 100,000 RMS sym etrical short circuit amperes ( 240V maximum).

The maximum fuse size allowed for use with each S200-DLS Drive, as well as suggested Bussmann fuses that meet both the restricted and non-restrictive

requirements as described above, is listed in Table 4-3.

t” restrictions, and must meet the

UL REQUIREMENTS

• In order to meet UL requirements for the S200-DLS Drive, the over-current protection device (fuses) must be UL-Listed Class RK1, J, or CC.

• The S21260-DLS must use Class J fuses, 30A or higher for protection.

Table 4-3: S200-DLS Drive Protection Devices

VIN = 240VAC

3 Phase

5A (LPJ-5SP)

8A (LPJ-8SP)

15A (LPJ-15SP)

S200-DLS

Drive Model

S20260-DLS

S20360-DLS

S20660-DLS

VIN = 120VAC

1 Phase

5A (LPJ-5SP)

10A (LPJ-10SP)

20A (LPJ-20SP)

Maximum Fuse Size

(Bussmann Fuse P/N)

VIN = 240VAC

1 Phase

5A (LPJ-5SP)

10A (LPJ-10SP)

20A (LPJ-20SP)

S21260-DLS N/A

S22460-DLS N/A

42 Kollmorgen - June 2014

30A (JKS-30)

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

S20250-DLS

S20350-DLS

10A (LPJ-10SP)

20A (LPJ-20SP)

5A (LPJ-5SP)

10A (LPJ-10SP)

N/A

VIN = 90VDC

S20330-DLS

S20630-DLS

a. This is the maximum fuse size that can be used for Device Protection

ATTENTION

The opening of branch-circuit protective device may be an indication that a fault has been interrupted. To reduce the risk of fire or electric shock, currentcarrying parts and other components of the controller should be examined and replaced if damaged.

(LP-CC-7)

15A

(LP-CC-15)

4.2.5 230V Smart Drive (SD) Protection Requirements

Although these drives provide solid state motor overload protection at 125% of the rated FLA Current and short circuit protection, this Integral solid state short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the National Electrical Code and any additional local

codes.

NOTE

Short Circuit Rating - 100kA, 240 Vac when used with Class RK1, J, or CC fuses.

Two types of Protection must be provided in case the Smart Drive malfunctions:

• Short Circuit Protection - this protection helps minimize damage to the Smart

Drive in the case of a Short Circuit condition. Short Circuit Protection is required to meet UL508C requirements.

• Branch Circuit Over Current Protection - this protection helps minimize damage to

7.2.10. Supplemental UL1007 protectors shall not be used to provide Branch Circuit Protection.

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MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

When using the 230V Smart Drive, the fuse that provides Short Circuit Protection a lso provides Over Current Circuit Protection, therefore a separate Short Circuit Protection fuse is not required.

Two types of fuses are defined for use with the 230V Smart Drive: Non-restricted - If the Branch Circuit supplying power to the drive is capable of

delivering no more then 5,000 RMS symetrical short circuit amperes (24 0V maximum), the fuse type provided for Protection has no “Clearing I

must meet the following requirements:

• have a current rating no greater than the “Maximum Fuse Size” in Table 4-4

• have an interrupt capability no less than the short circuit rating (Prospective Short-

circuit Symetrical Amperes) of the Branch Circuit supplying the drive.

Restricted - If the Branch Circuit supplying power to the drive is capable of delivering between 5,000 and 100,000 RMS symetrical short circuit amperes (240V maximum) ,

the fuse type provided for Protection has “Clearing I following requirements:

• meet both of the requirements for a non-restricted fu se (above)

• be a Class RK1, J, or CC dual element current limiting fuse

t” restrictions, and

t” restrictions, and must meet the

The requirements for both restricted and non restricte d fuses may be meet by using a single fuse that meets all requirement s. The easie st way to accomplish this is to use a “Current Limiting Fuse” from Table 4-4. These fuses meet all of the requirements for both Short Circuit Protection and Over Current Protection, and may be used on Branch Circuits that supply up to 100,000 RMS sym etrical short circuit amperes ( 240V maximum).

The maximum fuse size allowed for use with each 230V Smart Drive, as well as suggested Bussmann fuses that meet both the restricted and non-restrictive

requirements as described above, is listed in Table 4-4.

UL REQUIREMENTS

• In order to meet UL requirements for the 230V Smart Drive, the over-current protection device (fuses) must be UL-Listed Class RK1, J, or CC

• Model MMC-SD-3.0-230 must be used with 30 Amp fuses or smaller

44 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

Table 4-4: 230V Class J Smart Drive Protection Devices

Recommended Fuse Size (Bussmann Fuse P/N

230V Drive

Model

Maximum Fuse Size (Bussmann Fuse P/N)

VIN = 120VAC

1 Phase

VIN = 240VAC

1 Phase

VIN = 240VAC

3 Phase

b,c

MMC-SD-0.5-230

MMC-SD-1.0-230

MMC-SD-2.0-230

MMC-SD-3.0-230

a. Drive model pertains to Analog (no dash suffix) and Digital (-D & -DN) versions b. The largest fuse allowed under any circumstance is four times the motor FLA c. This is the maximum fuse size that can be used for Device Protection d. At 5A full load motor current e. At 10A full load motor current f. At 20A full load motor current

5A (LPJ-5SP) 12A (LPJ-12SP)

10A (LPJ-10SP) 15A (LPJ-15SP)

20A (LPJ-20SP) 30A (LPJ-30SP)

5A (LPJ-5SP) 12A (LPJ-12SP)

10A (LPJ-10SP) 15A (LPJ-15SP)

20A (LPJ-20SP) 30A (LPJ-30SP)

5A (LPJ-5SP) 12A (LPJ-12SP)

10A (LPJ-10SP) 15A (LPJ-15SP)

20A (LPJ-20SP) 30A (LPJ-30SP)

ATTENTION

4.2.6 460V Smart Drive (SD & SDN) Protection Requirements

NOTE

All information in this section pertains to both the 460V Smart Drive (SD) and the 460V Smart Drive NextGen (SDN), unless otherwise noted.

Kollmorgen - June 2014 45

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

provided in accordance with the National Electrical Code and any additional local codes, as described in this section.

NOTE

• The 460V Smart Drive (SD) is suitable for use on a circuit capable of delivering not more than 18,000 RMS symmetrical Amperes, 480 Volts maximum.

• The 460V Smart Drive NextGen (SDN) is suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical Amperes, 480 Volts maximum, when protected by fuses, as described in this section.

Two types of Protection must be provided in case the Smart Drive malfunctions:

• Short Circuit Protection - this protection helps minimize damage to the Smart

Drive in the case of a Short Circuit condition. Short Circuit Protection is required to meet UL508C requirements.

• Branch Circuit Over Current Protection - this protection helps minimize damage to

7.2.10. Supplemental UL1007 protectors shall not be used to provide Branch Cir-

cuit Protection. Two types of fuses are defined for use with the 460V Smart Drive: Non-restricted - If the Branch Circuit supplying power to the drive is capable of

delivering no more then 18,000 RMS symetrical short circuit amperes (480V maximum), the fuse type provided for Protection has no “Clearing I

must meet the following requirements:

t” restrictions, and

• have a current rating no greater than the “Maximum Fuse Size” in Table 4-5

• have an interrupt capability no less than the short circuit rating (Prospective Short-

circuit Symetrical Amperes) of the Branch Circuit supplying the drive. Restricted - If the Branch Circuit supplying power to the drive is capable of delivering

between 18,000 and 100,000 RMS symetrical short circuit amperes (480V maximum), the fuse type provided for Protection has “Clearing I

following requirements:

t” restrictions, and must meet the

• meet both of the requirements for a non-restricted fu se (above)

• have a “Clearing I

The requirements for both restricted and non restricted fuses may be meet by using one of two methods:

t” rating no greater than the “”Clearing I2t” rating in Table 4-5

• Use a single fuse that meets all requirements. The ea siest way to accomplish this

is to use a “Combination Fuse” from Table 4-5. These fuses meet all of the

requirements for both Short Circuit Protection and Over Current Protection, and

may be used on Branch Circuits that supply up to 100,000 RMS symetrical short

circuit amperes (480V maximum).

• Use two fuses connected in series, that, in combination, meet all of the require-

ments:

46 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

• Use an Over Current Protection fuse that has a current ra ting not greater than

the “Maximum Fuse Size” shown in Table 4-5, and an interrupt capability not less than the short circuit rating (Prospective Short-circuit Symetrical Amperes) of the Branch Circuit supplying the drive.

• Use a Short circuit Protection fuse (typically a se miconductor fuse) that h as a

“Clearing I ing greater than the Over Current Protection fuse (to avoid nuisance tripping).

See Table 4-6 on page 50 to for a listing of available fuses and fuse holders from

Kollmorgen..

In order to meet UL requirements, UL-Listed High Speed Class J (HSJ) semiconductor fuses (like those listed in Table 4-5) must be used for Branch circuit Protection of the 460V Smart Drive.

t” rating not greater than that shown in Table 4-5, and a current rat-

UL REQUIREMENTS

Kollmorgen - June 2014 47

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

Table 4-5: 460V Smart Drive High Speed Class J Protection Devices

460V Drive

Model

MMC-SD-1.3-460

MMC-SD-2.4-460

MMC-SD-4.0-460

MMC-SD-6.0-460

MMC-SD-8.0-460

MMC-SD-12.0-460

MMC-SD-16.0-460

MMC-SD-24.0-460

MMC-SD-30.0-460

I2t

Rating

< 228A2s

< 260A2s

< 340A2s

< 616A2s

< 1, 555A2s

< 15,000A2s

Maximum Fuse

Size

VIN = 230VAC

11A 9A HSJ6(DFJ6) HSJ6(DFJ6)

19A 16A HSJ15(DFJ15) HSJ15(DFJ15)

32A 27A HSJ15(DFJ15) HSJ15(DFJ15)

49A 41A HSJ20(DFJ20) HSJ20(DFJ20)

68A 56A HSJ30(DFJ30) HSJ25(DFJ25)

76A 64A HSJ35(DFJ35) HSJ30(DFJ30)

96A 80A HSJ40(DFJ40) HSJ35(DFJ35)

152A 126A HSJ60(DFJ60) HSJ45(DFJ45)

212A 176A

VIN = 460VAC

VIN = 230VAC

N/Af(DFJ80) N/Af(DFJ60)

Recommended Fuse

Ferraz (Bussmann)

VIN = 460VAC

d,e

MMC-SD-42.0-460

MMC-SD-51.0-460

MMC-SD-65.0-460

MMC-SD-72.0-460

MMC-SD-100-460

MMC-SD-144-460

MMC-SDN-1.8-460

MMC-SDN-3.6-460

MMC-SDN-7.2-460

MMC-SDN-14.4-460

a. Drive model pertains to analog (no dash suffix) and Digital (-D) b. This is the maximum “Clearing I

in the operating point below the stated release integral (I meet this requirement.

< 15,000A2s

< 83,700A2s

< 97,000A2s

< 685A2s

< 3,850A2s

280A 233A HSJ125(DFJ125) HSJ100(DFJ100)

336A 280A HSJ150(DFJ150) HSJ110(DFJ110)

420A 350A HSJ175(DFJ175) HSJ125(DFJ125)

404 388 HSJ175(DFJ175) HSJ150(DFJ150)

508 488 HSJ225(DFJ225) HSJ225(DFJ200)

740 711 HSJ350(DFJ350) HSJ300(DFJ300)

11A 10A HSJ6(DFJ6) HSJ6(DFJ6)

22A 21A HSJ10(DFJ10) HSJ10(DFJ10)

37A 35A HSJ15(DFJ15) HSJ15(DFJ15)

73A 70A HSJ30(DFJ30) HSJ30(DFJ30)

t Rating” of a fuse used for Device Protection. Use a fuse that falls

t). All of the listed “Combination Fuses”

48 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

c. This is the maximum fuse size that can be used for Device and Branch Circuit Protection. Kollmor-

gen recommends the use of HSJ or DFJ fuses only. d. Kollmorgen part numbers for these fuses can be found in Table 4-6 on page 50 e. Listed devices are UL Recognized. These fuses have an Interrupt current of 100,000A f. Combination fuse not available from Ferraz for this drive

ATTENTION

Kollmorgen - June 2014 49

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

Table 4-6: Available Fuses & Holders

Fuse Part

Combination Fuse

DFJ6 M.3000.0190 30 Amp M.1016.1046 DFJ10 M.3000.1321 30 Amp M.1016.1046 DFJ15 M.3000.0191 30 Amp M.1016.1046 DFJ20 M.3000.0192 30 Amp M.1016.1046 DFJ25 M.3000.0193 30 Amp M.1016.1046 DFJ30 M.3000.0194 30 Amp M.1016.1046 DFJ35 M.3000.0195 60 Amp M.1016.0612 DFJ40 M.3000.0196 60 Amp M.1016.0612 DFJ45 M.3000.0197 60 Amp M.1016.0612 DFJ60 M.3000.0198 60 Amp M.1016.0612 DFJ80 M.3000.0199 100 Amp M.1016.0613 DFJ100 M.3000.0200 100 Amp M.1016.0613

Number

Fuse Holder Type 3P

Fuse Holder Part Number

DFJ110 M.3000.0201 200 Amp M.1016.0614 DFJ125 M.3000.0202 200 Amp M.1016.0614 DFJ150 M.3000.0203 200 Amp M.1016.0614 DFJ175 M.3000.0204 200 Amp M.1016.0614 DFJ200 M.3000.1661 200 Amp M.1016.0614 DFJ225 M.3000.1662 400 Amp M.3000.1665 DFJ300 M.3000.1663 400 Amp M.3000.1665 DFJ350 M.3000.1664 400 Amp M.3000.1665

50 Kollmorgen - June 2014

4.3 Line Reactors

Danger Electric Shock Risk

MOTOR

MMC SMART DRIVE

LINE REACTOR

SCPD

AC Line Reactors are required when using some mo de ls of th e MM C Sm art D rive . They protect the drive from impermissible rates of current change and reduce harmonic current distortions. When required, they are m ounted between the drive and the mains input power source.

Multiple drives or inverters on a common power line require one reactor per drive. Individual reactors provide filtering between each drive (and thereby reduce crosstalk) and also provide optimum surge protection for ea ch unit. A single reactor serving several drives does not provide adequate protection, filtering or harmonic reduction when the system is partially loaded. Refer to

Figure 4-1 for an example of one line reactor connected to one drive.

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

NOTE

WARNING

The frame of line/load reactors must be grounded at one of the reactor mounting holes typically by using a star washer under the heads of the mounting bolts. INJURY OR DEATH MAY RESULT IF THESE SAFETY PRECAUTIONS ARE NOT OBSERVED.

Figure 4-1: Line Reactor Connection (Simplified)

Line reactors are not necessary for the 230V MMC Smart Drives or the 460V size 1 and 2 MMC Smart Drives. Line reactors are required for the 460V size 3 and size 4 MMC Smart Drives.

Kollmorgen - June 2014 51

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

7.25 MAX

2.35

3.43

0.38 x 0.75 (4 SLOTS)

LABEL

WIRE RANGE: 22-5 AWG

CAUTION - TERMINAL SCREW TIGHTENING TORQUE: 16 in-lb MAX

6.00 MAX

3.00

MAX

4.3.1 Specifications and Dimensions for Required Line Reactors Table 4-7: MMC-SD-12-460 Line Reactor Specifications

Fundamental

Amperage

Power

Loss

Inductance Weight

Part

Number

25A 52W 1.2 mH 14 lbs. M.1302.7373

52 Kollmorgen - June 2014

7.25 MAX

2.63

4.00

0.38 x 0.75 (4 SLOTS)

LABEL

WIRE RANGE: 22-5 AWG

CAUTION - TERMINAL SCREW TIGHTENING TORQUE: 16 in-lb MAX

5.75 MAX

3.00

MAX

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

Table 4-8: MMC-SD-16-460 Line Reactor Specifications

Fundamental

Amperage

Power

Loss

Inductance Weight

Part

Number

35A 54W 0.8 mH 16 lbs. M.1302.7374

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MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

9.00 MAX

3.16

4.75

0.38 x 0.75 (4 SLOTS)

LABEL

WIRE RANGE: 18-4 AWG

CAUTION - TERMINAL SCREW TIGHTENING

TORQUE: 16 in-lb MAX

7.35 MAX

3.00

MAX

Table 4-9: MMC-SD-24-460 Line Reactor Specifications

Fundamental

Amperage

Power

Loss

Inductance Weight

Part

Number

45A 62W 0.7 mH 28 lbs. M.1302.7375

54 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

Table 4-10: MMC-SD-30-460 Line Reactor Specifications

Fundamental

Amperage

55A 67W 0.5 mH 27 lbs. M.3000.0105

Power

Loss

Inductance Weight

Part

Number

Kollmorgen - June 2014 55

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

Table 4-11: MMC-SD-42-460 Line Reactor Specifications

Fundamental

Amperage

80A 86W 0.4 mH 51 lbs. M.3000.0106

Power

Loss

Inductance Weight

Part

Number

56 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

Table 4-12: MMC-SD-51-460 Line Reactor Specifications

Fundamental

Amperage

100A 84W 0.3 mH 51 lbs. M.3000.0107

Power

Loss

Inductance Weight

Part

Number

Kollmorgen - June 2014 57

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

Table 4-13: MMC-SD-65-460 Line Reactor Specifications

Fundamental

Amperage

130A 180W 0.2 mH 57 lbs. M.3000.0108

Power

Loss

Inductance Weight

Part

Number

58 Kollmorgen - June 2014

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

Table 4-14: MMC-SD-100-460 Line Reactor Specifications

Fundamental

Amperage

250A 231W 0.090 mH 80 lbs. M.3000.1666

Power

Loss

Inductance Weight

Part

Number

4.4 Isolation Transformers

The MMC Smart Drive does not require the use of isolation transformers. However, a transformer may be required to match the voltage requirements of the controller to the available service. To size a transformer for the main AC power inputs, the power output (KVA) of each axis must be known. This can be derived by calculating the horsepower for each axis and converting that horsepower into units of watts. If power is being supplied to more than one motor and a drive, simply add the kW ratings together from each calculation to get a system kW total.

For an autotransformer, ensure that the phase to neutral/ground voltages do not exceed the input voltage ratings of the drive.

If you are using the Motions Solutions Sizing Software, the average speed and average torque data has already been calculated and can be used in the eq uation. If you are not sure of the exact speed and torque in your application, record the speed/ torque curve for your drive/motor combination and use the resulting values as a worst case continuous speed and torque.

Calculations are multiplied by a factor to compensate for the power and loss elements within a power system. A factor of 2.0 is used with a single phase system and a factor

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KVA

Speed RPMTorque lb in–

63 025

------------------------------------------------------------------------------

0.746 KVA

----------------------------- -

2.0=

KVA

Speed RPMTorque lb in–

63 025

------------------------------------------------------------------------------

0.746 KVA

----------------------------- -

1.5=

of 1.5 is used with a three phase system. This factor should minimize the effects of the secondary line voltage sagging in the transformer during peak current periods.

The speed/torque curve information for 230V motors is based upon a drive input voltage of 230V AC. For a 115V AC input voltage, the maximum speed can be reduced up to one half.

Example single phase Formula:

Example three phase Formula:

NOTE

For 460V drives, the 3-Phase source powering the drive has to be a centergrounded “Y” configuration. Do not exceed 304 Volts RMS from any phase to ground.

For 220V drives, the 3-Phase source powering the d rive does not have to be a center-grounded “Y” configuration. Do not exceed 1 52 Volts RMS from any phase to ground.

4.5 External Shunts

Power from the motor is returned to the MMC Smart Drive during motor deceleration. Excessive power may have to be dissipated from the MMC Smart drive when large inertia loads are present. External shunts should be used to avoid excessive bus over voltage faults.

This section covers three aspects of External Shunts:

• Refer to section 4.5.1 on page 60 for information on choosing External Shunts.

• Refer to section 4.5.2 on page 62 for information on mounting External Shunts

• Refer to section 4.5.3 on page 69 for information on connecting External Shunts

4.5.1 Choosing External Shunts

This section describes how to select the proper External Shunt based on system parameters.

Kollmorgen recommends you use the Motion Solutions Sizing Software to determine the need for and type of external shunt. However, you may perform the following calculations to choose the external shunt for your application.

1. Obtain the Peak Generating Power for the drive in watts (W).

2. Perform the following calculation:

60 Kollmorgen - June 2014

W x T = Watts/sec or Joules

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

where:

W is watts from Step 1 above, T is decel time required by the application

3. Obtain the Absorption Energy in Joules for the drive from the Specifications section of the drive manual.

4. Determine the Peak Shunt Power from the drive that would be delivered to the shunt resistor for your application:

• (Number calculated in Step 2 above) - (Absorption Energy from the drive

Specifications table in either Chapter 5 or 6) = Watt-seconds

• (Watt-seconds computed in 5a. above) (Decel Time for the application) =

Peak Shunt Power in Watts

5. Determine the Continuous Shunt Power that would be delivered to the shunt resistor for this application:

• Duty Cycle of Peak or Peak x Decel Time) (Tot al Cycle T ime) = Continuous

Shunt Power in Watts

6. Choose an external shunt from Table 4-15.

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Table 4-15: Shunt Resistors

For Drive

MMC-SD-0.5-230 MMC-SD-1.0-230 MMC-SD-2.0-230 MMC-SD-3.0-230

MMC-SD-1.3-460 MMC-SD-2.4-460

MMC-SD-4.0-460

MMC-SD-6.0-460 MMC-SD-8.0-460

Shunt Resistor Module

For Single Phase Drives: 38300W,600V, Dynamic

For Three Phase Drives: 30300W Cont. Power. 215mm(L) x

60mm(W) x 30mm(H) 145, 450W Cont. Power, 5.4kW Peak Pow-

er, 820 V, 240 sec. Time Constant, 121 mm x 93 mm x 605 mm

130, 150W, Reduced Size Panel Mount M.3000.0504 95, 700W Cont. Power, 8kW Peak Power,

820 V, 250 sec. Time Constant, 121 mm x 93 mm x 705 mm

95, 300W, Reduced Size Panel Mount M.3000.0505 50, 1400W Cont. Power, 17kW Peak Pow-

er, 850V, 250 sec. Time Constant, 130 mm x 182 mm x 710 mm

50, 500W, Reduced Size Panel Mount M.3000.0506

Part

Number

M.3000.1346

M.3000.0503

M.1302.7048

M.1302.7049

M.1302.7060

25, 2800W Cont. Power, 32kW Peak Pow-

MMC-SD-12.0-460 MMC-SD-16.0-460

MMC-SD-24.0-460 MMC-SD-30.0-460 MMC-SD-42.0-460 MMC-SD-51.0-460 MMC-SD-65.0-460

MMC-SDN-XXX

a. Drive Model pertains to Analog (no dash suffix) and digital (-D)

er, 850V, 60 sec. Time Constant, 171 mm x 430 mm x 550 mm

25, 800W, Reduced Size Panel Mount M.3000.0507 18, 3900W Cont. Power, 70kW Peak Pow-

er, 850V, 70 sec. Time Constant, 180 mm x 445 mm x 490 mm

18, 1200W, Reduced Size Panel Mount M.3000.0508 See section 6.2.4.2 on page 151 for information on shunt (re-

gen) resistors for use with the SDN drives

4.5.2 Mounting External Shunts

This section describes the mounting requirements for External Shunts available from Kollmorgen.

M.1302.7061

M.1302.7063

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MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

EXTERNAL SHUNTS ON SMART DRIVE NEXTGEN (SDN)

DRIVES

For a detailed description of these shunt s, refer to the Kollmorgen “AKD/S700 Accessories Manual” which can be found at www.kollmorgen.com.

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Figure 4-2: Mounting Dimensions for 230V Active Shunt Kit (P/N M.3000.1346)

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2.52 in. (64 mm)

3.66 in. (93 mm)

4.76 in. (121 mm)

20.71 in. (526 mm)

23.82 in. (605 mm)

0 5, 5 x 8

2.52 in. (64 mm)

3.66 in. (93 mm)

4.76 in. (121 mm)

24.65 in. (626 mm)

27.76 in. (705 mm)

0 5, 5 x 8

5.90 in. (150 mm)

7.28 in. (185 mm)

5.12 in. (130 mm)

20.71 in. (526 mm)

23.82 in. (605 mm)

0 5, 5 x 8

Figure 4-3: Mounting Dimensions for 460V External Shunt (P/N M.1302.7048)

Figure 4-4: Mounting Dimensions for 460V External Shunt (P/N M.1302.7049)

Figure 4-5: Mounting Dimensions for 460V External Shunt (P/N M.1302.7060)

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MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

11.81 in. (300 mm)

5.91 in. (150 mm)

6.73 in (171 mm)

20.70 in. (526 mm)

0 5, 5 x

19.80 in. (503 mm)

21.65 in. (550 mm)

13.62 in. (346 mm)

13.38 in. (340 mm)

5.91 in. (150 mm)

16.93 in. (430 mm)

Figure 4-6: Mounting Dimensions for 460V External Shunt (P/N M.1302.7061)

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MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

11.81 in. (300 mm)

5.91 in. (150 mm)

6.73 in (171 mm)

20.70 in. (526 mm)

0 5, 5 x 8

19.80 in. (503 mm)

21.65 in. (550 mm)

13.62 in. (346 mm)

13.38 in. (340 mm)

5.91 in. (150 mm)

16.93 in. (430 mm)

Figure 4-7: Mounting Dimensions for 460V External Shunt (P/N M.1302.7063)

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MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

DIMENSIONS (mm)

PART N UMBER L1 L2 L3 W H D1 D2 LEADS

M.3000.0503 SHUNT RESISTOR, 300W 30 OHMS 215 196 175 30 60 5.3 9.5 500

M.3000.1344 SHUNT RESISTOR, 300W 38 OHMS 215 196 175 30 60 5.3 9.5 500

M.3000.0504 SHUNT RESISTOR, 150W 130 OHMS 210 197 170 22 41 4.3 6.5 500

M.3000.0505 SHUNT RESISTOR, 300W 95 OHMS 215 196 175 30 60 5.3 9.5 500

M.3000.0506 SHUNT RESISTOR, 500W 50 OHMS 335 316 295 30 60 5.3 9.5 500

M.3000.0507 SHUNT RESISTOR, 800W 25 OHMS 285 266 245 61 59 5.3 9.5 500

M.3000.0508 SHUNT RESISTOR, 1200W 18 OHMS 405 386 365 61 59 5.3 9.5 500

Figure 4-8: Mounting Dimensions for Reduced Size Panel mount Shunts

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MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

4.5.3 Connecting Shunt Modules

This section describes how to connect External Shunts to the drive. Use shielded, high temperature 75 C (167 F), 600V, 2.5-4.0 mm

m (10 ft) maximum, copper wire. Follow one of the methods given below to reduce the effects of EMI noise:

• Install wires using twisted pairs (two turns per foot minimum), as shown in the fig-

ure below. Keep unshielded wires as short as possible.

• Use shielded, twisted cable (ground shield at shunt and drive).

• Use shielded metal conduit (ground conduit at shunt and drive).

When two shunt modules are connected in parallel, the shunt capacity is doubled.

Do not connect more than two shunt modules to an MMC Smart Drive.

WARNING

(12-14 AWG), 3.05

4.5.3.1 230V, 1-Phase MMC Smart Drive Shunt Wiring

The 230V, 1-Phase MMC Smart Drive requires the use of an Active Shunt module. Refer to Figure 4-9 for wiring an Active Shunt Module to this drive.

The 230V, 3-Phase MMC Smart Drive requires the use of a Passive Shunt module (regen resistor). Refer to Figure 4-10 for wiring an Passive Shunt Module to this drive.

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MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

DC -

RES. -

RES. +

DC +

DC BUS

GND

BRAKING

B+

B-

MMC SMART DRIVE CENTURION DSA

CENTURION DSM

DYNA MIC BRA KE RESISTOR

DYN AMIC BR AKE MODULE

Figure 4-9: 230V, 1-Phase MMC Smart Drive Shunt Wiring

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230V MMC Smart Drive Bus/Regen Connector

BB+

R-

R+

Front of Drive

(located on bottom of drive)

Passive Shunt Module

Shunt Module

460V MMC Smart Drive Shunt/DC Bus Terminal Strip

BaBa+

1C1 1D1

Using twisted pair wire, Connect Ba + to + Terminal on Shunt Module, Connect Ba- to - Terminal on Shunt Module

Figure 4-10: 230V, 3-Phase MMC Smart Drive Shunt Wiring

4.5.3.2 460V, 3-Phase MMC Smart Drive (-SD) Shunt Wiring

The 460V, 3-Phase MMC Smart Drive requires the use of a Passive Shunt module (regen resistor). Refer to Figure 4-11 for wiring an Passive Shunt Module to this drive.

Figure 4-11: 460V, 3-Phase MMC Smart Drive (-SD) Shunt Wiring

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MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

1L1

1L2

1L3

2L1

2L2

2L3

1U1

1V1

1W1

4.6 Line Filters

Line Filters consist of combinations of capacitors, reactors, resistors and voltage limiters that are intended to reduce the electromagnetic influence of the environment.

LINE FILTERS ON SMART DRIVE NEXTGEN (SDN)

DRIVES

MMC-SDN-XXXX drives do not require line filters

4.6.1 Line Filters and CE Compliance

The direction of influence is bi-directional, i.e. there is a reaction in the units of emission of conducted disturbances, and, at the same time, an improvement in the immunity of the drive to interference that occurs in the case of lightning strikes, tripped fuses, or simple switching activities.

• The filter should be mounted to a grounded conductive surface.

• The filter must be mounted close to the drive input terminals. If the distance

exceeds 2 feet (600 mm), then a shielded cable should be used to connect the drive and filter, rather than a wire.

• The wires connecting the AC source to the filter should be shielded from, or at

least separated from the wires (or strap) connecting the drive to the filter. If the connections are not segregated from each other, then the EMI on the drive side of the filter can couple over to the source side of the filter, thereby reducing, or eliminating the filter effectiveness. The coupling mechanism can be radiation, or stray capacitance between the wires.

Figure 4-12: Block Diagram Simplified for 3-Phase Line Filter

72 Kollmorgen - June 2014

Line Reactor

(if necessary)

Power

Unit

1L1

1L2

1L3

Main

Contactor

LINE FILTER

2L1

2L2

2L3

L3L2

1U1

1V1 1W1

SCPD

MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

Figure 4-13: Connection Diagram for 3-Phase Line Filter

WARNING

High leakage currents exist in AC line filters. The filters must be grounded properly before applying power. Filter capacitors retain high voltages after removal. Measure voltages to determine safe levels prior to handling the equipment. Failure to do so could result in severe bodily injury.

NOTE

To be able to route the interference currents at low impedance back to the interference sources, the filter, the power unit, and the contact area of the motor cable shield must have a junction with the common mounting plate over as wide a surface as possible that has good conductive properties. The best way to ensure this is to use unpainted zinc-coated mounting plates.

Table 4-16: Part Numbers for AC Line Filters

Part

Number

M.1015.6922

6A, 250V, 1 Phase

Current For Drive

Single Phase Versions of: MMC-SD-0.5-230

MMC-SD-1.0-230

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Table 4-16: Part Numbers for AC Line Filters

Current For Drive

Single Phase Versions of:

10A, 250V, 1 Phase

16A, 480V, 3 Phase

7A, 480V, 3 Phase

16A, 480V, 3 Phase

30A, 480V, 3 Phase

42A, 480V, 3 Phase MMC-SD-24.0-460 M.1302.5246

56A, 480V, 3 Phase

MMC-SD-2.0-230 MMC-SD-3.0-230

Three Phase Versions of: MMC-SD-0.5-230

MMC-SD-1.0-230 MMC-SD-2.0-230 MMC-SD-3.0-230

MMC-SD-1.3-460 MMC-SD-2.4-460

MMC-SD-4.0-460 MMC-SD-6.0-460 MMC-SD-8.0-460

MMC-SD-12.0-460 MMC-SD-16.0-460

MMC-SD-30.0-460 MMC-SD-42.0-460

Part

Number

M.1015.6917

M.1302.5244

M.1302.5241

M.1302.5244

M.1302.5245

M.1302.5247

75A, 480V, 3 Phase MMC-SD-51.0-460 M.1302.5248 100A, 480V, 3 Phase MMC-SD-65.0-460 M.3000.0109

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Table 4-17: Technical Data for 230V Line Filters

M.1015.6922 M.1015.6917 M.1015.6918

Voltage/Freq. 250VAC @ 50/50Hz 250VAC @ 50/50Hz 250VAC @ 50/50Hz Current 6A @ 50°C 10A @ 50°C 23A @ 50°C

Overload Current

150% 1 minute 200% 1 second

Temperature -25 to 95°C -25 to 95°C -25 to 95°C

Leakage Current 5mA @ 240V, 50 Hz

46mA @ 240V, 50 Hz200mA @ 250V,

50Hz Electric Strength 2500VAC/1 minute 2500VAC/1 minute 2500VAC/1 minute Power Loss 3.5W (Full Load) 2.7W (Full Load) 10W (Full Load)

Terminals

2mm sq. spring clamp

M4 screw cross/ sq. 2x 2.5mm

M4 screw cross/ sq.

2x 2.5mm Weight 0.3Kg (0.66 Lb.) 0.95Kg (2.0 Lb) 1.6Kg (2.5 Lb)

Back Mounting

Side Mounting

4 x M4 4 x M4 4 x M4

2 x M5 2 x M6 2 x M6

a. Line filters are manufactured to millimeter dimensions (inches are approximate con-

versions).

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Table 4-18: Technical Data for 460V Line Filters

Part Number

Item

Maximum Supply Voltage

Rated current (at 40°C)

Peak current

Test Voltage Phase/Phase Phase/Ground

Maximum Connection Crosssection

Operational Environmental Temperature Range T

Power Loss (typical)

M.1302. 5241

7A 16A 30A 42A 56A 75A 100A

4mm

4W 8W 12W 15W 18W 24W 24W

M.1302. 5244

4mm

Reduction of rated current from 40°C onwards by 1.4% / °C

M.1302. 5245

1.5 x IN for < 1 min. per hour at TB = 40°

2.1 kVDC for 2 sec. at 25°C

2.7 kVDC for 2 sec. at 25°C

10mm

M.1302. 5246

3 x 480VAC, 50/60Hz

10mm

-25°C ... +55°C

M.1302. 5247

4mm

M.1302. 5248

25mm

M.3000. 0109

50mm

Site Altitude Below 2000 m above sea level (higher altitudes on request) Storage Tem-

perature Range

Type of Protection

Weight 0.6kg 1.0kg 1.3kg 1.6kg 1.9kg 2.6kg 4.0kg

-25°C ... +85°C

IP20

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MMC Smart Drive Hardware Manual - SYSTEM POWER DEVICES

NOTE: Spring c lips rep lace Terminal screws on 6 Amp F ilter (P/N 401-30222-00)

4.6.2 Dimensions for 230V Line Filters

MEASUREMENT mm in mm in mm in

SINGLE PHASE

M.1015.6922

SINGLE PHASE

10A

M.1015.6917

SINGLE PHASE

23A

M.1015.6918

A 170 6.7 214 8.4 214 8.4 A1 152 6.0 192 7.6 192 7.6 A2 9 0.4 11 0.4 11 0.4

B 92 3.6 145 5.7 204 8.0 B1 55 2.2 104 4.1 164 6.6 B2 18 0.7 20 0.8 20 0.8

C 25 1.0 40 1.6 47 1.8 C1 10 0.4 16 0.6 19 0.8

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4.6.3 Dimensions for 460V Line Filters

Part

Number

M.1302.5241 190 40 70 20 180 160 185

M.1302.5245 270 50 85 30 255 240 265 M.1302.5246 310 50 85 30 295 280 305

M.1302.5248 270 80 135 60 255 240 278 6.5

M.3000.0190 270 90 150 65 255 240 326 6.5

A B C D E F L G H

5.4

M5M.1302.5244 250 50 70 25 235 220 245

M6M.1302.5247 250 85 90 60 235 220 258

M1 0

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MMC Smart Drive Hardware Manual - 230V 3 PHASE MMC SMART DRIVE NEXTGEN

5 230V 3 Phase MMC Smart Drive NextGen

The 230V Smart Drive NextGen (the Drive) is an AC Servo Drive capable of driving a wide range of Brush-type and Brushless DC motors.

The Drives’ Power Section features the following:

• May be connected to a wide range of Mains power:

• 100-240VAC, 50/60Hz, 1 or 3 phase

• Built-in regen resistor (12A and 24A models only)

• Supports external regen resistors if required by application

• Brake Output (this can also be used as a General Purpose Output)

• Supports DC bus sharing

• Safe Torque Off capability

The Drive’s Control Section features the following:

• Connects to Kollmorgen’s Digital Link bus

• Two-digit error/status display

• A primary feedback connector (F1), containing the following features:

• High density female DB-15 connector

• Supports the following feedback devices:

• Incremental Encoder (without halls)

• Stegmann Hiperface encoder

• High Resolution Resolver

• 1V p-p Sinewave Encoder

• Endat 2.1 (2.2 in future release)

• BiSS (Mode B)

• SFD (Smart Feedback Device). Note: An SFD can be connected to F1 or

F2, not both

• A secondary feedback connector (F2), containing the following features:

• High density female DB-15 connector

• This connector can support one of the following functions:

• Emulated F1 encoder output

• Comcoder Input (Incremental Encoder with halls)

• SFD Input (Smart Feedback Device). Note: An SFD can be connected to

F1 or F2, not both.

• I/O connectors, containing the following features:

• Two pluggable 10-pin screw-terminal connectors

• Two Fast DC Inputs (sink or source in group of two)

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MMC Smart Drive Hardware Manual - 230V 3 PHASE MMC SMART DRIVE NEXTGEN

• Six General Purpose DC Inputs (sink or source in group of six)

• Two General Purpose DC Outputs (sourcing)

• Analog Input

• Analog Output

• Relay Output

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MMC Smart Drive Hardware Manual - 230V 3 PHASE MMC SMART DRIVE NEXTGEN

1 1

10 10

+24V

COM

-BR

+BR

+Ri

-RB

-DC

+RB

I O

I N

O T O

R E

G E N

W R

CAUTION Ris k of E lec tr ic al Sho ck

High volt age may exist up to 5 minutes after removing power

REGEN and AC PWR functions are combined into one connector on the 3A, 6A, and 12A Drives

Grounding Block not present on 3A, 6A, and 12A Drives

Figure 5-1: Front Panel, SDN Drives

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MMC Smart Drive Hardware Manual - 230V 3 PHASE MMC SMART DRIVE NEXTGEN

(10s)

(1s)

5.1 Control Section Connectors, Switches, LEDs

This section describes the connectors, switches, and LEDs located on the Control Section (right portion) of the drive.

5.1.1 Status Display

The St atus Display is located on the top-front of the drive, and consists of two 7segment displays. The Status Display will indicate the Drive’s current operating condition, including error codes. Refer to the PiCPro Help for the description of the various display conditions.

5.1.2 Node Address Rotary Switches

Two rot ary switches are used to set the drive addre ss. Rotate the switch to th e desired address.

Addresses can be set to any number from 1 through 64. The top switch (S1) represents values of base ten. The bottom switch (S2) represents values of base 1.

As an example, rotating S1 to a setting of 2 equals the value of 20 (2 x 10). Rotating S2 to a setting of 5 equals the value of 5. The actual address setting is 25 (20 + 5).

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5.1.3 Digital Link Ports

The two 8-pin RJ-45 Digital Link Port connectors (labeled “IN” and “OUT” on the front of the Drive) provide communications between the Drive and other Digital Link devices (another Digital Drive, a Standalone MMC Digital Control, Slice I/O Coupler, DL-DIU, etc.). There is a green "Link" light located in the uppe r -rig h t corne r of each connector. If this light is on, another Digital Link device is properly connected to the associated "IN" or "OUT" port.

A “straight-through” shielded cable must be used when connecting the Drive to other Digital Link devices. Connect a cable from another Digital Link device’s "OUT" port to the Drive’s “IN” port, and another cable from the Drive’s “OUT” port to the nex t Di gital Link device’s "IN" port.

• Pin descriptions for are provided in Table 5-1

• Pin assignments are provided in Table 5-2

• The available Digital Link Port to Digital Drive cables are described in Table 5-3

Table 5-1: Digital Link Port Pin Description

Digital Link Connector (IN/OUT)

Signals

Function Notes

Receive Data +

Receive Data -

Transmit Data +

Transmit Data -

Protective Ground

Receives data from connected drives.

Transmits data to connected drives.

Provides a path for the ground signal to an external single point ground.

“In” Connector

1 3

2 6

3 1

6 2

Connector Shell

“Out” Connector

Connector Shell

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“IN”

LINK

LED

“OUT”

LINK LED

Table 5-2: Digital Link Port Pin Assignments

Pin Label In/Out Connector Pinout IN Connector

1 Receive + In 2 Receive - In 3 Transmit + Out 4 Not Used N/A 5 Not Used N/A 6 Transmit - Out 7 Not Used N/A 8 Not Used N/A

Connector Shield

Provides a path for the ground signal to an external single point ground.

RJ-45 Connectors

OUT Connector

1 Transmit + Out 2 Transmit - Out 3 Receive + In 4 Not Used N/A 5 Not Used N/A 6 Receive - In 7 Not Used N/A 8 Not Used N/A

Provides a path for the Connector Shield

ground signal to an ex-

ternal single point

ground.

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Table 5-3: Digital Link Port “IN” to “OUT” Cables

Part Numbers: .3 M (1.0 ft): M.1302.8285 .6 M (2.0 ft): M.1302.8286 1 M (3.3 ft): M.1302.8287 2 M (6.6 ft): M.1302.8288 3 M (9.8 ft): M.1302.8289 5 M (16.4 ft): M.1302.8300 10 M (32.8 ft): M.1302.8301 15 M (49.2 ft): M.1302.8 302 30 M (98.4 ft): M.1302.8 303

Cable type: 28 AWG, shielded, twisted pair, 8 conduc to r.

8-Pin RJ-45 Plug (to Digital Link Port “OUT”, face view)

8-Pin RJ-45 Plug (to Digital

Drive “IN”, face view)

Pin Signal Pin Signal Notes

1 Transmit Data + 1 Receive Data + Twisted 2 Transmit Data - 2 Receive Data - Pair 3 Receive Data + 3 Transmit Data + Twisted 6 Receive Data - 6 Transmit Data - Pair 4 None 4 None Twisted 5 None 5 None Pair 7 None 7 None Twisted 8 None 8 None Pair Shell Drain Shell Drain

5.1.4 Feedback Connectors (F1 & F2)

The two 15-pin female Feedback connectors (labeled “F1” an d “F2” on th e front of the Drive) provide an interface between two feedback devices. A detailed description of the capabilities and limitations of connected devices can be found in section 5.1.4.1

on page 90.

• Pin descriptions for the F1 connector are provided in Table 5-4

• Pin assignments for the F1 connector are provided in Table 5-5

• Pin descriptions for the F2 connector are provided in Table 5-6

• Pin assignments for the F2 connector are provided in Table 5-7

• The available Flying Lead cable is described in Table 5-9.

• Available Breakout Boxes and Cables are described in Table 5-10.

• Breakout Box dimensions are shown in Figure 5-2

• Breakout Board dimensions are shown in Figure 5-3

• Feedback Port to Motor Cables are described in section 5.1.4.2 on page 95

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Table 5-4: Pin Description for Feedback Connector (F1)

F1 Feedback Signals

Signal Type Signal Name Notes Pin Incremental Encoder

Inputs Sinewave Encoder In-

puts

Sinewave Encoder Data Channel In/Out

SFD Communication Channel

Resolver Inputs Sin+, Sin-, Cos+, Cos-

Resolver Outputs Carrier+, Carrier-

Temperature Input Temperature

A1, A1/, B1, B1/, I1, I1/

Sin, Sin/, Cos, Cos/ Sinewave Encoder signals 12, 13, 14, 15

RS-485 Data +, RS-485 Data -, RS-485 Clock+, RS-485 Clock-

Com+, Com-

Differential A quad B encoder signals.

RS-485 signals for connecting the Sinewave Encoder Data Channel to the drive

SFD communication signals. An SFD can be connected to F1 or F2, not both

Resolver stator feedback signals

Resolver rotor excitation signals.

Thermostat (normally- closed) or Thermistor (Phillips KTY84130 PTC or equivalent recommended) input for detecting over temperature conditions within the motor. These inputs are shared with F2.

12, 13, 14, 15, 6, 7

6, 7, 2, 3

6, 7

12, 13, 14, 15

6, 7

8, 9

+5V Encoder Power Outputs

+5V Encoder Power Sense Lines

Signal and Power Common

Some Encoders, specifically the Stegmann Hiperface, require 8VDC power to operate. 8VDC Power can be provided on pins 10 and 11 by connecting the +5V Sense Lines (pins 4 & 5) together.

86 Kollmorgen - June 2014

+5V Source

+5V Sense+, +5V Sense-

Common

PROVIDING 8VDC ENCODER POWER

Regulated +5VDC for powering the attached encoder (350ma max).

These signals should be tied to the +5V power and ground lines at the encoder.

Return path for feedback signals and +5V power output

4, 5

MMC Smart Drive Hardware Manual - 230V 3 PHASE MMC SMART DRIVE NEXTGEN

Table 5-5: Pin Assignments for Feedback Connector (F1)

Feedback Device

Sinewave

Encoder

Digital Incremental

1 N/U (Not Used)

Encoder

Hiper-

face

Endat

BISS

1V p-p Sine

Wave

SFD

Resolver

In/ Out

Connector Pinout

2 N/U

3 N/U

4 5 6 I1 RS-485 Data+ N/U Com+ Carrier+ 7 I1/ RS-485 Data- N/U Com- Carrier8 9 10 +5V Source 11 Common N/U In/Out 12 A1 Sine N/U Sine N/U Sin+ 13 A1/ Sine/ N/U Sine/ N/U Sin14 B1 Cos N/U Cos N/U Cos+ 15 B1/ Cos/ N/U Cos/ N/U CosShell Shield N/A

a. Supports BiSS Mode B (digital) b. An SFD can be connected to F1 or F2, not both c. Stegmann Hiperface d. Supports Endat 1.1 (Support for Endat 2.1 & 2.2 in future release)

+8V

RS-485

Clock+

RS-485

Clock-

+5V Sense+

+5V Sense-

Temperature+

+5V Source N/U Out

Temperature-

N/U

N/U N/U

Out

Note

15-pin

Female

HD D-Sub

e. Use of Sens e Lin es is optio nal , ex cep t if co nnecting to a Hiperface encoder (see footnote h, below) f. Pins 6 and 7 are In/O ut fo r H ipe rf ac e, Enda t, an d SFD; In pu ts for Digital Incremental and BiSS; and Ou t-

puts for Resolver g. Temperature inputs (pins 8 and 9) are shared with the F2 connector h. Hiperface requires +8Vdc. To supply +8V from pin 10, connect +5V Sense lines (pins 4 & 5) together.

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Table 5-6: Pin Description for Feedback Connector (F2)

Signal Type Signal Name Notes Pin Incremental

Encoder Inputs

Emulated F1 Encoder Output

Motor Commutation Hall Sensor Inputs

SFD Communication Channel

A1, A1/, B1, B1/, I1, I1/

S1, S2, S3

Com+, Com-

Differential A quad B encoder signals. These can be defined as inputs or outputs in PiCPro.

RS485 drivers are used and the signal that is output depends on the encoder or resolver type used. See specifications in sec-

tion 5.3 on page 111 of this

manual. These signals are generated after the feedback from the F1connector is filtered and processed. These can be defined as inputs or outputs in PiCPro.

Hall-device input signals that are used to initialize the motor commutation angle. They consist of a 74HC14 input with a 10s filter and a 2.2K pull-up to +5V. Shared with F1.

SFD communication signals. An SFD can be connected to F1 or F2, not both. An SFD Device can only be connected to F2 if emulated F1 encoder is not used (in which case emulated I and I/ are output on F2 pins 6 &

7).

12, 13, 14, 15, 6, 7

1, 2, 3

6, 7

Temperature Input

+5V Encoder Power Output

Signal and Power Common

88 Kollmorgen - June 2014

Temperature

+5V Source

Common

Thermostat (normally- closed) or Thermistor (Phillips KTY84130 PTC or equivalent recommended) input for detecting over temperature conditions within the motor. These inputs are shared with F1.

Regulated +5VDC for powering the attached encoder (200ma max).

Return path for feedback signals and +5V power output

8, 9

MMC Smart Drive Hardware Manual - 230V 3 PHASE MMC SMART DRIVE NEXTGEN

Table 5-7: Pin Assignments for Feedback Connector (F2)

Pin Signal Name In/Out Connector Pinout

1 S1 In 2 S2 In 3 S3 In 4 N/U 5 N/U

Com+ (SFD

)

In/Out

I2/ (Encoder)

I2 (Encoder)

Com- (SFD

)

In/Out

8 Temperature+ In 9 Temperature- N/A 10 +5V Out 11 0V Out

12 A2

13 A2/

14 B2

15 B2/

In/Out

Shell Shield In

15-pin Female

HD D-Sub

a. An SFD can be connected to F1 or F2, not both. An SFD Device can only

be connected to F2 if emulated F1 encoder is not used (in which case emulated I and I/ are output on F2 pins 6 & 7).

b. This pin is an Input when F2 is configured for Encoder Input, an Output

when F2 is configured for Emulated Encoder Output, and an Input/Output when F2 is configured for SFD.

c. This pin is an Input when F2 is configured for Encoder Inpu t, and an Output

when F2 is configured for Emulated Encoder Output.

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5.1.4.1 Feedback Connectors (F1 and F2) Details

The F1 and F2 Feedback connectors support a variety of devices and functions. This section helps clarify the capabilities and limitations of connected devices.

• The Temperature Inputs are bussed internally between the two feedback connec-

tors F1 and F2. A temperature sensing device can be connected to F1 or F2, but not both.

• Either F1 or F2 can be designated (in PiCPro) as the motor feedback connector.

• F1 can be interfaced to an incremental encoder, sinewave encoder, resolver, or

SFD encoder. The signals from the F1 connector are conditioned and can be routed to the F2 connector.

• In PiCPro, the F2 connector can be configured in one of the following modes:

• To accept Encoder Inputs

• To provide conditioned Emulated Encoder Outputs derived from the F1

encoder signals

• To accept SFD feedback device signals

• Hall sensor inputs are only available on the F2 connector

• Refer to Table 5-8 for more information regarding the valid combinations of feed-

back on the F1 and F2 connectors.

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MMC Smart Drive Hardware Manual - 230V 3 PHASE MMC SMART DRIVE NEXTGEN

Table 5-8: Supported Feedback Combinations

Drive Feedback Configuration 1 and 4 (in PiCPro Drive Setup)

F1 (Motor mounted feedback

device for motor control)

F2 (Externally mounted

feedback device for position

feedback)

•Incremental Encoder

•Resolver

•1V p-p Sinewave Encoder

•Endat 2.1 (single or multi-turn)

•Stegmann Hiperface (single or multi-

turn)

•Incremental Encoder

•BiSS (single or multi-turn)

•SFD

Drive Feedback Configuration 2 and 3 (in PiCPro Drive Setup)

F1 (Externally mounted

feedback device for position

feedback)

•Incremental Encoder

F2 (Motor mounted feedback

device for motor control)

•Resolver

•1V p-p Sinewave Encoder

•Endat 2.1 (single or multi-turn)

•Stegmann Hiperface (single or multi-

turn)

•Incremental Encoder with halls

(Comcoder)

•SFD

•BiSS (single or multi-turn)

a. The F2 connector can support an Encoder input or Emulated F1 Encoder Output,

but not both

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Table 5-9: Feedback Port (F1 and F2) to Flying Lead Cable

1 M (3.3 ft): M.3000.1334 3 M (9.8 ft): M.3000.1335 6 M (19.7 ft): M.3000.1336 9 M (29.5 ft): M.3000.1337

Cable type: 28 AWG, (1 pair 16 AWG) shielded, twisted pair, 16 conductor.

15-Pin HD male D-sub (to F1/F2 Port, face view)

Pin Signal Color Notes

Yellow Twisted N/C N/A White/Yellow Pair 2

S2a, RS-485 Clock+

S3a, RS-485 Clock-

Brown Twisted

White/Brown Pair 4 +5V Sense+ Violet Twisted

5 +5V Sense- White/Violet Pair 6 RS-485 Data+, Com+, Carrier+ Black Twisted 7 RS-485 Data-, Com-, Carrier- White/Black Pair 8 Temperature+ Red Twisted 9 Temperature- White/Red Pair 10 +5V Source Gray Twisted

11 Common White/Gray

Pair

12 Sine/Sin+ Green Twisted

92 Kollmorgen - June 2014

13 Sine/, Sin- White/Green Pair 14 Cos, Cos+ Orange Twisted 15 Cos/, Cos- White/Orange Pair Shell Shield N/A

a. Hall signals S1, S2, an d S3 are on ly ava ila ble on F2 b. Pins 10 & 11 are 16 AWG

MMC Smart Drive Hardware Manual - 230V 3 PHASE MMC SMART DRIVE NEXTGEN

Table 5-10: Feedback Ports (F1 and F2) Breakout Box and Cables

Description Length Part Number

Drive F1/F2 Port Breakout Board

Drive F1/F2 Port Breakout Box

N/A M.1302.6970

N/A M.1302.6972 1 M (3.3 ft) M.3000.1330

MMC-SDN F1/F2 Port to Breakout Box Cable

3 M (9.8 ft) M.3000.1331 6 M (19.7 ft) M.3000.1332 9 M (29.5 ft) M.3000.1333

a. The Breakout Board (see Figure 5-3 on page 94) is mounted directly to the F1

and/or F2 connector, and provides screw terminal wire termination. Any combination of breakout board and feedback cable can be used on F1/F2, except a feedback cable on F1 and a breakout board on F2.

b. The Breakout Box (see Figure 5-2 on page 94) is DIN-rail mounted, and provides

screw terminal wire termination. Use one of the cables listed in the table to connect between the F1 and/or F2 connecto r an d the Bre ak ou t Box.

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Figure 5-2: Feedback Port (F1 and F2) Breakout Box Dimensions

Figure 5-3: Feedback Port (F1 and F2) Breakout Board Dimensions

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MMC Smart Drive Hardware Manual - 230V 3 PHASE MMC SMART DRIVE NEXTGEN

5.1.4.2 Feedback Port (F1/F2) to Motor Cables

Cables are available that allow easy connection between the F1 & F2 Feedback Port s and various Kollmorgen motors. These cables are outlined in Table 5-11. The wiring diagram for each cable is located in the indicated Table. For information on Non-Fle x

versus Hi-Flex cables, refer to section 10.1 on page 305.

Table 5-11: F1/F2 to AKM/DDR Motor Cables

Feedback Non-Flex P/N Hi-Flex P/N Wiring Diagram

Incremental Encoder

Endat/BiSS

Resolver

SFD VF-DA474N-XX CF-DA0374N-XX-0 Table 5-15 on page 99

a. "XX" in the above table denotes the length of the cable, in meters. Standard

"XX" values are 01, 03, 06, 09, and 12. Hi-Flex cables are available in additional lengths. Consult Kollmorgen for more information.

b. Feedback type not available on F2

Not Available CF-CB7374N-XX-0 Table 5-12 on page 96

VF-SB4474N-XX CF-SB7374N-XX-0 Table 5-13 on page 97

VF-RA2474N-XX CF-RA2574N-XX-0 Table 5-14 on page 98

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MMC Smart Drive Hardware Manual - 230V 3 PHASE MMC SMART DRIVE NEXTGEN

Table 5-12: Feedback Port (F1/F2) Encoder to AKM/DDR Motor

For Part Numbers, Table 5-11 on page 95

D-sub 15-Pin HD Male

Connector to MMC Smart

Connector to Motor

Drive

Twisted

Pair

24 AWG

(Except as

noted)

Wire

Color

Yellow 12 A 3 A

Yellow/Black 13 A/ 4 A/

Brown 14 B 1 B

Brown/Black 15 B/ 2 B/

Orange 6 I 5 I

Orange/Black 7 I/ 6 I/

Green 1

Black 2 White 3

Blue 8 Temperature+ 8 Temperature+

Number

Signal Type

Number

15 S1 16 S2 17 S3

Signal Type

Blue/Black 9 Temperature- 9 Temperature-

Grey 4 +5V Sense+

Grey/Black 5 +5V Sense-

Red

Inner Braid

Outer Braid Shell Shield Shell Shield

N/C N/A 11-14 N/C

a. Only applicable to F2 connector b. There are two wires in pin10 c. There are two wires in pin 7 d. This wire is 22 AWG

96 Kollmorgen - June 2014

10 +5 VDC 11 COM

+5V Sense+

+5V Sense-

+5 VDC

COM

MMC Smart Drive Hardware Manual - 230V 3 PHASE MMC SMART DRIVE NEXTGEN

Table 5-13: Feedback Port (F1) Endat/BiSS to AKM/DDR Motor

For Part Numbers, Table 5-11 on page 95

D-sub 15-Pin HD Male

Connector to MMC Smart

Connector to Motor

Drive

Twisted Pair

28 AWG

(Except as

noted)

Wire Color

Number

Signal Type

Green 12 Sine 11 Sine

White/Green 13 Sine/ 3 Sine/

Blue 14 Cos 9 Cos

White/Blue 15 Cos/ 1 Cos/

Red 6 RS-485 Data+ 5 RS-485 Data+

White/Red 7 RS-485 Data- 13 RS-485 Data-

Black 2 RS-485 Clock+ 8 RS-485 Clock+

Number

Signal Type

White/Black 3 RS-485 Clock- 15 RS-485 Clock-

Yellow 8 Temperature+ 7 Temperature+

White/Yellow 9 Temperature- 14 Temperature-

Orange

White/Orange

Grey

White/Grey

4 +5V Sense+

5 +5V Sense-

10 +5 VDC

11 COM

+5V Sense+

+5V Sense-

+5 VDC

COM

Outer Braid Shell Shield Shell Shield

N/A N/A N/A 6,10,12,16,17 N/C N/A 1 N/C N/A N/A

a. This wire is 22 AWG b. There are two wires in pin 4 c. There are two wires in pin 2 d. This wire is 16 AWG

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Table 5-14: Feedback Port (F1) Resolver to AKM/DDR Motor

For Part Numbers, Table 5-11 on page 95

D-sub 15-Pin HD Male

Connector to MMC Smart

Drive

Connector to Motor

Twisted Pair

28 AWG

Wire Color

Yellow 12 Sin+ 8 Sin+

White/Yellow 13 Sin- 4 Sin-

Blue 14 Cos 7 Cos

White/Blue 15 Cos- 3 Cos-

Black 6 Carrier+ 9 Carrier+

White/Black 7 Carrier- 5 Carrier-

Red 8 Temperature+ 2 Temperature+

Number

Signal Type

Number

Signal Type

White/Red 9 Temperature- 6 Temperature-

Outer Braid Shell Shield Shell Shield

N/A N/A N/A 1,10-12 N/C N/A 1-5,10,11 N/C N/A N/A

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Kollmorgen MMC-SD-6.0-460, MMC-SD-1.3-460, MMC-SD-2.4-460, MMC-SD-4.0-460, MMC-SD-8.0-460 Hardware Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

1 Introduction to the MMC Smart Drive

1.1 Overview

1.2 Contents of This Manual

1.3 Software and Manuals

1.3.1 Required Software and Manuals

1.3.2 Suggested Manuals

1.4 Kollmorgen Support Contact

2 Safety Precautions

2.1 System Safety

2.1.1 User Responsibility

2.1.2 Safety Instructions

2.2 Safety Signs

2.3 Warning Labels

2.4 Safety First

2.5 Safety Inspection

2.5.1 Before Starting System

2.6 After Shutdown

2.7 Operating Safely

2.8 Electrical Service & Maintenance Safety

2.9 Safe Cleaning Practices

3 Installing the MMC Smart Drive

3.1 Storing the Smart Drive Before Installation

3.2 Unpacking the Smart Drive

3.3 Handling an MMC Smart Drive

3.4 Inspecting the Smart Drive Before Installation

3.5 Complying with European Directives

3.6 Conforming with UL and cUL Standards

3.7 General Installation and Ventilation Requirements

3.8 Controlling Heat Within the System

3.9 Bonding

3.9.1 Bonding a Subpanel Using a Stud

3.9.2 Bonding a Ground Bus Using a Stud

3.9.3 Bonding a Ground Bus or Chassis Using a Bolt

3.9.4 Grounding Multiple Drive Cabinets

3.9.5 Bonding Multiple Subpanels

3.10 Drive Mounting Guidelines

3.1 1 Drive System Grounding Procedures

3.11.2 Grounding Multiple Drives in the Same Cabinet

3.12 System Wiring Guidelines

3.12.1 Recommended Signal Separation

3.12.2 Building Your Own Cables

3.12.3 Routing Cables

3.13 Wiring the Drive

3.13.1 Sizing the 24V Power Supply

3.13.2 System AC Power Wiring Guidelines

3.13.3 Connecting Interface Cables

3.13.4 Preparing Motor Connection Wires

4 System Power Devices

4.1 AC Input Power Requirements

4.2 Protection

4.2.1 Motor Overload Protection

4.2.2 Motor Thermal Protection

4.2.3 24VDC Input Power Protection (460V SD Only)

4.2.4 S200-DLS Drive Protection Requirements

4.2.5 230V Smart Drive (SD) Protection Requirements

4.2.6 460V Smart Drive (SD & SDN) Protection Requirements

4.3 Line Reactors

4.3.1 Specifications and Dimensions for Required Line Reactors Table 4-7: MMC-SD-12-460 Line Reactor Specifications

4.4 Isolation Transformers

4.5 External Shunts

4.5.1 Choosing External Shunts

4.5.2 Mounting External Shunts

4.5.3 Connecting Shunt Modules

4.5.3.1 230V, 1-Phase MMC Smart Drive Shunt Wiring

4.5.3.2 460V, 3-Phase MMC Smart Drive (-SD) Shunt Wiring

4.6 Line Filters

4.6.1 Line Filters and CE Compliance

4.6.2 Dimensions for 230V Line Filters

4.6.3 Dimensions for 460V Line Filters

5 230V 3 Phase MMC Smart Drive NextGen

5.1 Control Section Connectors, Switches, LEDs

5.1.1 Status Display

5.1.2 Node Address Rotary Switches

5.1.3 Digital Link Ports

5.1.4 Feedback Connectors (F1 & F2)