Kollmorgen S772, S748, S700 Instruction Manual

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Page 1

S700

Digital Servo Amplifier S748…S772

Instruction Manual

Edition 11/2018 Translation of the original instruction manual. Valid for Hardware Revision 02.30

For safe and proper use, follow these instructions. Keep them for future reference.

File s748_e.***

Page 2

Record of Document Revisions:

Revision Remarks

07/2009 First edition 09/2009 Repair, disposal, standards, directives, GOST-R 11/2009 Safety expansion cards S1/S2, UL listed, FAN option card F2

Part number scheme, safety approved, emergency Stop examples moved to WIKI, S1/S2 cards updated,

09/2011

06/2012 Expansion card FB-2to1 new, Stop/Emergency Stop/Emergency Off updated

07/2013

08/2013 Correction S2-2 (S4) safety card (SLP not possible) 11/2013 Hint automatic restart, fault table, switch off behaviour in case of faults, VBUSBAL=4 05/2014 Warning symbols updated, SSI emulation timing updated, safe to touch voltage 40V->60V 07/2014 Wiring thermo sensor updated (Feedback)

12/2014

02/2015 EAC certification, nameplate with EAC sign, coldplate version new

12/2015

02/2017

11/2018

new DriveGUI icon, bridge DGND-GND (dig-I/O) changed, notes holding brake, climatic classes, WIKI links updated, 2CAN module, company name&address, encoder emulation X1, BiSS-C

Feedback - ENCVON note, FBTYPE 34, CE declaration of conformity, formal improvements, BiSS C Renishaw, according to IEC 82079, safety cards S1/S2 replaced by S3/S4, diagram "Behavior in the event of an error" updated.

Note drive feedback restrictions with Safety Cards, CE declaration of conformity removed, GOST-R removed, Safety certificates removed, HWR, export classification

Functional Safety certification expanded, safety chapter typo: discharge time corrected, fax form removed, use as directed extended, safe to touch voltage 60V->50V, fuse FB1/2 to 100A, LVD 2014/35/EC, EMCD 2014/30/EC X6 Pin 1 corrected (no 5V output), warning notes, handling separate chapter, single cable connection new, SFD3/Hiperface DSL new

Connector X1 corrected (male->female), HR table updated, layout of the warning notes updated, user

expertise updated, new readers note on cover page, Wiki replaced by KDN

Hardware Revision (HR)

Hardware Revi-

sion

01.01 5.00 - 5.17 AL-3A225 Starting version (STO and Safety pending)

02.10 5.18 - 5.99 AL-3A225 STO and Safety Cards S1/S2 approved

02.20 5.18_ND0 - 5.99_ND0 - New data structure

02.30

WINDOWS is a registered trademark of Microsoft Corporation HIPERFACE is a registered trademark of Max Stegmann GmbH SERCOS is a registered trademark of sercos EnDat is a registered trademark of Dr.Johannes Heidenhain GmbH EtherCAT is a registered trademark and patented technology, licensed by Beckhoff Automation GmbH

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

All rights reserved. No part of this work may be reproduced in any form (by photocopying, microfilm or any other method) or stored, processed, copied or distributed by electronic means without the written permission of Kollmorgen Europe GmbH.

usable

Firmware

Revision

³ 6.00_ND0

Export

Classification

- SFD3/DSL support

international e.V.

Remarks

Page 3

Kollmorgen 11/2018 Contents

Page

1 General

1.1 About this manual................................................................7

1.2 Hints for the online edition (PDF format) ..............................................7

1.3 Symbols used ...................................................................8

1.4 Standards used..................................................................9

1.5 Abbreviations used ..............................................................10

2 Safety

2.1 You should pay attention to this ....................................................11

2.2 Use as directed.................................................................13

2.3 Prohibited use..................................................................14

2.4 Warning notes placed on the product................................................14

3 Handling

3.1 Transport .....................................................................15

3.2 Packaging.....................................................................15

3.3 Storage .......................................................................15

3.4 Decommissioning ...............................................................16

3.5 Maintenance and cleaning ........................................................16

3.6 Disassemble ...................................................................16

3.7 Repair ........................................................................17

3.8 Disposal ......................................................................17

4 Approvals

4.1 Conformance with UL............................................................18

4.2 CE conformance................................................................19

4.2.1 European Directives and Standards for the machine builder .........................19

4.2.2 Safety Conformance (STO) according to Machine Directive .........................20

4.3 EAC Conformance ..............................................................20

5 Package

5.1 Package supplied ...............................................................21

5.2 Nameplate ....................................................................21

5.3 Part number scheme ............................................................22

6 Technical description

6.1 The S748/772 family of digital servo amplifiers ........................................23

6.2 Technical data .................................................................26

6.2.1 Rated Data ...............................................................26

6.2.2 Inputs / outputs, aux. voltage supply............................................27

6.2.3 Connectors/Terminals .......................................................27

6.2.4 Recommended tightening torques .............................................27

6.2.5 Fusing ...................................................................28

6.2.6 Ambient conditions, ventilation, mounting position .................................28

6.2.7 Conductor cross-sections ....................................................29

6.3 LED display....................................................................29

6.4 Grounding system ..............................................................29

6.5 Motor holding brake .............................................................30

6.6 Dynamic Braking ...............................................................31

6.7 Switch-on and switch-off behavior ..................................................32

6.7.1 Behavior in standard operation ................................................33

6.7.2 Behavior in the event of an error (with standard setting) ............................34

6.8 Stop-, Emergency Stop-, Emergency Off Function to IEC 60204 ..........................35

6.8.1 Stop .....................................................................35

6.8.2 Emergency Stop ...........................................................36

6.8.3 Emergency Off.............................................................36

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6.9 Safety Function STO ............................................................37

6.9.1 Safety characteristic data ....................................................37

6.9.2 Safety notes...............................................................38

6.9.3 Use as directed STO ........................................................39

6.9.4 Prohibited Use STO ........................................................39

6.9.5 Enlosure .................................................................39

6.9.6 Wiring ...................................................................39

6.9.7 Technical Data ............................................................39

6.9.8 Technical data and pinning ...................................................40

6.9.9 Functional description .......................................................41

6.9.10 Functional test .............................................................46

6.10 Shock-hazard protection..........................................................48

6.10.1 Leakage current ...........................................................48

6.10.2 Residual current protective device (RCD)........................................48

6.10.3 Isolating transformers .......................................................48

7 Mechanical Installation

7.1 Important notes.................................................................49

7.2 Guide to mechanical installation....................................................49

7.3 Dimensions....................................................................50

7.3.1 Device with heat sink........................................................50

7.3.2 Device with Coldplate .......................................................51

7.4 Assembly .....................................................................52

7.4.1 Mounting the shielding plate ..................................................52

7.4.2 Backplane mounting - devices with heat sink .....................................53

7.4.3 Backplane mounting - devices with Coldplate ....................................54

8 Electrical installation

8.1 Important notes.................................................................55

8.2 Guide to electrical installation......................................................56

8.3 Wiring ........................................................................57

8.3.1 Shielding connection to the front panel..........................................58

8.3.2 Technical data for connecting cables ...........................................59

8.4 Components of a servo system ....................................................60

8.5 Block diagram..................................................................61

8.6 Connector assignments ..........................................................62

8.7 Connection Diagram (Overview) ...................................................63

8.8 Electrical supply ................................................................64

8.8.1 Connection to various mains supply networks ....................................64

8.8.2 Mains supply connection (X0) .................................................65

8.8.3 24V auxiliary supply (X4).....................................................65

8.9 DC bus link (X8) ................................................................66

8.9.1 DC Bus topology ...........................................................67

8.9.2 External brake resistor (X8) ..................................................67

8.9.3 Capacitor Module KCM (X8) ..................................................68

8.10 Motor connection ...............................................................69

8.10.1 Motor Power Connection (X8).................................................69

8.10.2 Motor holding brake (X8, X9B) ................................................70

8.11 Feedback Systems ..............................................................70

8.12 Primary and secondary feedback types ..............................................71

8.12.1 SFD3 (X1), single cable connection ............................................72

8.12.2 HIPERFACE DSL (X1), single cable connection ..................................73

8.12.3 Resolver (X2) .............................................................74

8.12.4 Sine Encoder with BiSS analog (X1)............................................75

8.12.5 Sine Encoder with BiSS digital (X1) ............................................76

8.12.6 Sine Encoder with EnDat 2.1 (X1) .............................................77

8.12.7 Encoder with EnDat 2.2 (X1)..................................................78

8.12.8 Sine Encoder with HIPERFACE (X1) ...........................................79

8.12.9 Sine Encoder with SSI (X1)...................................................80

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8.12.10 Sine Encoder without data channel (X1).........................................81

8.12.11 Sine Encoder with Hall (X1) ..................................................82

8.12.12 ROD (AquadB) 5V, 1.5MHz (X1) ..............................................83

8.12.13 ROD (AquadB) 5V, 350kHz (X1)...............................................84

8.12.14 ROD (AquadB) 5V, 350kHz with Hall (X1) .......................................85

8.12.15 ROD (AquadB) 24V (X3).....................................................86

8.12.16 ROD (AquadB) 24V with Hall (X3, X1) ..........................................87

8.12.17 SSI Encoder (X1) ..........................................................88

8.12.18 Hall sensors (X1)...........................................................89

8.13 Electronic Gearing, Master-slave operation ...........................................90

8.13.1 Signal source..............................................................90

8.13.2 Connection to stepper motor controllers (step and direction) .........................91

8.13.3 Master-slave operation ......................................................92

8.14 Encoder Emulation, position output .................................................93

8.14.1 Incremental encoder output - A quad B (X1) .....................................93

8.14.2 SSI encoder output (X1) .....................................................94

8.15 Digital and analog inputs and outputs ...............................................95

8.15.1 Analog Inputs (X3B) ........................................................95

8.15.2 Digital Inputs (X3A, X3B, X4) .................................................96

8.15.3 Digital Outputs (X3A, X3B, X4) ................................................98

8.16 RS232 interface, PC connection (X6) ..............................................100

8.17 CANopen interface (X6) .........................................................101

8.18 EtherNET interface (X7) .........................................................102

8.19 Memory Card .................................................................103

9Setup

9.1 Important notes................................................................105

9.2 Setup software ................................................................106

9.2.1 Use as directed ...........................................................106

9.2.2 Software description .......................................................106

9.2.3 Hardware requirements, operating systems .....................................107

9.2.4 Installation under WINDOWS ................................................107

9.3 Quickstart ....................................................................108

9.3.1 Preparation ..............................................................108

9.3.2 Connect .................................................................110

9.3.3 Important Screen Elements..................................................111

9.3.4 Setup Wizard.............................................................112

9.3.5 Motion Service (Jog Mode) ..................................................115

9.3.6 More Setup Screens .......................................................116

9.4 Multi axis system ..............................................................117

9.5 Keypad operation / LED display ...................................................117

9.5.1 Keypad operation .........................................................118

9.5.2 Status display ............................................................118

9.5.3 Standard menu ...........................................................118

9.5.4 Advanced menu ..........................................................119

9.6 Error messages ...............................................................120

9.7 Warning messages.............................................................121

9.8 Trouble Shooting ..............................................................122

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Contents 11/2018 Kollmorgen

Page

10 Expansions

10.1 Expansion cards for slot 1 .......................................................123

10.1.1 Guide to installation of expansion cards in slot 1 .................................123

10.1.2 Expansion card -I/O-14/08- ..................................................124

10.1.3 Expansion card -PROFIBUS- ................................................127

10.1.4 Expansion card -SERCOS-..................................................128

10.1.5 Expansion card - DEVICENET - ..............................................130

10.1.6 Expansion card -SYNQNET-.................................................133

10.1.7 Expansion card - FB-2to1 - ..................................................135

10.1.8 Expansion module -2CAN- ..................................................137

10.2 Expansion cards for slot 2 .......................................................139

10.2.1 Guide to installation of expansion cards in slot 2 .................................139

10.2.2 Option "F2", controlled Fan ..................................................139

10.2.3 Expansion card "PosI/O" and "PosI/O-Monitor" ..................................140

10.3 Expansion cards for slot 3 .......................................................149

10.3.1 Guide to installation of expansion cards in slot 3 .................................149

10.3.2 Option "F2", controlled Fan ..................................................149

10.3.3 Expansion cards "PosI/O" & "PosI/O-Monitor" ...................................149

10.3.4 Expansion card "Safety 2-2" (S4) .............................................150

10.3.5 Expansion card "Safety 1-2" (S3) .............................................152

11 Appendix

11.1 Glossary .....................................................................155

11.2 Order codes ..................................................................157

11.2.1 Servo amplifiers...........................................................157

11.2.2 Memory Card.............................................................157

11.2.3 Expansion cards ..........................................................158

11.2.4 Mating connectors .........................................................158

11.3 Index ........................................................................160

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Kollmorgen 11/2018 General

1 General

1.1 About this manual

This manual describes the S748/772 series of digital servo amplifiers (standard version: 48A ...72A rated current). S701 to S724 amplifiers are described in an additional product manual.

A more detailed description of the expansion cards that are currently available and the digital connection to automation systems can be found, together with our application notes, in Acrobat-Reader format on the accompanying CD-ROM (system requirements: WINDOWS, Internet Browser, Acrobat Reader) in different languages.

Technical data and dimensional drawings of accessories such as cables, brake resistors, mains supplies, etc., can be found in the accessories manual.

This documentation (PDF) can be printed out on any standard commercial printer. A printed copy of the documentation is available from us at extra cost.

More background information can be found in our "Kollmorgen Developer Network"

kdn.kollmorgen.com

1.2 Hints for the online edition (PDF format)

Bookmarks:

Table of contents and index are active bookmarks.

Table of contents and index in the text:

The lines are active cross references. Click on the desired line and the appropriate page is accessed.

Page/chapter numbers in the text:

Page/chapter numbers with cross references are active. Click at the page/chapter number to reach the indicated target.

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General 11/2018 Kollmorgen

DANGER

WARNING

CAUTION

NOTICE

1.3 Symbols used

Symbol Indication

Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a hazardous situation which, if not avoided, could re sult in death or serious injury. Indicates a hazardous situation which, if not avoided, could re sult in minor or moderate injury. This is not a safety symbol. Indicates situations which, if not avoided, could result in property damage. This is not a safety symbol. This symbol indicates important notes.

Warning of a danger (general). The type of danger is specified by the warning text next to it.

Warning of danger from electricity and its effects.

Warning of danger from hot surfaces.

Warning of danger from suspended loads.

Warning of danger from automatic start.

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Kollmorgen 11/2018 General

1.4 Standards used

Standard Content

ISO 4762 Hexagon socket head cap screws ISO 13849 Safety of machinery: Safety-related parts of control systems ISO 12100 Safety of machinery: Basic concepts, general principles for design IEC 60085 Electrical insulation - Thermal evaluation and designation Maintenance IEC 60204 Safety of Machinery: Electrical equipment of machinery IEC 60364 Low-voltage electrical installations IEC 60439 Low-Voltage Switchgear and Controlgear Assemblies IEC 60529 Protection categories by housing (IP Code) IEC 60664 Insulation coordination for equipment within low-voltage systems IEC 60721 Classification of environmental conditions IEC 61000 Electromagnetic compatibility (EMC) IEC 61131 Programmable controllers

IEC 61491

IEC 61508

IEC 61800 Adjustable speed electrical power drive systems

IEC 62061

IEC 82079 Preparation of instructions for use - Structuring, content and presentation

UL 840

UL 508C UL Standard for Safety Power Conversion Equipment

Electrical equipment of industrial machines – Serial data link for real-time communications between controls and drives. Functional safety of electrical/electronic/programmable electronic safety-related systems

Functional safety of electrical/electronic/programmable electronic safety-related systems

UL Standard for Safety for Insulation Coordination Including Clearances and Creepage Distances for Electrical Equipment

IEC International Electrotechnical Commission UL Underwriters Laboratories ISO International Organization for Standardization

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General 11/2018 Kollmorgen

1.5 Abbreviations used

Abbrev. Meaning

AGND Analog ground xAF Fuse, x Amps, fast xAM Fuse, x Amps, medium xAT Fuse, x Amps, slow BTB/RTO Ready to operate CAN Fieldbus (CANopen) CE Communité Europeenne CLK Clock signal COM Serial interface for a Personal Computer DGND Digital ground (for 24V and digital I/O) Disk Magnetic storage (diskette, hard disk) EEPROM Electrically erasable programmable memory EMC Electromagnetic compatibility F-SMA Fiber Optic Cable connector according to IEC 60874-2 IGBT Insulated-gate bipolar transistor KDN Kollmorgen Developer Network LED Light-emitting diode MB Megabyte NI Zero pulse PC Personal computer PL Performance Level PLC Programmable logic control PWM Pulse-width modulation RAM Volatile memory R

Brake/RB

RBext External brake resistor RBint Internal brake resistor RES Resolver ROD Digital encoder (A quad B) SDI Safe direction SIL Safety Integrity Level SIL CL Safety Integrity Level Claim Limit SLI Safe limited increments SLP Safe limited position SLS Safe limited speed SOS Safe operating stop SS1 Safe stop 1 SS2 Safe stop 2 SSI Synchronous serial interface SSR Safe speed range STO Safe torque off (former AS) V AC Alternating voltage V DC DC voltage VDE Society of German Electrical Technicians

Brake resistor (sometimes called "regen resistor")

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Kollmorgen 11/2018 Safety

2 Safety

2.1 You should pay attention to this

Read the documentation!

Read the available documentation before installation and commissioning. Improper han

dling of the servo amplifiers can cause harm to people or damage to property. The opera tor must therefore ensure that all persons entrusted to work on the S748/772 have read and understood the manual and that the safety notices in this manual are observed.

Perform a risk assessment!

The manufacturer of the machine must generate a risk assessment for the machine, and take appropriate measures to ensure that unforeseen movements cannot cause injury or damage to any person or property. Additional requirements on specialist staff may also result from the risk assessment.

pecialist staff required!

Only properly qualified personnel are permitted to perform such tasks as transport, instal lation and setup. Qualified specialist staff are persons with expertise in transport, installa tion, assembly, commissioning and operation of electrotechnical equipment.

Transport, storage, unpacking: only by personnel with knowledge of handling electro statically sensitive components.

Mechanical installation: only by qualified personnel with mechanical expertise.

Electrical installation: only by qualified personnel with electrotechnical expertise.

Basic tests / setup: only by qualified personnel with expertise in electrical engineering

and drive technology. The qualified personnel must know and observe ISO 12100 / IEC 60364 / IEC 60664 and national accident prevention regulations.

Check the Hardware Revision!

Check the Hardware Revision Number of the product (see product label). This revision number must match the Hardware Revision Number on the cover page of the manual. If the numbers do not match up, visit the European File Archive (http://www.wiki-kollmorgen.eu

). The 'Download' section contains the various manual ver

sions based on the hardware version number.

Pay attention to the technical data!

Adhere to the technical data and the specifications on connection conditions (rating plate and documentation). If permissible voltage values or current values are exceeded, the servo amplifiers can be damaged. Unsuitable motor or wrong wiring will damage the sys tem components. Check the combination of drive and motor. Compare the rated voltage and current of the units.

Observe electrostatically sensitive components!

The servo amplifiers contain electrostatically sensitive components which may be dam

aged by incorrect handling. Discharge your body before touching the servo amplifier. Avoid contact with highly insulating materials (artificial fabrics, plastic film etc.). Place the servo amplifier on a conductive surface.

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Safety 11/2018 Kollmorgen

Automatic restart

The drive might restart automatically after power on, voltage dip or interruption of the sup ply voltage, depending on the parameter setting. Risk of death or serious injury for humans working in the machine. If the parameter AENA sign to the machine (Warning: Automatic Restart at Power On) and ensure, that power on is not possible, while humans are in a dangerous zone of the machine. In case of using an undervoltage protection device, you must observe EN 60204-1:2006 chapter 7.5.

Hot surface!

The surfaces of the servo amplifiers can be hot in operation. Risk of minor burns! The surface temperature can exceed 80°C. Measure the temperature, and wait until the motor has cooled down below 40°C before touching it.

Earthing!

It is vital that you ensure that the servo amplifiers are safely earthed to the PE (protective earth) busbar in the switch cabinet. Risk of electric shock. Without low-resistance earthing no personal protection can be guaranteed and there is a risk of death from elec tric shock.

Leakage Current!

Since the leakage current to PE is more than 3.5 mA, in compliance with IEC61800-5-1 the PE connection must either be doubled or a connecting cable with a cross-section >10 mm² must be used. Deviating measures according to regional standards might be possible.

is set to 1, then place a warning

High voltages!

The equipment produces high electric voltages up to 900V. During operation, servo amplifiers may have uncovered live sections, according to their level of enclosure protection. Capacitors can have dangerous voltages present up to ten minutes after switching off the supply power. There is a risk of death or severe injury from touching exposed contacts. Keep all covers and cabinet doors closed during operation. Touching the equipment is allowed during installation and commissioning for properly qualified persons only.

There is a danger of electrical arcing when disconnecting connectors, because capacitors can still have dangerous voltages present up to ten minutes after switching off the supply power. Risk of burns and blinding. Wait at least ten minutes after disconnecting the servo amplifiers from the main supply power before touching potentially live sections of the equipment (such as contacts) or removing any connections. Always measure the voltage in the DC bus link and wait until the voltage is below 50V before handling components.

Reinforced Insulation!

Thermal sensors, motor holding brakes and feedback systems built into the connected motor must have reinforced insulation (according to IEC61800-5-1) against system com ponents with power voltage, according to the required application test voltage. All Kollmorgen components meet these requirements.

Never modify the servo amplifiers!

It is not allowed to modify the servo amplifiers without permission by the manufacturer. Opening the housing causes loss of warranty and all certificates become unvalid. Warning signs are added to the device housing. If these signs are damaged, they must be replaced immediately.

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Kollmorgen 11/2018 Safety

2.2 Use as directed

Servo amplifiers are safety components that are built into electrical plant or machines, and can only be operated as integral components of such plant or machines.

If the servo amplifiers are used in residential areas, in business/commercial areas, or in small industrial operations, then additional filter measures must be implemented by the user.

Cabinet and Wiring

The servo amplifiers must only be operated in a closed control cabinet, taking into account the ambient conditions defined on page 28. Ventilation or cooling may be neces sary to keep the temperature within the cabinet below 40°C.

Use only copper conductors for wiring. The conductor cross-sections can be derived from the standard IEC 60204 (for AWG: NEC Table 310-16, 60°C or 75°C column).

Power supply

Servo amplifiers in the S748/772 series (overvoltage category III acc. to EN 61800-5-1) can be supplied from 3-phase grounded (earthed) industrial supply networks (TN-system, TT-system with grounded neutral point, no more than 42kA symmetrical rated current at 208V (with an isolating transformer) is described on page 64. In case of mains voltage asymmetry >3% a mains choke must be used.

, 230V, 240V, 400V or 480V

-10%

+10%

). Connection to other types of supply networks

Periodic overvoltages between phases (L1, L2, L3) and the housing of the servo amplifier must not exceed 1000V crest. In accordance with IEC 61800, voltage spikes (< 50µs) between phases must not exceed 1000V. Voltage spikes (< 50µs) between a phase and the housing must not exceed 2000V.

For the cases of DC input power for single and group installations

S700 has not been evaluated by Kollmorgen, UL, or TÜV for replacing AC mains input with DC input - for either single or group installations.

DC installations must be reviewed and evaluated by the user for branch circuit protec tion*, wire size, wire voltage rating, fuse protection, system dielectric requirements, overvoltage and input** current rating.

In case of DC supplied drives the built-in EMC filter will not work. The user is responsible to keep the conducted emissions and the immunity of the drive within the required noise levels.

*Special care must be taken in branch circuit design with mixed rating drives to avoid the smaller drives becoming the effective ‘fuse’ rather than the circuit protective fuse.

**The power supply system design must ensure inrush current protection by limiting input current during power up. DC supply polarity must be properly wired. Improper polarity of DC power will damage the drive and void warranty.

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Safety 11/2018 Kollmorgen

NOTICE

Motors

The S748/772 family of servo amplifiers is exclusively intended for driving suitable brushless synchronous servomotors, asynchronous motors and DC motors with control of torque, speed and/or position. The rated voltage of the motors must be at least as high as the DC bus link voltage

divided by

Functional Safety

Observe the chapter "use as directed" on page 39 when you use the safety function STO.

produced by the servo amplifier (U

nMotor

³ UDC/

To achieve PL e or SIL CL3, the safe switching of the pulse inhibitor must be tested peri odically by analyzing the feedback signal from the safety control (ð p. 47).

Observe the user documentation for safety cards S1-2(S3) / S2-2(S4) when you use a safety expansion card.

2.3 Prohibited use

Other use than described in chapter 2.2 is not intended and can lead to damage of per sons, equipment or things.

The use of the servo amplifier in the following environments is prohibited:

- potentially explosive areas

- environments with corrosive and/or electrically conductive acids, alkaline solutions, oils, vapors, dusts

- directly on non-grounded supply networks or on asymmetrically grounded supplies with a voltage >240V.

- on ships or off-shore applications

Commissioning the servo amplifier is prohibited if the machine in which it was installed,

- does not meet the requirements of the EC Machinery Directive

- does not comply with the EMC Directive or with the Low Voltage Directive

- does not comply with any national directives

The control of holding brakes by the S748/772 alone may not be used in applications, where functional safety is to be ensured with the brake.

2.4 Warning notes placed on the product

Residual Voltage

Wait 10 minutes

after removing

power.

If these signs are damaged, they must be replaced immediately.

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Kollmorgen 11/2018 Handling

NOTICE

3 Handling

3.1 Transport

Transport by qualified personnel in the manufacturer’s original recyclable packaging

Avoid shocks while transporting

Transport temperature: -25 to +70°C, max. rate of change 20K / hour,

class 2K3 acc. to EN61800-2, EN 60721-3-1

Transport humidity: max. 95% relative humidity, no condensation,

class 2K3 acc. to EN61800-2, EN 60721-3-1

If the packaging is damaged, check the unit for visible damage. In such an event, in form the shipper and the manufacturer.

The servo amplifiers contain electrostatically sensitive components, that can be damaged by incorrect handling. Discharge yourself before touching the servo amplifier. Avoid con tact with highly insulating materials, such as artificial fabrics and plastic films. Place the servo amplifier on a conductive surface.

3.2 Packaging

Recyclable cardboard with inserts

Dimensions: 390 x 600 x 400 mm

Labeling: name plate on outside of box

3.3 Storage

Storage only in the manufacturer’s original recyclable packaging

Max. stacking height: 3 cartons

Storage temperature: -25 to +55°C, max. rate of change 20K / hour,

Storage humidity: 5 … 95% relative humidity, no condensation,

Storage duration: Less than 1 year: without restriction. More than 1 year: capacitors must be re-formed before setting up and operating the servo amplifier. To do this, remove all electrical connections and apply single-phase 230V AC for about 30 minutes to the terminals L1 / L2.

class 1K4 acc. to EN61800-2, EN 60721-3-1

class 1K3 acc. to EN61800-2, EN 60721-3-1

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Handling 11/2018 Kollmorgen

NOTICE

3.4 Decommissioning

Only professional staff who are qualified in electrical engineering are allowed to decom mission parts of the drive system.

DANGER: Lethal voltages! There is a danger of serious personal injury or death by

electrical shock or electrical arcing.

Switch off the main switch of the switchgear cabinet.

Secure the system against restarting.

Block the main switch.

Wait at least 10 minutes after disconnecting.

3.5 Maintenance and cleaning

The device does not require maintenance. Opening the device voids the warranty. The inside of the unit can only be cleaned by the manufacturer

Do not immerse or spray the device. Avoid that liquid enters the device.

To clean the device exterior:

1. Decommission the device (see chapter 3.4).

2. Casing: Clean with isopropanol or similar cleaning solution.

CAUTION: Highly Flammable! Risk of injury by explosion and fire.

- Observe the safety notes given on the cleaning liquid package.

- Wait at least 30 minutes after cleaning before putting the device back into

operation.

3. Protective grill on fan: Clean with a dry brush.

3.6 Disassemble

Only professional staff who are qualified in electrical engineering are allowed to disassemble parts of the drive system.

1. Decommission the device (see chapter 3.4).

2. Check temperature.

CAUTION: High Temperature! Risk of minor burns.

During operation, the heat sink of the drive may reach temperatures above 80 °C (176 °F). Before touching the device, check the temperature and wait until it has cooled below 40 °C (104 °F).

3. Remove the connectors. Disconnect the potential earth connection last.

4. Demount: loosen the fastening screws. Remove the device.

16 S748-S772 Instructions Manual

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Kollmorgen 11/2018 Handling

NOTICE

3.7 Repair

Only professional staff who are qualified in electrical engineering are allowed to exchange parts of the drive system.

CAUTION: Automatic Start! During replacement work a combination of hazards and

multiple episodes may occur.

- Work on the electrical installation may only be performed by trained and qualified personnel, in compliance with the regulations for safety at work, and only with use of prescribed personal safety equipment.

Exchange of servo amplifier

Only the manufacturer can repair the device. Opening the device voids the warranty.

1. Decommission the device (see chapter 3.4).

2. Demount the device (see chapter 3.6).

3. Contact Kollmorgen and clarify the logistics. Send the device to the address given by Kollmorgen.

4. Install a new device as described in this manual.

5. Setup the servo amplifier as described in this manual.

Exchange of other drive system parts

3.8

If parts of the drive system ( for example cables) must be replaced, proceed as follows:

1. Decommission the device (see chapter 3.4).

2. Exchange the parts.

3. Check all connections for correct fastening.

4. Setup the servo amplifier as described in this manual.

Disposal

dispose the unit properly, contact a certified electronic scrap disposal merchant.

In accordance with the WEEE-2012/19/EC-Guidelines and similar, the manufacturer accepts returns of old devices and accessories for professional disposal. Transport costs are the responsibility of the sender.

Decommission the device as described in chapter 3.4 and demount the device as described in chapter 3.6.

Contact Kollmorgen and clarify the logistics. Send the device to the address given by Kollmorgen.

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Approvals 11/2018 Kollmorgen

4 Approvals

Certificates (CE, functional safety) can be found in the download section of the "File

Archive".

4.1 Conformance with UL

This servo amplifier is listed under UL file number E217428.

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

This standard describes the fulfillment by design of minimum requirements for electrically operated power conversion equipment, such as frequency converters and servo amplifi

ers, which is intended to eliminate the risk of fire, electric shock, or injury to persons, being caused by such equipment. The technical conformance with the U.S. standard is determined by an independent UL inspector through the type testing and regular check

ups.

Apart from the notes on installation and safety in the documentation, the customer does not have to observe any other points in direct connection with the UL-certification of the equipment.

UL 508C

UL 508C describes the fulfillment by design of minimum requirements for electrically operated power conversion equipment, such as frequency converters and servo amplifiers, which is intended to eliminate the risk of fire being caused by such equipment.

UL 840

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

UL Markings

Use 60°C or 75°C copper wire only for every model of this section.

Tightening torque and wire size for field wiring terminals. X0 8-2 AWG, TQ Lb In. 40. X8 8-2 AWG, TQ Lb In. 40.

For use in a pollution degree 2 environment only.

These devices provide solid state motor overload protection at 130% of full load current.

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.

These devices are not provided with motor over-temperature sensing.

Suitable for use on a circuit capable of delivering not more than 42kA rms symmetri cal amperes” for a max. Voltage of 480 Vac.

Supply circuit protection:

Model Fuse class Voltage Rating Max. Fuse and SCC Rating

S7480 RK5, CC, J, T 600V AC 60A / 200kA S7720 RK5, CC, J, T 600V AC 80A / 200kA

For use on a solidly grounded wye source only.

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Kollmorgen 11/2018 Approvals

NOTICE

4.2 CE conformance

The servo amplifiers have been tested by an authorized testing laboratory in a defined configuration, using the system components that are described in this documentation. Any divergence from the configuration and installation described in this documentation means that you will be responsible for carrying out new measurements to ensure confor mance with regulatory requirements.

Kollmorgen declares the conformity of the products S748, S772 with the following direc tives

EC Machinery Directive (2006/42/EC)

EC EMC Directive (2014/30/EC)

EC Low Voltage Directive (2014/35/EC)

The servo amplifier meets the noise immunity requirements to the 2nd environmental cat egory (industrial environment). For noise emission the amplifier meets the requirement to

a product of the category C2 (motor cable £ 10m). With a motor cable length of 10m or longer, the servo amplifier meets the requirement to the category C3.

This product can cause high-frequency interferences in non industrial environments. This can require measures for interference suppression like additional external EMC filters.

4.2.1 European Directives and Standards for the machine builder

Servo amplifiers are safety components that are intended to be incorporated into electrical plant and machines for industrial use. When the servo amplifiers are built into machines or plant, the amplifier must not be used until it has been established that the machine or equipment fulfills the requirements of the

EC Machinery Directive (2006/42/EC)

EC EMC Directive (2014/30/EC)

EC Low Voltage Directive (2014/35/EC)

Standards to be applied for conformance with the EC Machinery Directive (2006/42/EC) IEC 60204-1 (Safety and Electrical Equipment in Machines) ISO 12100 (Safety of Machines)

The manufacturer of the machine must generate a risk assessment for the machine, and must implement appropriate measures to ensure that unforeseen movements cannot cause injury or damage to any person or property. The machine/plant manufacturer must check whether other standards or EC Directives must be applied to the machine/plant.

Standards to be applied for conformance with the EC Low Voltage Directive(2014/35/EC) IEC 60204-1 (Safety and Electrical Equipment in Machines) IEC 60439-1 (Low-voltage switchgear and controlgear assemblies)

Standards to be applied for conformance with the EC EMC Directive (2014/30/EC) IEC 61000-6-1 / 2 (Interference Immunity in Residential & Industrial Areas) IEC 61000-6-3 / 4 (Interference Generation in Residential & Industrial Areas)

The manufacturer of the machine/plant is responsible for ensuring that it meets the limits required by the EMC regulations. Advice on the correct installation for EMC can be found in this documentation.

We only guarantee the conformance of the servo system with the standards cited in this chapter if the components (motor, cables, chokes etc.) are those supplied by us.

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Approvals 11/2018 Kollmorgen

4.2.2 Safety Conformance (STO) according to Machine Directive

The S748/772 servo amplifier offers a two channel STO function (Safe Torque Off). The function blocks the trigger pulses of the power transistors (pulse inhibitor).

The STO safety concept is certified by the TÜV. The safety circuit concept for realizing the safety function "Safe Torque Off" in the servo amplifiers S748/772 is suited for SIL CL3 according to IEC 62061 and PLe according to ISO 13849-1.

The subsystems (servo amplifiers) are totally described for safety technics with the characteristic data SIL CL, PFH

and TM.

Device Operation mode ISO 13849-1 IEC 62061 PFH

[1/h] TM[Year]

STO single channel PLd, Cat. 3 SIL CL 2 7,05E-08 20 STO dual channel PLd, Cat. 3 SIL CL 2 7,05E-08 20

STO

dual channel with

periodical testing

PLe, Cat. 4 SIL CL 3 1,38E-09 20

SIL2 / PLd solutions can be implemented with single-channel or dual-channel control with simple safety switching devices. A SIL3 / PLe solution requires a safety control that periodically tests the safe switching of the pulse inhibitor by analyzing the feedback (status) signals.

Expansion card "Safety 2-2" (S4)

This expansion card (Basic version) includes various safety functions for the safe operation of drive shafts. All functions fulfill the safety requirements SIL CL2 according to IEC 62061 respectively performance level PLd according to ISO 13849-1. The functional safety is certified by the TÜV. Safety characteristic data are listed in the Instructions Manual of the expansion card.

Expansion card "Safety 1-2" (S3)

This expansion card (full version) includes several safety functions. All functions fulfill the safety requirements SIL CL3 acc. to IEC 62061 respectively performance level PLe acc. to ISO 13849-1. The functional safety is certified by the TÜV. Safety characteristic data are listed in the Instructions Manual of the expansion card.

4.3 EAC Conformance

EAC is the abbreviation for Eurasian Conformity. The mark is used in the states of the Eurasian Customs Union (Russia, Belarus, Kazakhstan) similar to the European CE mark.

Kollmorgen declares, that the S748/772 has passed all required conformity procedures in a member state of the Eurasian Customs Union, and that the S748/772 meets all techni

cal requirements requested in the member states of the Eurasian Customs Union:

Low voltage (TP TC 020/2011)

EMC (TP TC 004/2011)

Contact in Russia: Intelisys LLC. , Bakuninskaya Str. d 14, Building 1, RU-105005 Moskau

20 S748-S772 Instructions Manual

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Kollmorgen 11/2018 Package

Typenbezeichnung

Spannungsversorgung

Model Number

Power Supply

Ser. Nr

Nennstrom

Ser. No.

Nom. Current

Bemerkung Comment

Umgebungstemp. Surrounding temp.

Hardware Revision

Schutzart Encl.Rating

Kollmorgen Europe GmbH Pempelfurtstraße 1 D-40880 Ratingen www.kollmorgen.com

E217428

1VD4

LISTED

IND. CONT. EQ.

RoHS

conform

5 Package

5.1 Package supplied

When an amplifier from the S748/772 series is ordered (order numbers ðp.157), the fol lowing is supplied:

— Servo amplifier S748/772, shielding plate, shield clamps — Safety Guide S700 (printed) — Online documentation and setup software DRIVEGUI.EXE on CD-ROM — Mating connectors X3A, X3B, X4, X9A, X9B

The mating SubD connectors are not part of the package!

Accessories :

— Motor cable as a cut-off length — Feedback cable (prefabricated)

or both feedback connectors separately, with the feedback cable as a cut-off length — External brake resistor BAR(U) — Communication cable to the PC (ð p.100) for setting parameters from a PC — Power cable, control cables, fieldbus cables (as cut-off lengths) — Mains choke if mains voltage is more than 3% asymmetrical

5.2 Nameplate

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

(must be ordered separately, if required; description see accessories

manual)

Servo amplifier type

2D bar code

Electrical supply

Installed load

Enclosure

Rating

CommentsSerial number

max. surrounding temperature

Output current

in cont. operation

Hardware

Revision

Software

Version

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Package 11/2018 Kollmorgen

5.3 Part number scheme

The part number is identical with the order code.

S7720 2 -EIF2 PM -NA1- 000

Family

S7 S700

Current Rating

48 48 Arms 72 72 Arms

Voltage Rating

0 208...480V

electr./mech. Options

2 Standard F Coated PCBs S748 only: C Coldplate A Coldplate + coated PCBs

Expansion Cards Slot 1

NA no expansion card in Slot 1,

EtherCAT&CANopen onboard 2C Module 2CAN mounted DN DEVICENET PB PROFIBUS SE SERCOS II SN SYNQNET EI I/O Extension FB FB-2to1 at X1

Firmware Options

NA no option

(EtherCAT&CANopen)

Expansion Cards Slot 3

NA no expansion card in slot 3,

EtherCAT&CANopen onboard F2 Fan controller PM PosI/O PA PosI/O-Monitor

Safety card S1-2, SIL 3

Safety card S2-2, SIL 2

Expansion Cards Slot 2

NA no expansion card in Slot 2,

EtherCAT&CANopen onboard F2 Fan controller PM PosI/O PA PosI/O-Monitor

1 is void with standard 2 is void with standard, additional coding defines customer specific specials. 3 described in separate documentation 4 not with expansion cards.

Example: S77202-EIF2PM-NA-000 S7 S700 series 72 72A rated current 0 Supply voltage 208...480V 2 no electrical/mechanical option EI I/O Extension card in Slot 1 F2 Fan controller in Slot 2 PM PosI/O expansion card in Slot 3 NA Standard Firmware (EtherCAT & CANopen onboard) 000 no customer specific specials

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Kollmorgen 11/2018 Technical description

6 Technical description

6.1 The S748/772 family of digital servo amplifiers

Standard version

Large supply voltage range: 3 x 208V

… 3 x 480V

-10%

(with mains voltage below 300V set parameters NONBTB=3 and VBUSBAL=1.)

CANopen onboard

EtherCAT onboard

RS232 and 24V pulse direction interface onboard

Resolver-, Encoder-, AquadB Encoder-, ComCoder-evaluation onboard

Position controller onboard

STO (Safe Torque Off) onboard (up to SIL CL3, PLe)

3 frontside slots for expansion cards

Memory Card slot onboard

Synchronous servomotors, linear motors, asynchronous motors, and DC motors can be used

+ 10%

Power section

Directly on grounded 3-phase supply, 208V

-10%

… 480V

(with mains voltage below 300V set parameters NONBTB=3 and VBUSBAL=1.)

TN-network or TT-network with grounded neutral point, 42kA max. symmetrical cur-

+10%

, 50/60 Hz

rent rating, connection to other supply types only via isolating transformer, ðp.64

Overvoltage category III acc. to EN 61800-5-1

B6 bridge rectifier, integral supply filter and soft-start circuit

Single-phase supply operation possible (e.g. for setup)

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

Shielding All shielding connections are made directly on the amplifier

Output stage IGBT module with floating current measurement

Brake circuit with dynamic distribution of the generated power between

several amplifiers on the same DC bus link circuit. External brake resistors if required.

DC bus link voltage 260...900 V DC, can be connected in parallel.

Interference suppression filters are integrated for the electrical supply feed and the 24V auxiliary supply voltage (with motor cable £ 10m for C2 as per IEC 61800-3, with

motor cable < 10m for C3 as per IEC 61800-3).

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Technical description 11/2018 Kollmorgen

Integrated safety

Appropriate insulation/creepage distances and electrical isolation ensure safe electri cal separation, as per IEC 61800-5-1, between the power input / motor connections and the signal electronics.

Soft-start, overvoltage detection, short-circuit protection, phase-failure monitoring.

Temperature monitoring of the servo amplifier and motor (if our motors and prefabri cated cables are used).

Safe stop (SIL CL3 according to IEC 62061, PLe according to ISO 13849-1) ð p. 37.

Slot for optionalsafety card with more safety functions for the safe drive operation, ð p. 150

Auxiliary supply voltage 24V DC

Electrically isolated, internal fusing, from an external 24V DC power supply unit.

Separate 24V supply input for internal electronic supply

Separate 24V supply input for motor holding brake supply

Separate 24V supply input for digital outputs

Operation and parameter setting

With our user-friendly setup software DRIVEGUI.EXE, for setup via the serial interface of a PC.

If no PC is available: direct operation by two keys on the servo amplifier and a 3-character LED display.

Fully programmable via RS232 interface.

Read/write access to parameter records and firmware via memory card.

Completely digital control

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

Adjustable digital speed controller (62.5 µs)

Integrated position controller, with adaptation possibilities for all applications (250 µs, optionally 125µs)

Integrated 24V step/direction interface for connecting a servomotor to a stepper con troller

Inputs/Outputs

2 programmable analog inputs ð p. 95

4 programmable digital inputs ð p. 96

2 programmable digital inputs/outputs (direction selectable) ð p. 98

programmable logical combinations of digital signals

1 input Enable ð p. 78

2 inputs STO Enable ð p. 97

2 outputs STO Status ð p. 99

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Kollmorgen 11/2018 Technical description

Expansions

Slot 1

Expansion cards in slot 1 can be combined with F2 Option in slot 2. More combinations of slot 1 and slot 2 expansion cards are not possible.

I/O-14/08 expansion card, ð p. 124

PROFIBUS expansion card, ð p. 127

sercos®II expansion card, ð p. 128

DeviceNet expansion card, ð p. 130

SynqNet expansion card, ð p. 133

FB-2to1 expansion card, ð p. 135

-2CAN- expansion module, separated connectors for CAN bus and RS232 ð p. 137

Slot 2

PosI/O expansion card, ð p. 140

PosI/O-Monitor expansion card, ð p. 140

F2 Option, controlled fan, later insertion not possible, ð p. 119, can be combined with expansion cards in slot 1.

Slot 3

PosI/O expansion card, ð p. 136

PosI/O-Monitor expansion card, ð p. 136

F2 Option, controlled fan, later insertion not possible, ð p. 149

Safety expansion cards (S4) S2-2 (SIL CL2), ð p. 150

Safety expansion cards (S3) S1-2 (SIL CL3), ð p. 140

Several third-party expansion cards (ModBus, LightBus, FIP-IO etc. please contact the manufacturer for further information)

Macro programming

More information can be found in our KDN (Macro-Programming).

62.5µs / 250µs / 1ms / 4ms / 16ms / IDLE / IRQ

128 kByte memory

IEC 61131 structured text

400 easy instructions every 62.5 µs

CAN objects for multi axis control

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Technical description 11/2018 Kollmorgen

6.2 Technical data

6.2.1 Rated Data

Electrical data DIM S748 S772

Rated supply voltage (L1,L2,L3) (grounded supply, phase to phase) Rated input power for continuous operation kVA 35 50 Permitted switch on/off frequency 1/h 30 Auxiliary voltage supply — ð p.27 Rated DC bus link voltage V= 290 - 675 Rated output current (rms value, ± 3%)

at 3x208V Arms 48 72 at 3x230V Arms 48 72 at 3x400V Arms 48 72 at 3x480V Arms 48 72

Peak output current (for approx.5s, ± 3%) Switching frequency of output stage kHz 8/16 Voltage rise speed dU/dt, (measured without connected motor, see hints on page 69!)

at 3x208V kV/µs 2.1 at 3x230V kV/µs 2.3 at 3x400V kV/µs 4.0

at 3x480V kV/µs 4.8 Technical data for brake circuit — ð p.31 Threshold for overvoltage switch-off VDC ð p.31 Motor inductance min.

at 3x208V mH 0.38 0.26

at 3x230V mH 0.42 0.29

at 3x400V mH 0.74 0.51

at 3x480V mH 0.88 0.61

Motor inductance max. mH

Form factor of the output current (rated conditions, min. load inductance) Bandwidth of current controller kHz > 1.2 (bis 5) Residual voltage drop at rated current V 6 Thermal dissipation, output stage disabled, max. W 24 Thermal dissipation at rated current (without brake dissipation)

at 3x230V W 555 885

at 3x400V W 635 1005

at 3x480V W 685 1135 Noise emission max. dB(A) 62 68

Mechanical data

Weight kg 13 Weight Coldplate version (S7480C, S7480A) kg 10.4 Height, without connectors and shielding plate mm 386 Height, with connectors and shielding plate mm 505 Width mm 190 Depth, without connectors mm 244 Depth, with connectors mm 285

* In case of mains voltage below 300V, set parameters NONBTB=3 and VBUSBAL=1.

Arms 96 140

— 1.01

3 x 208V

+10%

480V

Consult our customer

support

…3x

-10%

, 50/60 Hz

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Kollmorgen 11/2018 Technical description

6.2.2 Inputs / outputs, aux. voltage supply

Interface electr. data

Analog inputs1/2

Max. common-mode voltage

Digital control inputs

Digital control outputs

BTB/RTO output, relay contacts

24V-IO for digital outputs 20V … 30V

Auxiliary supply voltage, electrically isolated

Electronics 24V (-0% +15%) Current electronics* 2A Holding Brake 24V (-0% +15%) Output current brake min./max. 0.15A / 3A

* = with fan but without option card

6.2.3 Connectors/Terminals

as per EN 61131-2 Type 1,

max. 30VDC, 15mA

as per EN 61131-2 Type 1,

max. 30VDC, 100mA

max. 30VDC, max 42VAC

±10V ±10V

500mA

Connector/Terminals Type

X0 Mains Terminals 35mm² 125A 1000V X1 Encoder input SubD15poles (female) 0.5mm² 1A <100V X2 Resolver input SubD 9poles (female) 0.5mm² 1A <100V X3A, B Control signals Mini-Combicon connector 1.5mm² 4A 160V X4 Aux. voltage, STO Mini-Combicon connector 1.5mm² 4A 160V X5 optional, Encoder emulation, ROD/SSI

SubD 9poles (male) 0.5mm² 1A <100V

X6 PC interface, CAN SubD 9poles (male) 0.5mm² 1A <100V

X7A, B EtherNET RJ45 connector

X8 DC Bus link, Motor, Brake Resistor

Terminals 35mm² 125A 1000V

X9A, B Motor brake Mini-Combicon connector 1.5mm² 4A 160V

*1 single-line connection *2 single-line connection with recommended conductor cross section (chapter 6.2.7) *3 rated voltage with pollution level 2

6.2.4 Recommended tightening torques

Connection Tightening torque

X0 with up to 25mm² wire 2.5 Nm X0 with 35mm² wire 4.5 Nm X3A, B Cage clamps X4 Cage clamps X8with up to 25mm² wire 2.5 Nm X8 with 35mm² wire 4.5 Nm

X9A

Grounding bolt 3.5 Nm

max. cross

section

permiss. current

FTP CAT.5, 26AWGx4P

as per EN50173

Cage clamps

Mounting flange: 0.5 Nm

permiss.

voltage

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Technical description 11/2018 Kollmorgen

NOTICE

6.2.5 Fusing

Internal fusing, wire fuse or electronic

Circuit S748…S772

24V Electronics 4 A 24V Motor brake 4 A Brake resistor electronic

External fusing by user (US fuses in brackets)

Fusing information are explained in detail in the "KDN

S748 S772

AC Supply F

N1/2/3

24V Electronics F 24V Motor Brake F Brake Resistor F

B1/2

H1/2

H3/4

60 A* 80 A* 8 A** 8 A** 8 A** 8 A**

100 A*** 100 A***

* EU fuses gRL or gL 400V/500V

US fuses: class RK5/CC/J/T, 600VAC 200kA, time-delay ** e.g. wire fuses or micro fuse or Automatic Circuit Brakers *** EU fuses: Bussmann HLS, 690V/100A

US fuses: Bussmann FWP-xxA22F, Size 22x58mm, UL approved for 500Vdc

6.2.6 Ambient conditions, ventilation, mounting position

Storage hints Transport hints Surrounding air temperature in operation Humidity in operation

Site altitude

Pollution Level Vibrations Enclosure Protection Mounting Position Ventilation

The servo amplifier shuts down (error F01/F13, see p.120, motor has no torque) in case of excessively high temperature in the control cabinet. Make sure that there is sufficient forced ventilation within the control cabinet.

ð p.15 ð p.15

0...+40°C under rated conditions +40...+55°C with power derating 2.5% / K rel. humidity 85%, no condensation up to 1000 meters a.m.s.l. without restriction 1000…2500 meters a.m.s.l. with power derating

1.5% / 100meters Pollution level 2 as per IEC 60664-1 Class 3M1 according to IEC 60721-3-3 IP 20 according to IEC 60529 vertical ð p.52 built-in fan.

Kollmorgen requirements for servo amplifiers with Coldplate:

Flatness of the mounting (cooling) plate: £ 25 µm / 100 mm

Mains volt age

Max. thermal resis tance

Max. allowed temperatur: Coldplate center

230V 0,063 K/W 75 °C 400V 0,055 K/W 75 °C 480V 0,051 K/W 75 °C

The cooling plate temperature must not be more than 10 K below the environment tem perature. With a difference of more than 10 K there is a risk of condensation. Condensa tion may destroy the electronics of the servo amplifier.

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Kollmorgen 11/2018 Technical description

NOTICE

6.2.7 Conductor cross-sections

Recommendations for cables (material and construction (ð p. 59)).

Following IEC 60204 (B2), we recommend for single-axis systems:

Interface Cross section Techn. requirements

AC connection

DC bus link

Brake resistor

Motor cables

Resolver, motor thermal control, max.100m* Encoder, motor thermal control, max. 50m* ComCoder, motor thermal con trol, max. 25m Set points, AGND, max 30m 0.25 mm² twisted pairs, shielded Control signals, BTB, DGND, max. 30m

Holding brake (Motor) min. 0.75 mm²

+24 V Electronics, max 30m max. 1.5 mm² +24 V Motor brake, max 30m max. 1.5 mm² For multi-axis systems, observe the specific operating conditions for your system. To reach functional safety with the max. permitted cable length, observe cable requirements ð p. 59.

* Kollmorgen North America supplies cables up to 39 meters

* Kollmorgen Europe supplies cables up to max. length

S748: 16 mm² S772: 25 mm² S748: 25 mm² S772: 25 mm² S748: 35 mm² S772: 35 mm² S748: 16 mm² S772: 25 mm²

4x2x0.25 mm²

7x2x0.25 mm² twisted pairs, shielded

8x2x0.25 mm² twisted pairs, shielded

0.5 mm²

600V,80°C

1000V, 80°C, shielded for lengths >0.50m 1000V, 80°C, shielded for lengths >0.50m 600V,80°C, shielded, C<150pF/m twisted pairs, shielded, C<120pF/m

600V, 80°C, shielded,

check voltage drop check voltage drop check voltage drop

6.3 LED display

A 3-character LED-Display indicates the status of the amplifier after switching on the 24V supply (ð p.119). When the keys on the front panel are used, the parameter and function numbers are shown, as well as the numbers for any errors and warnings that may occur (ð p.120ff).

6.4 Grounding system

AGND analog inputs, internal analog ground DGND 24V-IO, digital inputs and outputs, optically isolated. GND internal digital ground, encoder Emulation, RS232, CAN XGND 24V supply, STO Enable BRGND 24V supply for the motor holding brake

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Technical description 11/2018 Kollmorgen

X3B/9-10

X3A/1

X4/5+X4/7

TBRAKE

STO-ENABLE 1/2

X9B/1-2

Analog-In

ENABLE

max.5s

tbrH

EMRGTO

DECDIS

VEL0

tbrL

TBRAKE0

Speed Setpoint

Braking force

BRAKE

internal

ENABLE

Speed

internal

ramp

stop ramp

emergency

NOTICE

CAUTION

6.5 Motor holding brake

A 24V holding brake in the motor can be controlled directly by the amplifier. A special 24V supply voltage (X9B) is used. Brakes with up to 3A can be controlled directly.

No functional safety!

Danger by falling load (in case of suspended load, vertical axes). An additional mechanical brake is required for functional safety, which must be safely operated, e.g. via the Safety Card S1-2 (see p. 140).

The brake only works with sufficient voltage level (ð p.27). Check voltage drop, measure the voltage at brake input and check brake function (brake and no brake).

The brake function must be enabled through the BRAKE setting (screen page: Motor). In the diagram below you can see the timing and functional relationships between the ENABLE signal, speed setpoint, speed and braking force. All values can be adjusted with parameters, the values in the diagram are default values.

30 S748-S772 Instructions Manual

During the internal ENABLE delay time of 100ms (DECDIS), the speed setpoint of the servo amplifier is internally driven down an adjustable ramp to 0V. The output for the brake is switched on when the speed has reached 5 rpm (VELO), at the latest after 5 s (EMRGTO). The release delay time (t

) and the engage delay time (t

brH

) of the holding

brL

brake that is built into the motor are different for the various types of motor (see motor manual), the matching data are loaded from the motor database when the motor is selected. A description of the interface can be found on page 69.

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Kollmorgen 11/2018 Technical description

6.6 Dynamic Braking

During braking with the aid of the motor, energy is fed back into the servo amplifier. This generated energy is dissipated as heat in the brake resistor. The brake resistor is switched in by the brake circuit.

The setup software can be used to adapt the brake circuit (thresholds) according to the electrical supply voltage.

Our customer service can help you with the calculation of the brake power that is neces sary for your system. A simple method interface can be found on page 67.

Functional description:

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

When the energy fed back from the motor has an average or peak power that exceeds the preset level for the brake power rating, then the servo amplifier generates the warning “n02 brake power exceeded” and the brake circuit is switched off.

The next internal check of the DC bus link voltage (after a few milliseconds) detects an overvoltage and the output stage is switched off, with the error message “Overvoltage F02” (ð p.120).

The BTB/RTO contact (terminals X3B/14,15) will be opened at the same time (ð p.99)

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

Using the built-in brake circuit, several amplifiers of the same series can be operated off a common DC bus link (observe page 66), without requiring any additional measures.

90% of the combined power of all amplifiers is always available for peak and continuous power. The switch-off on overvoltage takes place as described under 1. (above) for the amplifier that has the lowest switch-off threshold (resulting from tolerances).

is described in the "KDN". A description of the

Technical data of the brake circuits depend on the mains voltage (VBUSBAL

Technical Data Brake Circuit Supply voltage (VBUSBAL

Rated data DIM 1: 230V 2: 400V 3*: 480V

Switch-on threshold of brake circuit V 400 720 840 790 Overvoltage F02 V 455 800 900 900 Pulse brake power kW 16 50 70 70 External brake resistor (RBe) for S748 Ohm 15 External brake resistor (RBe) for S772 Ohm 10 Continuous brake power external (RBe) kW 8

* Kollmorgen recommends setting VBUSBAL=4 in case of 480V mains supply, with this setting the optimized calculation method is used.

Suitable external brake resistors can be found in our accessories manual.

)

4*: 480V

S748/772

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6.7 Switch-on and switch-off behavior

This chapter describes the switch-on and switch-off behavior of the S748/772 and the steps required to achieve operational stopping or emergency stop behavior that complies with standards.

The ASCII commands ACTFAULT see ERRCODE

) and STOPMODE (Enable signal response) dictate how the drive will

(error response, also depends on the specific error,

behave.

ACTFAULT / STOPMODE

1 (default)

Behavior (see also ASCII reference in the online help

ware) Motor coasts to a standstill in an uncontrolled manner Motor is braked in a controlled manner

of the setup soft

Behavior during a power failure

The servo amplifiers use an integrated circuit to detect if one or more input phases (power supply feed) fail. The behavior of the servo amplifier is set using the setup soft

ware: Under “Response to Loss of Input Phase” (PMODE) on the Basic Setup screen, select:

Warning if the higher-level control system is to bring the drive to a standstill: Warn

ing n05 is output if an input phase is missing, and the motor current is limited. The servo amplifier is not disabled. The higher-level control system can now selectively end the current cycle or start bringing the drive to a standstill. Therefore, the error message “MAINS BTB, F16" is output on a digital output of the servo amplifier and evaluated by the control system, for instance.

Error message if the servo amplifier is to bring the drive to a standstill: Error message F19 is output if an input phase is missing. The servo amplifier is disabled and the BTB contact opens. Where the factory setting is unchanged (ACTFAULT=1), the motor is braked using the set “EMERGENCY STOP RAMP”.

Behavior when undervoltage threshold is reached

If the undervoltage threshold is undershot in the DC bus link (the threshold value depends on the type of servo amplifier), the error message “UNDERVOLTAGE, F05" is displayed. The drive response depends on the ACTFAULT/STOPMODE setting.

Behavior with enabled “holding brake” function

Servo amplifiers with an enabled holding brake function have a special procedure for switching off the output stage ( ð p. 30). Removing the ENABLE signal triggers electrical braking. As with all electronic circuits, the general rule applies that there is a possibility of the inter nal “holding brake” module failing. Functional safety, e.g. with hanging load (vertical axes), requires an additional mechanical brake which must be safely operated, e.g. via the Safety Card S1-2.

Behavior of the safety function STO

With the functional safe restart lock STO, the drive can be secured on standstill using its internal electronics so that even when power is being supplied, the drive shaft is pro

tected against unintentional restart. The chapter “Safety function STO” describes how to use the STO function. See page 37 onwards.

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X4/5,7

X3B/14,15

SW-ENABLE

X3A/1 &

HW-ENABLE

> 100ms

STO-ENABLE

BTB/RTO

L1,L2,L3 X0

X4/1,2

24V

< 15s (Boot-time)

VELO

5...8 min.

X4/6,8

STO-Status

~500ms

Motor speed

Power Stage enable (inter nal)

DC bus link

6.7.1 Behavior in standard operation

The behavior of the servo amplifier always depends on the current setting of a number of different parameters (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc. see online

help). The diagram below illustrates the correct functional sequence for switching the

servo amplifier on and off.

Devices which are equipped with a selected “Brake” function use a special sequence for switching off the output stage (ð p.30).

safety is ensured at the drive shaft (ð p. 37).

The built-in safety function STO can be used to switch off the drive, so that functional

In case of a built-in safety card, wait for the Ready Acknowledge (X30 Pin 16) of the safety card before enabling the servo amplifier again.

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ENABLE extern

F06

24V

BTB/RTO

Boot-Time

~500ms

VELO

STO-ENABLE

> 100ms

Standard Operation

Motor Speed

Power Stage

Main Power

enable

DC-Bus

Fault Motor Temperature

Start

CAUTION

6.7.2 Behavior in the event of an error (with standard setting)

The behavior of the servo amplifier always depends on the current setting of a number of different parameters (ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see online help

Uncontrolled coasting!

Some faults (see ERRCODE ) force the output stage to switch-off immediately, independant from the ACTFAULT the load. An additional mechanical brake is required for funktional safety, which must be safely operated

The diagram shows the startup procedure and the procedure that the internal control system follows in the event of motor overtemperature, assuming that the standard param eter settings apply. Fault F06 does not switch-off the output stage immediately, with ACTFAULT=1 a controlled emergeny brake is started first.

setting. Danger of injury by uncontrolled coasting of

(F06 = error messages "Motor Temperature")

Even if there is no intervention from an external control system (in the example, the ENABLE signal remains active), the motor is immediately braked using the emergency stop ramp if this error is detected and assuming that no changes have been made to the factory setting (ACTFAULT=1).

In case of a built-in safety card, wait for the Ready Acknowledge (X30 Pin 16) of the safety card before enabling the servo amplifier again.

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6.8 Stop-, Emergency Stop-, Emergency Off Function to IEC 60204

With the functional safe, certified function STO (see page 37 onwards) the drive can be secured on standstill (torque-free) using its internal electronics so that even when power is being supplied, the drive shaft is protected against unintentional restart (SIL CL3 according to IEC 62061, PLe according to ISO 13849-1).

With built-in “Safety” expansion card, more safe drive functions in accordance with IEC 61800-5-2 (see page 150 ff) are provided.

The parameters “STOPMODE” and “ACTFAULT” must be set to 1 in order to implement the stop and emergency stop categories. If necessary, change the parameters via the ter minal screen of the setup software and store the data in the EEPROM.

Examples for implementation can be found in the KDN on page Stop and Emergency

Stop Function.

6.8.1 Stop

The Stop function is used to shut down the machine in normal operation. The Stop func tions are defined by IEC 60204.

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

drive machinery (i.e. an uncontrolled shut-down); this can be done with the built-in STO functionality (see page 37)

Category 1: A controlled shut-down , whereby the energy supply to the drive

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

Category 2: A controlled shut-down, whereby the energy supply to the drive

machinery is maintained.

The Stop Category must be determined by a risk evaluation of the machine. In addition, suitable means must be provided to guarantee a reliable shut-down.

Category 0 and Category 1 Stops must be operable independently of the operating mode, whereby a Category 0 Stop must have priority. Stop functions must be implemented by disconnection of the appropriate circuitry, and have priority over assigned start func tions.

If necessary, provision must be made for the connection of protective devices and lock-outs. If applicable, the Stop function must signal its status to the control logic. A reset of the Stop function must not create a hazardous situation.

Examples for implementation can be found in the KDN on page Stop and Emergency

Stop Function.

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6.8.2 Emergency Stop

The Emergency Stop function is used for the fastest possible shutdown of the machine in a dangerous situation. The Emergency Stop function is defined by IEC 60204. Princi ples of emergency stop devices and functional aspects are defined in ISO 13850.

The Emergency Stop function will be triggered by the manual actions of a single person. It must be fully functional and available at all times. The user must understand instantly how to operate this mechanism (without consulting references or instructions).

The Stop Category for the Emergency Stop must be determined by a risk evaluation of the machine.

In addition to the requirements for stop, the Emergency Stop must fulfil the following requirements:

Emergency Stop must have priority over all other functions and controls in all operat ing modes.

The energy supply to any drive machinery that could cause dangerous situations must be switched off as fast as possible, without causing any further hazards ( Stop Category 0) or must be controlled in such a way, that any movement that causes danger, is stopped as fast as possible (Stop Category 1).

The reset must not initiate a restart.

Examples for implementation can be found in the KDN on page Stop and Emergency

Stop Function.

6.8.3 Emergency Off

The Emergency Off function is used to switch-off the electrical power supply of the machine. This is done to prevent users from any risk from electrical energy (for example electrical impact). Functional aspects for Emergency Off are defined in IEC 60364-5-53.

The Emergency Off function will be triggered by the manual actions of a single person.

The result of a risk evaluation of the machine determines the necessity for an Emergency Off function.

Emergency Off is done by switching off the supply energy by electro-mechanical switch ing devices. This results in a category 0 stop. If this stop category is not possible in the application, then the Emergency Off function must be replaced by other measures (for example by protection against direct touching).

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6.9 Safety Function STO

A frequently required application task is the safe torque off and the protection of person nel against unintentioned restarting of drives. The S748/772 servo amplifier offers, even in the basic version, a two channel STO function (Safe Torque Off). The function blocks the trigger pulses of the power transistors (pulse inhibitor).

Advantages of the safety function STO :

— the DC bus link remains charged up, since the mains supply line remains active — only low voltages are switched, so there is no contact wear — very little wiring is required — single or dual channel control possible — SIL2 or SIL3 solutions possible

The STO safety function corresponds to stop category 0 (uncontrolled stopping) acc. to EN 60204-1. The safety function STO can be operated from external safety switch gears (relays), from a safe external control (semiconductor output or driven contact) or from the built-in safety card S1-2 or S2-2 (see p. 150).

6.9.1 Safety characteristic data

The subsystems (servo amplifiers) are totally described for safety technics with the characteristic data SIL CL, PFH

Device Operation mode EN 13849-1 EN 62061 PFH

STO single channel PLd, Cat. 3 SIL CL 2 7,05E-08 20 STO dual channel PLd, Cat. 3 SIL CL 2 7,05E-08 20

STO

dual channel with

periodical testing

and TM.

[1/h] TM[Year]

PLe, Cat. 4 SIL CL 3 1,38E-09 20

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NOTICE

WARNING

CAUTION

WARNING

6.9.2 Safety notes

High electrical voltage!

Risk of electric shock! The function STO does not provide an electrical separation from the power output. If access to the motor power terminals is necessary,

the S748/772 must be disconnected from mains supply,

consider the discharging time of the intermediate circuit.

No Brake Power!

Serious injury could result when a suspended load is not properly blocked. The servo amplifier cannot hold a vertical load when STO is active.

Add a safe mechanical blocking (for instance, a motor-holding brake).

Uncontrolled movement!

Danger of personal injury. If STO is engaged during operation by separating input STO1-Enable and STO2-Enable from 24 VDC, the motor runs down out of control and the servo amplifier displays the error F27. There is no possibility of braking the drive controlled.

Brake the drive in a controlled way first and then separate the STO inputs from +24 VDC time-delayed.

In case of single channel control: If the STO is automatically activated by a control system, then make sure that the output of the control is supervised for possible malfunction. This can be used to prevent a faulty output from unintentionally activating the function STO. Since STO is used in a single-channel system, erroneous engaging will not be recognized.

Controlled braking: Keep to the following functional sequence when STO is used :

1. Brake the drive in a controlled manner (speed setpoint = 0V)

2. When speed = 0 rpm, disable the servo amplifier (enable = 0V)

3. If there is a suspended load, block the drive mechanically

4. Activate STO (STO1-Enable and STO2-Enable = 0V

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6.9.3 Use as directed STO

The STO function is exclusively intended to provide functional safety, by preventing the restart of a system. To achieve this functional safety, the wiring of the safety circuits must meet the safety requirements of IEC 60204, ISO 12100, IEC 62061 respectively ISO 13849-1.

In case of single channel control: if STO is automatically activated by a control system, then make sure that the output of the control is monitored for possible malfunction.

To achieve PLe or SIL CL3, the safe switching of the pulse inhibitor must be tested peri odically by analyzing the feedback signal from the safety control (ð p. 47).

6.9.4 Prohibited Use STO

The STO function must not be used if the drive is to be made inactive for the following reasons :

1. Cleaning, maintenance and repair operations, long inoperative periods: In such cases, the entire system should be disconnected from the supply by the personnel, and secured (main switch).

2. Emergency-stop situations: In an emergency-off situation, switched off the main contactor (by the emergency-off button).

6.9.5 Enlosure

Since the servo amplifier meets enclosure IP20, you must select the enclosure ensuring a safe operation of the servo amplifier referring to the enclosure. The enclosure must meet IP54 at least.

6.9.6 Wiring

When using STO wiring leads outside the control cabinet, the cables must be laid durably (firmly), protected from outside damage (e.g. laying in a cable duct), in different sheathed cables or protected individually by grounding connection. Wiring remaining within the demanded enclosure must meet the requirements of the standard IEC 60204-1.

6.9.7 Technical Data

Input voltage Input current Peak current Response time (falling edge at STO input until energy supply to motor is interrupted)

20V..30V 33mA – 40mA (Ieff) 100mA (Is) STO1: 1ms STO2: 2ms

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SIL CL2, PLd

+24V

SIL CL3, PLe

SIL CL2, PLd

+24V

Safety Controller

+24V +24V

XGND

4 3

+24V +24V

XGND XGND

5 4

7 6

XGND

+24V

2 1

5 4

8 7

switchgear

safety

interlock

Single Channel

Dual Channel

interlock

Dual Channel

switchgear

safety

switchgear

safety

6.9.8 Technical data and pinning

A SIL3 / PLe solution requires a safety control that periodically tests the safe switching of the pulse inhibitor by analyzing the status signals.

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NOTICE

6.9.9 Functional description

In case of use of the STO function the inputs STO1- Enable and STO2-Enable must be connected to the exits of a safety control or a safety relay, which meets at least to the requirements of the SIL CL2 according to IEC 62061 and PLd according to ISO 13849-1 (see the connection diagrams from page 43).

Possible states of the servo amplifier in connection with STO:

STO1-ENABLE STO2-ENABLE

0 V 0 V -S- no yes

0 V +24 V F27 no yes +24 V 0 V normal status e.g. 06 no no +24 V +24 V normal status e.g. E06 yes no

SIL2/PLd Single Channel Control

With the single-channel control of the STO (SIL2/PLd) safety function, both switch-off paths STO1-Enable and STO2-Enable are switched by one output of a safety switching device (e.g. safety relay), see example ð p. 43. In case of single channel usage of STO, erroneous engaging will not be recognized. Therefore the output of the control must be supervised for possible malfunction.

SIL2/PLd Dual Channel Control

With the dual-channel control of the STO (SIL2/PLd) safety function, the switch-off paths STO1-Enable and STO2-Enable are switched separately by two outputs of a safety switching device (e.g. safety relay), see example on ð p. 44.

SIL3/PLe Dual Channel Control

With the dual-channel control of the STO safety function, the switch-off paths STO1-Enable and STO2-Enable are switched separately by two outputs of a safety control, see example on ð p. 45. To achieve PL e or SIL CL 3, the safe switching of the pulse inhibitor must be tested periodically by analyzing the feedback (status) signals from the safety control (ð p. 47).

ENABLE Display

Motor has

torque

SIL CL2 or 3

safety

When wiring the STO inputs within one enclosure it must be paid attention to the fact that the used cables and the enclosure meet the requirements of IEC 60204-1. If the wiring leads outside the demanded enclosure, the cables must be laid durably (firmly), and protected from outside damage (see chapter 6.9.6).

If STO function is not needed in the application, then the inputs STO1-ENABLE and STO2-ENABLE must be connected directly with +24VDC. STO is passed by now and cannot be used. Now the servo amplifier is not a safety component referring to the EC Machine Directive.

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Enable

STO1-Enable

X3A/1

X4/7

X4/5

STO2-Enable

³100ms

speed

6.9.9.1 Safe operation sequence

If a controlled braking before the use of STO is necessary, the drive must be braked and the inputs STO1-ENABLE and STO2-Enable have to be separated from +24 VDC time-delayed.

1. Brake the drive in a controlled manner (speed setpoint = 0V)

2. When speed = 0 rpm, disable the servo amplifier (enable = 0V)

3. If there is a suspended load, block the drive mechanically

4. Activate STO (STO1-Enable and STO2-Enable = 0V)

The diagram shows how STO should be used to ensure a safe stop of the drive and error free operation of the servo amplifier.

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+24VDC

S21

S34S12

PNOZ S3

S12S11

S22 13

Reset

-S1

A2 S12 S34

2414

S22

E-Stop

-S2

PNOZ S3

A1 S11 S21S12

2313

BTB

X3B

BTB

Y2Y1

Mains contactor

6.9.9.2 Control circuit single channel SIL CL2/PLd (example)

The example shows a circuit diagram with one axis connected to an emergency stop cir cuit. The STO of the drives is switched by a protective screen. A single channel switch-off is used. The safety switch gears used in the example are manufactured by Pilz and fulfill at least the PLd acc. to ISO 13849-1. Further information to the safety switch gears is available from Pilz. The use of safety switch gears of other manufacturers is possible, if these also fulfill the SIL CL 2 according to IEC 62061 and PLd according to ISO 13849-1.

Emergency-stop circuit

acc. to ISO 13849-1

PLe

Safety function STO, SIL CL2 / PLd, single channel, 1 drive

Consider the wiring instructions on page 39.

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PNOZ S3

A2 S12 S34 14

+24VDC

E-Stop

S22

S21S11A1 S12 S22 13

S12

PNOZ S3

S11

Reset

-S1

S34

S12 S21

14 24

13 23

-S2

BTB

14 15

Y1 Y2

BTB

X3B

Mains contactor

6.9.9.3 Control circuit dual channel SIL CL2/PLd (example)

The example shows a circuit diagram with one axis connected to an emergency stop cir cuit. The STO of the drives is switched by a protective screen. A dual channel switch-off is used. The safety switch gears used in the example are manufactured by Pilz and fulfill at least the PLd acc. to ISO 13849-1. Further information to the safety switch gears is available from Pilz. The use of safety switch gears of other manufacturers is possible, if these also fulfill the SIL CL 2 according to IEC 62061 and PLd according to ISO 13849-1.

Emergency-stop circuit

acc. to ISO 13849-1

PLe

Safety function STO, SIL CL2 / PLd, dual channel, 1 drive

Consider the wiring instructions on page 39.

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STO2-Enable

+24VDC

E-Stop

S22

S12

PNOZ S3

S11

Reset

-S1

S34

S12 S21

14 24

13 23

-S2

BTB

14 15

BTB

Y1 Y2

X3B

STO1-Enable

STO2-Status STO1-Status

PNOZ mm0p

I2 I3 O0 O1

Mains contactor

6.9.9.4 Control circuit dual channel SIL CL3/PLe (example)

The example shows a circuit diagram with one axis connected to an emergency stop cir cuit. The STO of the drives is switched by a protective screen. A dual channel switch-off is used. The safe switching of the pulse inhibitor must be tested periodically by analyzing the feedback signals (status) in the safety control. The safety controller used in the example is manufactured by Pilz and fulfills at least the PLe acc. to ISO 13849-1. Further information to the safety controllers are available from Pilz. The use of safety controlelrs of other manufacturers is possible, if these also fulfill the SIL CL 3 according to IEC 62061 and PLe according to ISO 13849-1.

Emergency-stop circuit

acc. to ISO 13849-1

PLe

Safety function STO, SIL CL3 / PLe, dual channel, 1 drive

S748-S772 Instructions Manual 45

Consider the wiring instructions on page 39

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S3 S4

Safety door switch

mains 3~

NOTICE

6.9.9.5 Mains supply circuit (example)

S748/772

6.9.10 Functional test

6.9.10.1 SIngle or Dual Channel control, SIL CL2 / PLd

With initial starting and after each interference into the wiring of the drive or after exchange of one or several components of the drive the function of STO must be tested.

1. Method:

1. Stop drive, with setpoint 0V, keep servo amplifier enabled (Enable=24V).

DANGER: Do not enter hazardous area!

2. Activate STO1-Enable and STO2-Enable e.g. by opening protective screen (voltage at X4A/3=0V and X4B/6=0V).

Correct behavior: the BTB/RTO contact opens, the net contactor releases and the servo amplifier displays error F27.

2. Method:

1. Stop all drives, with setpoint 0V, disable servo amplifier (Enable=0V).

2. Activate STO1-Enable and STO2-Enable e.g. by opening protective screen (voltage at X4A/3=0V and X4B/6=0V).

Correct behavior: the servo amplifier displays -S-.

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Enable

STO1-Enable

X3A/1

X4/7

X4/5

STO2-Enable

X4/8

X3B/14,15

BTB/RTO

X4/1

24V DC

X4/6

Start

T1 T2 T3 T4 T5

End

6.9.10.2 SIL CL3 / PLe Dual Channel control

To achieve PLe / SIL CL3, the safe switching of the pulse inhibitor must be tested periodi cally by analyzing the feedback signal from a safety control:

At the start of a system

At the restart after triggering a protective device

At least every 8 hours by the operator.

The inputs STO1-ENABLE and STO2-ENABLE are switched in turns according to a defined test sequence. The switching states of the pulse inhibitor are available at the sta tus outputs of the S748/772 and are analyzed by a safety control.

The test sequence for the functional test of the safe pulse inhibitor must be performed as shown in the following time chart. Prerequisites for the start of the test sequence:

Operational readiness BTB/RTO = “1"

Enable signal ENABLE = “0"

STO1-ENABLE and STO2-ENABLE = “0"

Legend:

STO1-ENABLE: digital input, 1st switch-off path STO2-ENABLE: digital input, 2nd switch-off path STO1-STATUS: digital output, switching state of pulse inhibitor 1st switch-off path STO2-STATUS: digital output, switching state of pulse inhibitor 2nd switch-off path T1 … T5: Test sequence Start: Start of test sequence End: End of test sequence

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6.10 Shock-hazard protection

6.10.1 Leakage current

Leakage current via the PE conductor results from the combination of equipment and cable leakage currents. The leakage current frequency pattern comprises a number of frequencies, whereby the residual-current circuit breakers definitively evaluate the 50Hz current. As a rule of thumb, the following assumption can be made for leakage current on our low-capacity cables at a mains voltage of 400 V, depending on the clock frequency of the output stage:

= n x 20mA + L x 1mA/m at 8kHz clock frequency at the output stage

leak

= n x 20mA + L x 2mA/m at a 16kHz clock frequency at the output stage

leak

(where Ileak=leakage current, n=number of amplifiers, L=length of motor cable)

At other mains voltage ratings, the leakage current varies in proportion to the voltage.

Example: 2 x servo amplifiers + a 25m motor cable at a clock frequency of 8kHz:

2 x 20mA + 25m x 1mA/m = 65mA leakage current.

Since the leakage current to PE is more than 3.5 mA, in compliance with IEC 61800-5-1 the PE connection must either be doubled or a connecting cable with a cross-section >10mm² must be used. Use the PE terminals and the PE bolt in order to fulfil this require ment.

The following measures can be used to minimize leakage currents. — Reduce the length of the engine cable — Use low-capacity cables (see p.59) — Remove external EMC filters (radio-interference suppressors are integrated)

6.10.2 Residual current protective device (RCD)

In conformity with IEC 60364-4-41 – Regulations for installation and IEC 60204 – Electrical equipment of machinery, residual current protective devices (called RCD below) can be used provided the requisite regulations are complied with. The S748/772 is a 3-phase system with a B6 bridge. Therefore, RCDs which are sensitive to all currents must be used in order to detect any D.C. fault current. Rated residual currents in the RCD

10 -30 mA

50 -300 mA

Recommendation: In order to protect against direct contact (with motor cables shorter than 5 m) we recommend that each servo amplifier be protected individually using a 30mA RCD which is sensitive to all currents.

If you use a selective RCD, the more intelligent evaluation process will prevent spurious tripping of the RCD.

Protection against "indirect contact" for stationary and mobile equipment, as well as for "direct contact". Protection against "indirect contact" for stationary equipment

6.10.3 Isolating transformers

When protection against indirect contact is absolutely essential despite a higher leakage current, or when an alternative form of shock-hazard protection is sought, the S748/772 can also be operated via an isolating transformer (schematic connection see p.64). A ground-leakage monitor can be used to monitor for short circuits.

Be advised to keep the length of wiring between the transformer and the servo amplifier as short as possible.

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NOTICE

CAUTION

7 Mechanical Installation

7.1 Important notes

High leakage current!

There is a danger of electrical shock by high EMC level which could result in injury, if the servo amplifier (or the motor) is not properly EMC-grounded.

Do not use painted (i.e. non-conductive) mounting plates.

In unfavourable circumstances, use copper mesh tape between the earthing bolts and earth potential to deflect currents.

Protect the servo amplifier from impermissible stresses. In particular, do not let any com ponents become bent or any insulation distances altered during transport and handling. Avoid contact with electronic components and contacts.

The servo amplifier will switch-off itself in case of overheating. Ensure that there is an adequate flow of cool, filtered air into the bottom of the control cabinet, or use a heat exchanger. Please refer to page 28.

Don't mount devices, which produce magnetic fields, directly beside the servo amplifier. Strong magnetic fields could directly affect internal components. Install devices which produce magnetic field with distance to the servo amplifiers and/or shield the magnetic fields.

7.2 Guide to mechanical installation

The following notes should help you to carry out the mechanical installation.

In a closed control cabinet. Please refer to page 28.

Site

Ventilation

The site must be free from conductive or corrosive materials. For the mounting position in the cabinet ð p.52.

Check that the ventilation of the servo amplifier is unimpeded, and keep within the permitted ambient temperature ð p.28. Keep the re quired space clear above and below the servo amplifier ð p.52.

Assembly

Grounding

Shielding

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

For EMC-compliant shielding and grounding ð p.63. Ground the mounting plate, motor housing and CNC-GND of the control system. Notes on connection techniques ð p.58.

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244

363

386

190

145

118

227

477

369

7.3 Dimensions

7.3.1 Device with heat sink

Material: four M5 hexagon socket screws to ISO 4762

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345

363.25

190

145

453

345

230 210

102.5

205

174

NOTICE

7.3.2 Device with Coldplate

These devices are not UL listed and are not EAC and Safety certified.

Material: six M5 hexagon socket screws to ISO 4762

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7.4 Assembly

7.4.1 Mounting the shielding plate

Material: unscrew existing screws and re-use them Tool required : standard screw driver (cross)

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150

>50mm

385mm

>110mm

>2,5mm

>285mm

1.5mm

150 15050 5030

>30

365mm

Cable duct

Cabinet door

conductive (zinc-coated)

mounting panel

screw for hex key EN 4762

>2"

15.16"

>4.3"

>0.1"

0.06"

>11.22"

Cable duct

14.37"

>1" 5.9" 5.9" 5.9"1.97" 1.97"

>1"

7.4.2 Backplane mounting - devices with heat sink

Material: four M5 hexagon socket screws to ISO 4762 Tool required:4mmAllen key

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NOTICE

>50mm

363.25mm

200mm

210

102.5mm

70mm

102.5mm

Cable duct

Cabinet door

mounting panel

>2"

14.30"

>4.3"

7.87"

Cable duct

>1"

8.27"

>1"

8.27"

4.04"

2.76"

4.04"

7.4.3 Backplane mounting - devices with Coldplate

These devices are not UL listed and are not EAC and Safety certified.

Material: six M5 hexagon socket screws to ISO 4762 Ambient requirements see p.28, mounting plate flatness: £ 25 µm / 100 mm

Heat conducting film to increase the heat conduction, e.g. Kunze KU-CG20. Tool required:4mmAllen key

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DANGER

8 Electrical installation

8.1 Important notes

High voltage up to 900V!

There is a danger of serious personal injury or death by electrical shock or electrical arcing. Capacitors can still have dangerous voltages present up to 10 minutes after switching off the supply power. Control and power connections can still be live, even if the motor is not rotating.

Only install and wire the equipment when it is not live.

Make sure that the cabinet is safely disconnected (for instance, with a lock-out and warning signs).

Never remove electrical connections to the drive while it is live.

Wait at least 10 minutes after disconnecting the drive from the main supply power before touching potentially live sections of the equipment (e.g. contacts) or undoing any connections.

To be sure, measure the voltage in the DC bus link and wait until it has fallen below 50 V.

Wrong mains voltage, unsuitable motor or wrong wiring will damage the amplifier. Check the combination of servo amplifier and motor. Compare the rated voltage and current of the units. Implement the wiring according to the connection diagram on p. 57. Make sure that the maximum permissible rated voltage at the terminals L1, L2, L3 or +DC, –DC is not exceeded by more than 10% even in the most unfavorable circumstances (see IEC 60204-1).

Excessively high external fusing will endanger cables and devices. The fusing of the AC supply input and 24V supply must be installed by the user, best values are given on p.28. Hints for use of Residual-current circuit breakers (FI) ð p.48.

The servo amplifier's status must be monitored by the PLC to acknowledge critical situa tions. Wire the BTB/RTO contact in series into the emergency off circuit of the installation. The emergency off circuit must operate the supply contactor.

It is permissible to use the setup software to alter the settings of the servo amplifier. Any other alterations will invalidate the warranty.

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8.2 Guide to electrical installation

Correct wiring is the basis for reliable functioning of the servo system. Route power and control cables separately. We recommend a distance of at least 200mm. This improves the interference immunity. If a motor power cable is used that includes cores for brake control, the brake control cores must be separately shielded. Ground the shielding at both ends. Ground all shielding with large areas (low impedance), with metalized connector housings or shield connection clamps wherever possible. Notes on connection techniques can be found on page 58.

Feedback lines may not be extended, since thereby the shielding would be interrupted and the signal processing could be disturbed. Lines between amplifiers and external brake resistor must be shielded. Install all cables with an adequate cross-section, as per IEC 60204 (ð p.29) and use the requested cable material (ð p. 59) to reach max. cable length.

The following notes should help you to carry out the electrical installation.

Cable selection

Grounding

Shielding

Wiring

Select cables in accordance with IEC 60204 ð p.29.

For EMC-compliant shielding and grounding ð p.63. Ground the mounting plate, motor housing and CNC-GND of the control system. Notes on shield connection techniques ð p.58.

NOTE: Route power leads and control cables separately. Wire the BTB/RTO contact in series into the emergency off circuit of the system.

1. Connect the digital control inputs and outputs.

2. Connect the analog input source, if required.

3. Connect the feedback device.

4. Connect the expansion card

— (see corresponding notes from page 123).

5. Connect the motor cable

— Connect shielding at both ends.

6. Connect motor-holding brake, connect shielding at both ends.

7. Connect external brake resistor (with fusing)

8. Connect the auxiliary supply

— (maximum permissible voltage values ð p.28).

9. Connect the main electrical supply

— (maximum permissible voltage values ð p.28), hints for use of

Residual-current circuit breakers (FI) ð p.48

10.Connect the PC (ð p.100).

Final check

Final check of the implementation of the wiring against the wiring diagrams that have been used.

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DANGER

8.3 Wiring

The installation procedure is described as an example. A different procedure may be appropriate or necessary, depending on the application of the equipments. We provide further know-how through training courses (on request).

High voltage up to 900V!

There is a danger of electrical arcing with damage to contacts and serious personal injury.

Only install and wire up the equipment when it is not live, i.e. when neither the elec trical supply nor the 24 V auxiliary voltage nor the supply voltages of any other con nected equipment is switched on.

Make sure that the cabinet is safely disconnected (for instance, with a lock-out and warning signs).

The ground symbol must take care to provide an electrically conductive connection with the largest feasible surface area between the unit indicated and the mounting plate in the control cabinet. This connection is for the effective grounding of HF interference, and must not be con fused with the PE-symbol W (PE = protective earth, safety measure as per IEC 60204).

Use the following connection diagrams: Overview : page 63 Restart lock STO : page 43 Mains power : page 65 Motor : page 69 Feedback : page 71ff Electronic Gearing / Master Slave

Master-Slave : page 90

Pulse-Direction : page 91 Digital and analog inputs and outputs : page 95ff RS232 / PC : page 100 CAN Interface : page 101 EtherNET Interface : page 102 Expansion cards for slot 1:

I/O-14/08 : page 126

PROFIBUS : page 127

sercos

DeviceNet : page 130

SynqNet : page 134

FB-2to1 : page 135

2CAN : page 137 Expansion cards for slot 2:

PosI/O & PosI/O-Monitor : page 140ff Expansion cards for slot 3:

PosI/O & PosI/O-Monitor : page 136ff

Safety : page 150ff

X, which you will find in all the wiring diagrams, indicates that you

II : page 129

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8.3.1 Shielding connection to the front panel

Remove the outside shroud of the cable and the shielding braid on the desired core length. Secure the cores with a cable tie.

Remove the outside shroud of the line on a



length from for instance 30mm without da maging the shielding braid.

Strip all wires and fit wire end ferrules.

Use cable ties to attach the cable to the side (1) shroud or bottom (2) shielding plate of the servo amplifier, securing the braided shield of the cable to the shroud of the servo amplifier with a cable tie.





Alternatively you can use shield connection terminal clamps (see accessories manual). These hook into the bottom shroud and ensure optimum contact between the shield and the shroud.

Wire the plug-in terminal blocks as shown in the connection diagram.

The motor cable shield is connected via a shield connection clamp to the bottom shielding plate (3). Clamp and shielding plate are part of delivery.

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SHIELD

Capazity Phase-to-Shield

Core Isolation

Core

Isolation

Fill material

Shield

8.3.2 Technical data for connecting cables

For further information on the chemical, mechanical and electrical characteristics of the cables please refer to the accessories manual or contact our customer service.

Observe the rules in the section "Conductor cross-sections" on page 29. To reach the max. permitted cable length, you must use cable material that matches the capacitance requirements listed below.

Capacitance (core to shield)

Motor cable less than 150 pF/m Resolver/Encoder cable less than 120 pF/m

Example: Motor cable

Technical data

For a detailed description of Kollmorgen cable types and how to assemble them, please refer to the accessories manual.

Chokes

With motor cables longer than 25m the use of a motor choke 3YLN may be necessary depending on the system. Contact our customer support.

If mains voltage is more than 3% asymmetrical, a mains choke 3L with 2% uk must be used. See Accessories Manual.

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8.4 Components of a servo system

Mains

Drive cut-out

S748/S772

EtherNET

Feedback cable

PLC

Brake Resistor

Power Cable

Brake Cable

24V PSU

Motor

Mains

Cables drawn bold are shielded. The required accessories are described in our accesso ries manual.

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SinCos

RDC

XGND

+24V

4AM

Analog-In 2+

Analog-In 2-

AGND

-AS-

DIGITAL-INOUT2

DIGITAL-INOUT1

DIGITAL-IN2

DIGITAL-IN1

Analog-In 1-

Analog-In 1+

BTB/RTO

ENABLE

DIGITAL-IN4

DIGITAL-IN3

CAN

RS232

-AS-

CAN

232

-DC

BRAKE+

BRAKE-

M3~

-RB

+RB

L3 PE

Comcoder

STO1-ENABLE

+24V-IO

DGND

EtherCat

ETHER

NET

SynqNet

TCP/IP

BR +24V

BRGND

+DC

STO1-STATUS

STO2-STATUS

STO2-ENABLE

VBUS

EMI

Intermediate circuit

Inrush circuit

Power stage

Encoder

Resolver

EMI

Controller

Internal power supply

Kollmorgen 11/2018 Electrical installation

8.5 Block diagram

The block diagram below just provides an overview.

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DIGITAL-IN21/OUT1

DIGITAL-IN22/OUT2

X6 PC/CAN

CANL

CANH

BTB/RTO

Analog-In 1+

Analog-In 1-

Analog-In 2-

Analog-In 2+

DIGITAL-IN3

DIGITAL-IN4

ENABLE

DIGITAL-IN1

DIGITAL-IN2

DGND

8 7 6 5 4

BTB/RTO

2 1

6 7

TxD

RxD

reserve

GND

SHIELD

8 7 6

12 11

2 1

16 15

13 12

+24V-IO

AGND

X3B

X7B

Ethernet

I/O

X3A

24V/STO

BR+

BR-

X9A

X9B

2 1

BR+24V

BRGND

L1PE

-RB

V2W2

+RB -DC

PE+DC

X7A

Ethernet

+24V

STO2-ENABLE

STO1-ENABLE

STO1-STATUS

STO2-STATUS

XGND

4 3

n.c.

built-in connectors

thefaceofthe

X8 motor/brake

X0 Mains

Coding Keys

Brake

ENCODER

8.6 Connector assignments

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S748...S772

X3A/B

FN3

FN2

FB2

PE L1 L2 L3

FN1

FH3

FH1 FH2

24V DC

+24V

XGND

+RB

-RB

FB1

B+

B-

W1 V1

digital

BR+ BR-

CAN

BTB/RTO

Ethernet

COM1/COM2

CAN-Master

DIGITAL-IN22/OUT2

DIGITAL-IN3

DIGITAL-IN4

ENABLE

DIGITAL-IN21/OUT1

DIGITAL-IN1

DIGITAL-IN2

Analog-In 2-

Analog-In 2+

Analog-In 1-

Analog-In 1+

AGND

Digital2

Digital1

CNC-GND

STO2-ENABLE

Feedback

I/O-14/08 PROFIBUS SERCOS DEVICENET SYNQNET

DGND

+24V-IO

EtherCat

SynqNet

X9A

X9B

BRGND

BR +24V

24V DC

FBR

I/O-GND

STO1-ENABLE

XGND

Status 2

Status 1

STO2-STATUS

STO1-STATUS

Safety

- S1.2 (S3)

- S2.2 (S4)

Mains contactor

supply unit

Resolver

included

Resolver

thermal control

included

thermal control

PE-connection (protective earth)

shield connection at the front panel

shield connection via plug

chassis ground connection (panel)

to 0V/GND

+24V referred

+/-10V speed

setpoint2 referred to

CNC-GND

referred to

setpoint1

+/-10V speed

Control

Participant

Emerg. Stop

supply unit

Brake resistor

Circuit

Encoder

8.7 Connection Diagram (Overview)

Reference Safety Instructions (ð p.11) and Use As Directed (ð p.13) !

ð p.70ff

ð p.74

ð p.69

ð p.70

ð p.67

ð p.65

ð p.96

ð p.98

ð p.100

ð p.95

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208...480V

208...240V

400...480V

1:1

mains

Isolating transfo

mains

Isolating transfo

mains

NOTICE

8.8 Electrical supply

8.8.1 Connection to various mains supply networks

An isolating transformer is required for 400V to 480V networks that are asymmetrically grounded or not grounded as shown below.

S748/772

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FN1

FN3

FN1

FN3

3L...

NOTICE

XGND

+24V

4AM

8.8.2 Mains supply connection (X0)

— Directly to 3-phase supply network, filter is integrated, supply networks ð p.64

(with mains voltage below 300V set parameters NONBTB=3 and VBUSBAL=1.)

— Fusing (e.g. fusible cut-outs) to be provided by the user ð p.28 — Screw driver for plus-minus-screws (Combiprofile Slotted/Pozidriv) size 2

S748/772

If mains voltage is more than 3% asymmetrical, a mains choke 3L with 2% uk must be used. See Accessories Manual. For EMC reasons the choke should be mounted electri cally isolated to the cabinet.

S748/772

8.8.3 24V auxiliary supply (X4)

— External 24V DC power supply, electrically isolated, e.g. via an isolating transformer — Required current rating ð p.26 — Integrated EMC filter for the 24V auxiliary supply

S748/772

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-DC

FB2

RBext

FB1

-DC

+DC

-RB

+RB+RB

-RB

-DC

+DC

-DC

+RB

-DC

-RB

-DC

+DC

NOTICE

8.9 DC bus link (X8)

Terminals X8/-DC and X8/+DC. Can be connected in parallel, whereby the brake power is divided between all the amplifiers that are connected to the same DC bus link circuit. — Screw driver for plus-minus-screws (Combiprofile Slotted/Pozidriv) size 2

In case of mains supply from the same mains (identical mains supply voltage) three servo amplifiers S748/772 may be connected by the DC bus link.

The servo amplifiers can be destroyed, if DC bus link voltages are different. Only servo amplifiers with mains supply from the same mains (identical mains supply volt age) may be connected by the DC bus link.

The setting of VBUSBAL must be identical with all devices on the bus.

The sum of the rated currents for all of the servo amplifiers connected in parallel to an S748/772 must not exceed 96 Arms (140 Apeak).

Use unshielded single cores (cross section see p. 29) with a max. length of 500mm. Use shielded cables for longer lengths.

Servo amplifiers working generatively very often, should be placed beside amplifiers, which need energy. That reduces current flow on longer distances.

Fusing information are explained in detail in the KDN on page "DC Bus link in parallel

S748

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S700 S700 S700 S700 S700 S700

DC DC DC DC DC DC

FB1+RB

FB2-RB

RBext

+DC

-DC

8.9.1 DC Bus topology

Without intermediate circuit fuses, other devices can become damaged or destroyed if, for example, a device fails due to an internal short circuit. If a device fails due to a short-circuit, only its intermediate fuses are tripped and the rest of the network continues uninterrupted. Fuses cannot avoid damage by current peaks completely. Fuse types: see section "Fuses" on page 28.

The solid busbars can conduct large currents. For this reason, almost as many servo amplifiers as desired can be connected in parallel in this form.

8.9.2 External brake resistor (X8)

An external brake resistor can be connected to X8 (-RB, +RB). Fuse types: see section "Fuses" on page 28. Information for brake circuit and technical data can be found on page 31. If you want to link the DC bus with neighbored S748/772 servo amplifiers, see connection example on page 66, Chapter "DC Bus link". — Screw driver for plus-minus-screws (Combiprofile Slotted/Pozidriv) size 2

S748/772

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DANGER

8.9.3 Capacitor Module KCM (X8)

KCM modules (KOLLMORGEN Capacitor Modules) absorb energy gen

erated by the motor when it is operating in generator mode. Normally, this energy is dissipated as waste via brake resistors. KCM modules, however, feed the energy they have stored back into the DC Bus link as and when it is required. Dimensions (HxWxD) : 300x100x201 mm

KCM-S Saves energy: The energy stored in the capacitor module during regenerative

braking is available the next time acceleration happens. The module’s inception voltage is calculated automatically during the first load cycles.

KCM-P Power in spite of power failure: If the power supply fails, the module provides

the servo amplifier with the stored energy that is required to bring the drive to a standstill in a controlled manner (this only applies to the power supply voltage; battery-back the 24 V supply separately).

KCM-E Expansion module for both applications. Expansion modules are available in

two capacitance classes.

The KCM modules can be connected to S7010 ... S7480 devices (mains supply voltage 400/480V). Information for mounting, installation and setup can be found in the KCM Instructions Manual and in

KDN.

Technical Data of KCM Modules

Storage

capacity

Type [Ws] [V DC] [V DC] [kW] [V DC] [kg]

KCM-S200 1600 KCM-P200 2000 470 VDC 6,9 KCM-E200 2000 - 4,1 KCM-E400 4000 - 6,2

Rated sup-

ply

voltage

max.

850 VDC

Peak supply

voltage

max.

950 VDC

(30s in 6min)

Power

18 IP20

Protec-

tion

class

Inception

voltage

evaluated 6,9

Weight

High DC voltage up to 900 V!

There is a danger of serious personal injury or death by electrical shock or electrical arcing. It can take over an hour for the modules to self-discharge.

Switch off (disconnect) the line voltage. You must only work on the connections when the system is disconnected.

Check the state of charge with a measuring device that is suitable for a DC voltage of up to 1,000 V.

When measuring a voltage of over 50V between the DC+/DC- terminals or to ground, wait some minutes and measure again or discharge the modules as de scribed in the KCM instructions manual.

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NOTICE

8.10 Motor connection

8.10.1 Motor Power Connection (X8)

The S748/772 drive is able to protect the connected motor from overloading, if the param eters are set correctly and the thermal protection sensor is connected and supervised. With Kollmorgen motors the valid data are automatically set by the internal motor data

base. With motors from other manufacturers the data from the nameplate must be entered to the referring fields in the motor view of the setup software DriveGUI.

Together with the motor supply cable and motor winding, the power output of the servo amplifier forms an oscillating circuit. Characteristics such as cable capacity, cable length, motor inductance, frequency and voltage rise speed (see Technical Data, p. 26) deter

mine the maximum voltage in the system.

The dynamic voltage rise can lead to a reduction in the motor’s operating life and, on unsuitable motors, to flash overs in the motor winding. — Only install motors with insulation class F (acc. to IEC 60085) or above — Only install cables that meet the requirements on p.29 and p.59

Use screw driver for plus-minus-screws (Combiprofile Slotted/Pozidriv) size 2

Standard applications up to 25m cable length

S748/772

Application with cable length >25m and special conditions

With long motor cables overvoltage may endanger the motor winding. For cable lengths above 25m a motor choke 3YLN may be wired into the motor cable, close to the amplifier. Contact our customer support.

S748/772

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BRGND

X9B 1

BRGND

BR +24V

24V

BRGND

MarkusGrohnert Sigismundstr.16 45470Mülheim

X9A

BR-

BR+

Brake+

Brake-

CAUTION

8.10.2 Motor holding brake (X8, X9B)

The motor holding brake can be controller by the servo amplifier. An external 24V supply voltage delivers the required electrical power for the connected brake. Observe the requirements to the supply voltage listed on page 27.

No functional safety!

Serious injury could result when a suspended load is not properly blocked.

An additional mechanical brake is required for functional safety, which must be safely operated, e.g. via the Safety Card S1-2 (see p. 140).

8.11 Feedback Systems

S748/772

Every closed servo system will normally require at least one feedback device for sending actual values from the motor to the servo drive. Depending on the type of feedback device used, information will be fed back to the servo amplifier using digital or analog means. Up to three feedback devices can be used at the same time.

S748/772 supports the most common types of feedbacks whose functions must be assigned in the setup software DRIVEGUI.EXE with the parameters:

FBTYPE (screen page FEEDBACK), primary Feedback EXTPOS (screen page POSITION CONTROLLER), secondary Feedback GEARMODE (screen page ELECTRONIC GEARING), secondary Feedback (ð p.83)

Scaling and other settings must always be made in the software. For a detailed descrip tion of the ASCII parameters, please refer to the online help

of the setup software.

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SFD3 HIPERFACE DSL

8.12 Primary and secondary feedback types

This chapter provides an overview of the supported feedback types, their corresponding parameters and a reference to the relevant connection diagram in each case.

Single Cable connection (Power and Feedback in one cable)

Hybrid cables on request

primary secondary

Feedback type Connector Wiring FBTYPE EXTPOS

SFD3 X1 HIPERFACE DSL X1

ð p.72 ð p.73

Dual cable connection (Power and Feedback separated)

Motor cables and Feedback cables see Accessories Manual

36 35 -

primary secondary

Feedback type

Connec-

tor

Resolver X2 SinCos Encoder BiSS (B) analog X1

SinCos Encoder BiSS (B, C

) digital X1 SinCos Encoder ENDAT 2.1 X1 Encoder ENDAT 2.2 X1 SinCos Encoder HIPERFACE X1 SinCos Encoder SSI (linear) X1 SinCos Encoder w/o data channel X1 SinCos Encoder + Hall X1 ROD* 5V without zero, 1.5MHz X1 ROD (AquadB) 5V with zero, 350kHz X1 ROD (AquadB) 5V with zero + Hall X1 ROD (AquadB) 24V without zero X3 ROD (AquadB) 24V without zero + Hall X3/X1 SSI X1 Hall X1 Step/Direction 24V X3

Wiring

diagram

ð p.74 ð p.75 ð p.76 ð p.77 ð p.78 ð p.79 ð p.80 ð p.81 ð p.82 ð p.83 ð p.84 ð p.85 ð p.86 ð p.87 ð p.88 ð p.89 ð p.91

FBTYPE EXTPOS

23, 24 -

20, 22, 33 11, 12

4, 21 8

32, 34 13

1, 3, 7, 8 6, 7

5, 6 30, 31 30 17, 27 10

15 -

12, 16 2

14 -

11 -

-1

Sensorless (w/o Feedback) - - 10 -

with expansion card "PosI/O" or "PosI/O-Monitor"

ROD (AquadB) 5V with zero X5 ROD (AquadB) 5V with zero + Hall X5/X1 SSI X5 SinCos Encoder SSI (linear) X1 Step/Direction 5V X5

* ROD is an abbreviation for “incremental encoder”.

Switch on the encoder supply voltage on X1: set ENCVON to 1

BiSS C support for Renishaw sncoders, Hengstler encoders are not supported.

ð p.141 ð p.142 ð p.143 ð p.144 ð p.145

,19

18 -

9 28 -

-4

The expansion card FB2to1 (see p. 135) enables simultaneous connection of a digital pri mary and of an analog secondary feedback to the connector X1.

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SFD3

COM+

COM-

Brake-

Brake+

BR-

BR+

Drive

max. 250mA

Motor

Power

Brake

8.12.1 SFD3 (X1), single cable connection

Connection of the Kollmorgen feedback system SFD3 (primary, ð p.71). SFD3 can be used only with the special Kollmorgen hybrid cable (on request).

Maximum cable length 25 m.

FBTYPE: 36

The pin assignment shown on the encoder side relates to the Kollmorgen motors (connector code D).

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Feedback

DSL+

DSL-

COM+

COM-

Brake-

Brake+

BR-

BR+

HIPERFACE DSL

Drive

max. 250mA

Motor

Power

Brake

8.12.2 HIPERFACE DSL (X1), single cable connection

Connection of HIPERFACE DSL feedback (primary, ð p.71). HIPERFACE DSL can be used only with the special Kollmorgen hybrid cable (on request).

Maximum cable length 25 m.

FBTYPE: 35

The pin assignment shown on the encoder side relates to the Kollmorgen motors (connector code D).

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100µH

100µH14R7

4R7

min. 5VDC/5mA

Resolver

thermal control

Motor

8.12.3 Resolver (X2)

Connection of a Resolver (2 to 36-poles) as a feedback system (primary, ð p.71). The thermal control in the motor is connected via the resolver cable to X2 and evaluated there.

If cable lengths of more than 100m are planned, please consult our customer service.

FBTYPE: 0

S748/772

SubD9

12pol.round

The pin assignment shown on the encoder side relates to the Kollmorgen motors.

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max. 250mA

10k

Sense

10k

CLOCK

Sense

A+

A-

B-

B+

min. 5VDC/5mA

1414

voltage supply

Motor

sine

cosine

thermal control

Encoder

8.12.4 Sine Encoder with BiSS analog (X1)

Wiring of a single-turn or multi-turn sine-cosine encoder with BISS interface as a feed

back system (primary, ð p.71).

The thermal control in the motor is connected via the encoder cable to X1 and evaluated there. All signals are connected using our pre-assembled encoder connection cable. If cable lengths of more than 50m are planned, please consult our customer service.

Frequency limit (sin, cos): 350 kHz

Type FBTYPE EXTPOS GEARMODE Up

5V analog (BiSS B) 23 - - 5V +/-5% 12V analog (BiSS B) 24 - - 7,5...11V

S748/772

SubD 15

17pol.round

The pin assignment shown on the encoder side relates to the Kollmorgen motors.

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max. 250mA

Sense

CLOCK

Sense

min. 5VDC/5mA

Encoder

thermal control

voltage supply

Motor

8.12.5 Sine Encoder with BiSS digital (X1)

Wiring of a single-turn or multi-turn digital encoder with BISS interface as a feedback sys tem (primary and secondary, ð p.71).

Frequency limit : 1.5 MHz

Type FBTYPE EXTPOS GEARMODE Up

5V digital (BiSS B) 20 11 11 5V +/-5% 12V digital (BiSS B) 22 11 11 7,5...11V 5V digital (BiSS C, Renishaw) 33 12 12 5V +/-5%

S748/772

SubD 15

17pol.round

The pin assignment shown on the encoder side relates to the Kollmorgen motors.

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5V +/-5

max. 250mA

10k

EnDat

DATA

CLOCK

DATA

CLOCK

A-

A+

B+

B-

min. 5VDC/5mA

1414

sense

voltage supply

Motor

sense

Encoder

thermal control

8.12.6 Sine Encoder with EnDat 2.1 (X1)

Wiring of a single-turn or multi-turn sine-cosine encoder with EnDat 2.1 interface as a feedback system (primary and secondary, ð p.71). Preferred types are the optical encoders ECN1313 / EQN1325 and the inductive encoders ECI 1118/1319 or EQI 1130/1331. The thermal control in the motor is connected via the encoder cable to X1 and evaluated there. All signals are connected using our pre-assembled encoder connection cable. If cable lengths of more than 50m are planned, please consult our customer ser vice. Frequency limit (sin, cos): 350 kHz

Type FBTYPE EXTPOS GEARMODE

ENDAT 2.1 4 8 8 ENDAT 2.1 + Wake&Shake 21 8 8

S748/772

SubD15

17pol.round

The pin assignment shown on the encoder side relates to the Kollmorgen motors.

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max. 250mA

EnDat 2.2

DATA

CLOCK

DATA

CLOCK

min. 5VDC/5mA

1414

sense

voltage supply

Motor

sense

Encoder

thermal control

8.12.7 Encoder with EnDat 2.2 (X1)

Wiring of a single-turn or multi-turn encoder with EnDat 2.2 interface as a feedback sys tem (primary and secondary, ð p.71). The thermal control in the motor is connected via the encoder cable to X1 and evaluated there. All signals are connected using our pre-assembled encoder connection cable. If cable lengths of more than 50m are planned, please consult our customer service.

Frequency limit: 1.5 MHz

Type FBTYPE EXTPOS GEARMODE Up

5V ENDAT 2.2 32 13 13 5V +/-5%

12V ENDAT 2.2 34 13 13 7,5...11V

S748/772

SubD15

17pol.round

The pin assignment shown on the encoder side relates to the Kollmorgen motors.

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10k

RS485

REFSIN

REFCOS

+COS

+SIN

max. 250mA

7.5V ...11V

min. 5VDC/5mA

1414

Motor

voltage supply

Encoder

thermal control

8.12.8 Sine Encoder with HIPERFACE (X1)

Wiring of a single-turn or multi-turn sine-cosine encoder with HIPERFACE interface as a feedback system (primary and secondary, ð p.71).

The thermal control in the motor is connected via the encoder cable to X1 and evaluated there. All signals are connected using our pre-assembled encoder connection cable.

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

Frequency limit (sin, cos): 350 kHz

Type FBTYPE EXTPOS GEARMODE

HIPERFACE 2 9 9

S748/772

SubD15

17pol.round

The pin assignment shown on the encoder side relates to the Kollmorgen motors.

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max. 250mA

10k

Sense

10k

CLOCK

Sense

A+

A-

DATA

B-

B+

min. 5VDC/5mA

Encoder

voltage supply

Motor

sine

cosine

thermal control

8.12.9 Sine Encoder with SSI (X1)

Wiring of sine-cosine encoder with SSI interface as a linear feedback system (primary, ð p.71).

Frequency limit (sin, cos): 350 kHz

Type FBTYPE EXTPOS GEARMODE

SinCos SSI 5V linear 26 - -

Switch on the encoder supply voltage on X1: set ENCVON to 1

S748/772

SubD 15

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A-

A+

B+

B-

max. 250mA

RS 485

100pF

120

min. 5VDC/5mA

Encoder

voltage supply

sine

cosine

zero

Motor

thermal control

sense

WARNING

8.12.10 Sine Encoder without data channel (X1)

Wiring of a sine-cosine encoder without data channel as a feedback (primary and sec

ondary, ð p.71). Every time the 24V auxiliary voltage is switched on, the amplifier needs start-up information for the position controller (parameter value MPHASE). Depending on the feedback type either wake&shake is executed or the value for MPHASE is read out of the amplifier's EEPROM.

Vertical load can fall!

With vertical load the load could fall during wake&shake, because the brake is not active and torque is not sufficient to hold the load. Don't use wake&shake with vertical load (hanging load).

The thermal control in the motor is connected via the encoder cable to X1 and evaluated there. If lead lengths of more than 50m are planned, please consult our customer service. Frequency limit (sin, cos): 350 kHz

Type FBTYPE EXTPOS GEARMODE Up Remarks

SinCos 5V 1 6 6 5V +/-5% MPHASE from EEPROM SinCos 12V 3 7 7 7,5...11V MPHASE from EEPROM SinCos 5V 7 6 6 5V +/-5% MPHASE wake & shake SinCos 12V 8 7 7 7,5...11V MPHASE wake & shake

S748/772

SubD 15

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max. 250mA

10k

NI-

NI+

A+

A-

B-

B+

min. 5VDC/5mA

thermal control

voltage supply

HALL

Hall-U

Hall-V

Hall-W

Encoder

cosinus

sinus

Zero

Sense

MOTOR

8.12.11 Sine Encoder with Hall (X1)

Feedback devices (incremental or sine-cosine), which don't deliver an absolute informa tion for commutation, can be used as complete feedback system combined with an addi

tional Hall encoder (primary, ð p.71).

The thermal control in the motor is connected to X1 and evaluated there.

All signals are connected to X1 and evaluated there. If cable lengths of more than 25m are planned, please consult our customer service.

Frequency limit (sin, cos): 350 kHz

Type FBTYPE EXTPOS GEARMODE Up

SinCos 5V with Hall 5 - - 5V +/-5% SinCos 12V with Hall 6 - - 7,5...11V

S748/772

SubD15

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5V +/-5

max. 250mA

min. 5VDC/5mA

10k

120

sense

voltage supply

Motor

thermal control

Incremental Encoder

WARNING

8.12.12 ROD (AquadB) 5V, 1.5MHz (X1)

Wiring of a 5V incremental encoder (ROD, AquadB) as a feedback (primary or second

ary, ð p.71). Every time the 24V auxiliary voltage is switched on, the amplifier need start-up information for the position controller (parameter value MPHASE). Depending on the setting of FBTYPE a wake&shake is executed or the value for MPHASE is taken out of the servo amplifier's EEPROM. The thermal control in the motor is connected via the encoder cable to X1 and evaluated there. All signals are connected using our pre-assembled encoder connection cable. If cable lengths of more than 50m are planned, please consult our customer service.

Vertical load can fall!

With vertical load the load could fall during wake&shake, because the brake is not active and torque is not sufficient to hold the load. Don't use wake&shake with vertical load (hanging load).

Frequency limit (A, B): 1,5MHz

Type FBTYPE EXTPOS GEARMODE Remarks

AquadB 5V 31 30 30 MPHASE from EEPROM AquadB 5V 30 30 30 MPHASE wake & shake

S748/772

SubD15

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10k

max. 250mA

5V +/-5

min. 5VDC/5mA

Motor

voltage supply

Incremental Encoder

thermal control

sense

WARNING

8.12.13 ROD (AquadB) 5V, 350kHz (X1)

Wiring of a 5V incremental encoder (ROD, AquadB) as a feedback (primary or second

ary, ð p.71). Every time the 24V auxiliary voltage is switched on, the amplifier need start-up information for the position controller (parameter value MPHASE). With this feed back type the amplifier executes a wake&shake every time.

Vertical load can fall!

With vertical load the load could fall during wake&shake, because the brake is not active and torque is not sufficient to hold the load. Don't use wake&shake with vertical load (hanging load).

The thermal control in the motor is connected to X1 and evaluated there. If lead lengths of more than 50m are planned, please consult our customer service. Frequency limit (A, B): 350 kHz

Type FBTYPE EXTPOS GEARMODE Remarks

AquadB 5V 27 10 10 MPHASE from EEPROM AquadB 5V 17 10 10 MPHASE wake & shake

S748/772

SubD15

The pin assignment shown on the encoder side relates to the Kollmorgen motors.

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max. 250mA

5V +/-5

100pF

120

min. 5VDC/5mA

sense

thermal control

Hall-U

Hall-V

Hall-W

Motor

voltage supply

Comcoder

8.12.14 ROD (AquadB) 5V, 350kHz with Hall (X1)

Wiring of a ComCoder as a feedback unit (primary, ð p.71). For the commutation hall sensors are used and for the resolution an incremental encoder. The thermal control in the motor is connected to X1 and evaluated there. With our ComCoder cable all signals are connected correctly. If cable lengths of more than 25m are planned, please consult our customer service. With separate feedback devices (Encoder and Hall are two devices) the wiring must be done similar to chapter 8.12.11, but the amplifier's pinout is identical to the wiring diagram shown below. Frequency limit (A,B): 350 kHz

Type FBTYPE EXTPOS GEARMODE

AquadB 5V + Hall 15 - -

S748/772

SubD15

17pol.round

The pin assignment shown on the encoder side relates to the Kollmorgen motors.

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DGND

X1/X2

DIGITAL-IN1

DIGITAL-IN2

GND

X3B 16

X3A

X3A 2

min. 5VDC/5mA

incremental encoder

Motor

+24V ref. to GND

track B

track A

thermal control

WARNING

8.12.15 ROD (AquadB) 24V (X3)

Wiring of a 24V incremental encoder (ROD AquadB) as a feedback system (primary or secondary, ð p.71). This uses the digital inputs DIGITAL-IN 1 and 2 on connector X3. Every time the 24V auxiliary voltage is switched on, the amplifier need start-up informa tion for the position controller (parameter value MPHASE). With this feedback type the amplifier executes a wake&shake is executed every time the 24V auxiliary voltage is switched on.

Vertical load can fall!

With vertical load the load could fall during wake&shake, because the brake is not active and torque is not sufficient to hold the load. Don't use wake&shake with vertical load (hanging load).

The thermal control in the motor is connected to X1 or X2. If cable lengths of more than 25m are planned, please consult our customer service.

Frequency limit: 100 kHz, transition time tv £ 0.1µs

Type FBTYPE EXTPOS GEARMODE Remarks

AquadB 24V 12 2 2 MPHASE from EEPROM AquadB 24V 16 2 2 MPHASE wake & shake

S748/772

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DGND

DIGITAL-IN1

DIGITAL-IN2

GND

5V +/-5 max. 250mA

X3A

X3B

X3A

min. 5VDC/5mA

HALL

Hall-U

Hall-V

Hall-W

thermal control

sense

Motor

sense

track B

track A

+24V ref. to GND

Incremental Encoder

voltage supply

8.12.16 ROD (AquadB) 24V with Hall (X3, X1)

Wiring of a 24V incremental encoder (ROD, AquadB) and Hall sensors as a feedback unit (primary, ð p.71). For the commutation hall sensors are used and for the resolution an incremental encoder.

The thermal control in the motor is connected to X1 and evaluated there. If cable lengths of more than 25m are planned, please consult our customer service.

Frequency limit X3: 100 kHz, X1: 350 kHz

Type FBTYPE EXTPOS GEARMODE

AquadB 24V + Hall 14 - -

S748/772

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RS 485

CLOCK

SSI Absolut

5V +/-5 max. 250mA

min. 5VDC/5mA

120

10k

voltage supply

sense

thermal control

Sense

Motor

8.12.17 SSI Encoder (X1)

Wiring of a synchronous serial absolute-encoder as a feedback system (primary or sec ondary, ð p.71). The signal sequence can be read in Gray code or in Binary (standard) code. The thermal control in the motor is connected to X1 and evaluated there. If cable lengths of more than 50m are planned, please consult our customer service.

Frequency limit: 1.5MHz Resolution/turn: max. 16 Bit Turns: max. 16 Bit

Type FBTYPE EXTPOS GEARMODE

SSI 25 25 25

Switch on the encoder supply voltage on X1: set ENCVON to 1

S748/772

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5V +/-5 max. 250mA

min. 5VDC/5mA

HALL

Hall-U

Hall-V

Hall-W

sense

thermal control

sense

voltage supply

Motor

8.12.18 Hall sensors (X1)

Wiring of Hall sensors as a feedback unit (primary, ð p.71).

The thermal control in the motor is connected to X1 and evaluated there. If cable lengths of more than 25m are planned, please consult our customer service.

Frequency limit: 350 kHz

Type FBTYPE EXTPOS GEARMODE

Hall 11 - -

S748/772

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8.13 Electronic Gearing, Master-slave operation

In the case of the “electronic gearing” functionality (see setup software and description of GEARMODE parameter), the servo amplifier is controlled by a secondary feedback device as a slave.

It is possible to set up master/slave systems, use an external encoder as a setpoint encoder or connect the amplifier to a stepper motor control.

The amplifier is parameterized using the setup software (electronic gearing, parameter GEARMODE).

The resolution (number of pulses per revolution) can be adjusted.

If input X1 is used without the X1 power supply (pins 2, 4, 10, 12), e.g. master-slave oper ation with other servoamplifiers, the monitoring of this power supply must be switched off in order to prevent error message F04 from appearing. To do this, you must change Bit 20 of the DRVCNFG2 parameter (see ASCII object reference in the online help).

8.13.1 Signal source

The following types of external encoders can be used as master signal source for elec tronic gearing:

secondary Feedback type

SinCos Encoder BISS digital 1.5MHz X1 SinCos Encoder ENDAT 2.1 350kHz X1 Encoder ENDAT 2.2 1.5MHz X1 SinCos Encoder HIPERFACE 350kHz X1 SinCos Encoder without data channel 350kHz X1 ROD* (AquadB) 5V 1.5MHz X1 ROD* (AquadB) 5V 350kHz X1 ROD* (AquadB) 24V 100kHz X3 SSI 5V 1.5MHz X1 Step/direction 5V 1.5MHz X1 Step/direction 24V 100kHz X3

Frequency

limit

Connec

tor

diagram

Wiring

ð p.76 ð p.77 ð p.78 ð p.79 ð p.81 ð p.83 ð p.84 ð p.86 ð p.88 ð p.91 ð p.91

GEARMODE

11, 12

6, 7

30 10

2 25 27

With a "PosI/O" or "PosI/O-Monitor" expansion card in slot 2 or 3, the following additional encoder types can be used:

tor

Wiring

diagram

ð p.143 ð p.145 ð p.145

GEARMODE

secondary Feedback type

SSI 5V 1.5MHz X5 ROD* (AquadB) 5V 1.5MHz X5 Step/direction 5V 1.5MHz X5

* ROD is an abbreviation for incremental encoder

Frequency

limit

Connec

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Master

RS 485

10k

120

GND

RS 485

120

pulse

direction

+5V ref. to GND

direction

pulse

GND

Master

DGND

DIGITAL-IN1

DIGITAL-IN2

X3B 16

X3A

X3A 2

direction

+24V ref. to GND

direction

pulse

8.13.2 Connection to stepper motor controllers (step and direction)

You can connect the servo amplifier to a third-party stepper-motor controller. Parameter setting for the slave amplifier is carried out with the aid of the setup software (electronic gearing). The number of steps can be adjusted, so that the servo amplifier can be adapted to match the step-direction signals of any stepper controller. Various monitor ing signals can be generated.

Using an A quad B encoder provides better EMC noise immunity.

8.13.2.1 Step/Direction with 5 V signal level (X1)

Wiring of the servo amplifier (SubD connector X1) to a stepper-motor controller with a 5V signal level. Frequency limit: 1.5 MHz

Type GEARMODE

Step/direction 5V 27

S748/772

8.13.2.2 Step/Direction with 24 V signal level (X3)

Wiring of the servo amplifier to a stepper-motor controller with a 24 V signal level. Used are the digital inputs DIGITAL-IN 1 and 2 on connector X3.

Frequency limit: 100 kHz,

Type GEARMODE

Step/direction 24V 1

S748/772

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B-

B+

A-

150 *Ù

A+

RS 485

B+

B-

A-

A+

GND

RS 485

Slave

Master

* matches RS485 with resistor according

to line impedance

8.13.3 Master-slave operation

8.13.3.1 Connection to an S748/772 master, 5V signal level (X1)

You can link two S748/772 amplifiers together in master-slave operation. One slave amplifier can be controlled by the master, via the encoder output X1 (see p. 93).

Master: position output to X1 (screen page "Encoder emulation") Slave: screen page "Electronic gearing" (GEARMODE)

Frequency limit: 1.5 MHz

Example for Master-Slave operation with two S748/772 amplifiers (ROD emulation): Slave GEARMODE: 30 Master ENCMODE:9

S748/772

If using SSI emulation, then the master must be set to ENCMODE 10 and the slave to GEARMODE 25.

8.13.3.2 Connection to an S748/772 Master, 5V signal level (X5)

If an expansion card PosI/O or PosI/O-Monitor (see p.140 ff) is built-in, you can use the encoder emulation via X5. With this interface up to 16 Slaves can be connected to one Master, because no internal termination resistors are built-in with X5. Wiring see p.145.

S748/772

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RS 485

150 *Ù

A+

B+

A-

GND

B-

NI-

NI+

150 *Ù

aatdaa

GND

I UI 2V/20mAÄ ³

GND

RS 485

* according to line impedance

zero I

track A

track B

Control

Edge spacing a 0.20 µs³

Edge steepness tv 0.1 µs£

Delay NI-td 0.1 µs£

8.14 Encoder Emulation, position output

8.14.1 Incremental encoder output - A quad B (X1)

Fast incremental encoder interface. Select encoder function ROD (A Quad B) Encoder (“Encoder Emulation” screen page). The servo amplifier calculates the motor shaft posi tion from the cyclic- absolute signals of the resolver or encoder, generating incremen tal-encoder compatible pulses from this information. Pulse outputs on the SubD connec tor X1 are 2 signals, A and B, with 90° phase difference (i.e. in quadrature, hence the alternative term “A quad B” output), with a zero pulse. The resolution (before multiplication) can be set:

Encoder function (ENCMODE)

9, ROD => X1

Feedback system (FBTYPE)

Resolution (ENCOUT)

0, Resolver 32...4096

>0, Encoder etc.

256...524288

…219)

Zero pulse (NI)

once per turn (only at A=B=1)

With built in safety card only binary resolutions up to 212are possible.

Use the NI-OFFSET parameter to adjust + save the zero pulse position within one mechanical turn. The drivers operate off an internal supply voltage.

The maximum permissible cable length is 100 meters.

Connections and signals for the incremental encoder interface : Default count direction: UP when the motor shaft is rotating clockwise (looking at the shaft's end)

S748/772

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RS 485

DATA

CLOCK

DATA

GND

CLOCK

DATA

CLOCK

Clock

123456 87 9 10 11 14

12 13 15 16

2117 18 19 20 22 23 24 25

I UI 2V/20mAD³

GND

I UI 0.3VD³

Gray

3026 2927 28 333231

G31

Time Out tp = 3µs/13µs (SSITOUT)

150 *W

GND

Control

* according to line impedance

Binary

Output Input

Switch over time Data tv 300nsec£ Period T = 600 ns

8.14.2 SSI encoder output (X1)

SSI interface (synchronous serial absolute-encoder emulation). Select encoder function SSI (“Encoder Emulation” screen page, ENCMODE 10). The servo amplifier calculates the motor shaft position from the cyclic-absolute signals of the resolver or encoder. From this information a SSI date (Stegmann patent specification DE 3445617C2) is provided. Max 32 bits are transferred. The leading data bit contains the number of revolutions and are selectable from 12 to 16 bits. The following max. 16 bits contain the resolution and are not variable.

The following table shows the allocation of the SSI date depending upon selected number of revolutions:

Revolution

Resolution (variable)

SSIREVOL

1514131211109876543210

14131211109876543210

Bit

131211109876543210

1514131211109876543210

1211109876543210

11109876543210

The signal sequence can be output in Gray code or in Binary (standard) code. The servo amplifier can be adjusted to the clock frequency of your SSI-evaluation with the setup software.

The drivers operate off an internal supply voltage.

Connection and signals for the SSI interface : Default count direction: UP when the motor shaft is rotating clockwise (looking at the end of the motor shaft)

S748/772

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10k

10n

10k

Analog-In 2-

Analog-In 2+

Analog-In 1-

Analog-In 1+

10n

AGND

X3B

GND

CNC-GND

150k

setpoint 2 +/-10V

ref. to CNC-GND

setpoint 1 +/-10V

control

8.15 Digital and analog inputs and outputs

8.15.1 Analog Inputs (X3B)

The servo amplifier is fitted with two programmable differential inputs for analog setpoints. AGND (X3B/13) must always be joined to the GND of the controls as a ground reference.

Technical characteristics

— Differential-input voltage max. ± 10 V — Ground reference AGND, terminal X3B/13

— Input resistance 150 kW — Common-mode voltage range for both inputs ± 10 V — Update rate 62.5 µs

S748/772

Analog-In 1 input (terminals X3B/10-9)

Differential input voltage max. ± 10 V, resolution 16 Bit (accuracy 13 Bit), scalable. Standard setting: speed setpoint

Analog-In 2 input (terminals X3B/12-11)

Differential input voltage max. ± 10 V, resolution 16 Bit (accuracy 13 Bit), scalable. Standard setting: torque setpoint

Application examples for setpoint input Analog-In 2: — adjustable external current limit — reduced-sensitivity input for setting-up/jog operation — pre-control / override

If an input was freshly assigned to a pre-programmed function, then the data set must be saved in the EEPROM of the servo amplifier and a reset has to be carried out (with the amplifier setup software for example).

Defining the direction of rotation

Standard setting : clockwise rotation of the motor shaft (looking at the shaft end) — Positive voltage between terminal X3B/10 (+ ) and terminal X3B/9(-)or — Positive voltage between terminal X3B/12 (+ ) and terminal X3B/11(-)

To reverse the direction of rotation, swap the connections to terminals X3B/10-9 or X3B/12-11 respectively, or change the COUNT DIRECTION parameter in the “Feedback”

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DIGITAL-IN2

DIGITAL-IN1

DGND

ENABLE

DIGITAL-IN4

DIGITAL-IN3

X3A

NSTOP

ENABLE

I/O-GND

PSTOP

DIGITAL-IN21*

DIGITAL-IN22*

X3B

24V

STO1-Enable

XGND

24V

STO2-Enable

against I/O-GND

Controls

8.15.2 Digital Inputs (X3A, X3B, X4)

S748/772

* DIGITAL-IN 21 and 22 must be defined as inputs using the setup software (“Digital I/O” screen page).

8.15.2.1 Connectors X3A, X3B

Input ENABLE

— PLC compatible (IEC 61131-2 type 1), floating, reference ground is DGND — High: 15...30 V / 2...15 mA , Low: -3...5V/<1mA — Update rate: Software 250 µs

The output stage of the servo amplifier is enabled by applying the ENABLE signal (Termi nal X3A/1, active high). Enable is possible only if inputs STOx-Enable have a 24 V signal (see page 37ff). In the disabled state (low signal) the connected motor has no torque.

A software enable by means of the setup software is also required (AND link), although this can also be permanently enabled (“Basic Setup” screen page of the DRIVEGUI.EXE setup software).

Programmable digital inputs

You can use the digital inputs X3A/2...7 to initiate pre-programmed functions that are stored in the servo amplifier. A list of these pre-programmed functions can be found on the “Digital I/O” screen page of our setup software. If an input was freshly assigned to a pre-programmed function, then the data set must be saved in the EEPROM of the servo amplifier and a reset has to be carried out (with the amplifier setup software for example).

(X3):

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NOTICE

Digital Inputs DIGITAL-IN 1...2 (X3A/2,3):

These inputs are particularly fast and are therefore suitable for latch functions or for high-speed feedback signals, for example.

— PLC compatible (IEC 61131-2 type 1), floating, reference ground is DGND — High: 15...30 V / 2...15 mA , Low: -3...5V/<1mA — Update rate: Hardware 2µs

Digital Inputs DIGITAL-IN 3...4 (X3A/4,5):

The PSTOP and NSTOP limit switch evaluation functions, for instance, can be assigned to these inputs. Choose the function you require in the setup software (“Digital I/O” screen page).

— PLC compatible (IEC 61131-2 type 1), floating, reference ground is DGND — High: 15...30 V / 2...15 mA, Low: -3...5V/<1mA — Update rate: Software 250 µs

Digital Inputs DIGITAL-IN 21...22 (X3A/6,7):

Pins 6 and 7 on X3A can be used as either inputs or outputs. Choose the function you require in the setup software (“Digital I/O” screen page).

— PLC compatible (IEC 61131-2 type 1), floating, reference ground is DGND — High: 15...30 V / 2...15 mA, Low: -3...5V/<1mA — Update rate: Software 250 µs

Depending on the selected function the inputs are high or low active.

8.15.2.2 Connector X4

You can thus achieve a restart lock for functional safety by using the STOx-enable inputs in conjunction with an external safety circuit.

Inputs STO1-ENABLE (X4/7), STO2-Enable (X4/5)

— Floating, reference ground is XGND — 20V...30V / 33mA...45mA

These inputs are not compatible with IEC 61131-2.

These additional digital inputs release the power output stage of the amplifier as long as a 24 V signal is applied to these inputs. If one STOx-Enable input goes open-circuit, then power will no longer be supplied to the motor, the drive will lose all torque and coast

down to a stop.

Failsafe braking of the drive, if required, must be provided by means of an additional mechanical brake, since electrical braking by the drive is no longer possible.

You can find further information and connection examples on page 37ff.

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DIGITAL-OUT2*

DGND

100n

DIGITAL-OUT1*

BTB/RTO

I/O-GND

Digital 2

Digital 1

X3B

X3A

X3B

X3A

24V-IO

X3A

+24V

XGND

STO2-Status

STO1-Status

STO2-Status

Safety Control

Emergency Stop

control

Circuit

8.15.3 Digital Outputs (X3A, X3B, X4)

Technical characteristics

— Power supply at terminals X3A/8 (24V-IO) and X3B/16 (DGND) — All digital outputs are floating — 24V-IO : 20V DC … 30V DC

DIGITAL-OUT1 / 2 : PLC compatible (IEC 61131-2 type 1), max. 100mA STO1/2-Status : PLC compatible (IEC 61131-2 type 1), max. 100mA BTB/RTO : Relay output, max. 30V DC or 42V AC, 0.5A

— Update rate : 250 µs

S748/772

* DIGITAL-OUT 1 and 2 must be defined as outputs using the setup software (“Digital I/O” screen page).

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8.15.3.1 Connectors X3A, X3B

Ready-to-operate contact BTB/RTO (X3B/14,15)

Operational readiness (terminals X3B/14 and X3B/15 ) is signaled by a floating relay contact. The contact is closed when the servo amplifier is ready for operation, and the signal is not influenced by the enable signal, the I²t-limit, or the brake threshold.

All faults cause the BTB/RTO contact to open and the output stage to be switched off (if the BTB/RTO contact is open, the output stage is inhibited -> no power output). A list of the error messages can be found on page 120.

Programmable digital outputs DIGITAL-OUT1/2(X3A/6,7):

Pins 6 and 7 on X3A can be used as either inputs or outputs. Choose the function you require in the setup software. The outputs are floating outputs, so the 24 V switching volt age must be provided by an external supply via X3A/8.

If they are programmed as digital outputs, messages from pre-programmed functions stored in the servo amplifier can be output here. A list of these pre-programmed functions can be found on the “I/O digital” screen page of our setup software.

If an output is to be freshly assigned to a pre-programmed function, then the parameter set must be saved in the EEPROM of the servo amplifier and a reset has to be carried out (with the amplifier setup software for example).

8.15.3.2 Connector X4

Status messages STO1-Status (X4/8) and STO2-Status (X4/6):

Pin 6 and 8 on X4 report the status of the STO-Enable inputs. The outputs are floating outputs, so the 24 V switching voltage must be provided by an external supply via X3A/8.

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TxD

RxD

TxD

RxD

RS 232

see below

Pin-No.

RS232

GND

RxD

TxD

GND

RxD

TxD

RxD

TxD

GND

TxD

RxD

GND

RS232

female

Sub-D 9 poles

Sub-D 25 poles Sub-D 9 poles

Sub-D 9 poles

8.16 RS232 interface, PC connection (X6)

Operating, position control, and motion-block parameters can be set up by using the setup software on an ordinary commercial PC (see p.107).

Connect the PC interface (X6) of the servo amplifier to a serial interface on the PC via a null-modem cable, while the supply to the equipment is switched off.

Do not use a null-modem power link cable!

S748/772

This interface has the same electrical potential as the CANopen interface.

The interface is selected and set up in the setup software.

Further notes on page 106.

With the optional expansion module -2CAN- the two interfaces for RS232 and CAN, which otherwise use the same connector X6, are separated onto two connectors ð p.137).

Interface cable between the PC and servo amplifiers of the

S748/772 series:

(View : looking at the solder side of the SubD sockets on the cable)

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