Kollmorgen S700 Series, S74802-NANAF2, S77202-NANANA, S77202-NAF2NA, S74802 Instruction Manual
...
S700
Digital Servo Amplifier S748x2...S772x2 (STO dual channel)
Instructions Manual
Edition: July 2019,
Translation of the original document
Valid for Hardware Revision 02.30
For safe and proper use, follow
these instructions.
Keep them for future reference.
Record of Document Revisions
Revision Remarks
... Table with lifecycle information of this document see (➜ # 165)
02/2017 X6 Pin 1 corrected (no 5V output), warning notes, handling separate chapter, single cable con-
nection new, SFD3/Hiperface DSL new
11/2018 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
07/2019 CE Conformity (RoHS), dc bus link (examples), layout updates
Hardware Revision (HR)
Hardware
Rev.
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 approved
02.20 5.18_ND0 - 5.99_ND0 - New data structure
02.30 ≥ 6.00_ND0 - SFD3/DSL support
Firmware
Rev.
Export classi-
fication
Remarks
Trademarks
WINDOWS is a registered trademark of Microsoft Corporation
HIPERFACE is a registered trademark of Max Stegmann GmbH
sercos®is a registered trademark of sercos®international e.V.
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!
This document is the intellectual property of Kollmorgen. 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.
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S748-772 Instructions Manual | Table of Contents
1 Table of Contents
1 Table of Contents 3
2 General 9
2.1 About thismanual 9
2.2 Using the PDF Format 9
2.3 SymbolsUsed 10
2.4 Standards used 11
2.5 AbbreviationsUsed 12
3 Safety 13
3.1 You should payattention to this 13
3.2 Warning notes placed on the product 15
3.3 Use asDirected 16
3.4 Prohibited Use 17
4 Product life cycle handling 18
4.1 Transport 18
4.2 Packaging 18
4.3 Storage 18
4.4 Decommissioning 18
4.5 Maintenance and cleaning 19
4.6 Disassembly 19
4.7 SystemRepair 20
4.8 Disposal 20
5 Approvals 21
5.1 Conformance with UL 21
5.2 CE conformance 22
5.2.1 European Directivesand Standards for the machine builder 22
5.2.2 Functional Safety Conformance according to EC Machinery Directive 23
5.3 Conformance with RoHS 23
5.4 Conformance with REACH 23
5.5 Conformance with EAC 24
6 Package 25
6.1 Package supplied 25
6.2 Nameplate 25
6.3 Part number scheme 26
7 Technical description 27
7.1 The S700 family of digitalservo amplifiers 27
7.2 Technicaldata 30
7.2.1 Rated data 30
7.2.2 Inputs, outputs, aux. voltage supply 31
7.2.3 Connectors 31
7.2.4 Recommended tightening torques 31
7.2.5 Fusing 32
7.2.6 Ambient Conditions,Ventilation,and Mounting Position 32
7.2.7 Conductor cross-sections 33
7.3 Motor holding brake 34
7.4 LED display 35
7.5 Grounding system 35
7.6 Dynamic braking(brake circuit) 35
7.7 Switch-on and switch-off behavior 36
7.7.1 Behavior in standard operation 37
7.7.2 Behavior in the event of an error (with standard setting) 38
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S748-772 Instructions Manual | Table of Contents
7.8 Stop-, Emergency Stop-, Emergency Off Function to IEC 60204 39
7.8.1 Stop 39
7.8.2 Emergency Stop 40
7.8.3 Emergency Off 40
7.9 Safety functionSTO 41
7.9.1 Safety characteristic data 41
7.9.2 Safety notes 42
7.9.3 Use as directed 43
7.9.4 Prohibited Use STO 43
7.9.5 Enclosure 43
7.9.6 Wiring 43
7.9.7 Technicaldata 43
7.9.8 Pinout 44
7.9.9 Functional description 45
7.9.9.1 Safe operation sequence 46
7.9.9.2 Control circuit single channel SIL2/PLd (example) 47
7.9.9.3 Control circuit dual channel SIL2/PLd (example) 48
7.9.9.4 Control circuit dual channel SIL3/PLe (example) 49
7.9.9.5 Mains supply circuit (example) 50
7.9.10 Functional test 50
7.9.10.1 SIngle or Dual Channel control, SIL CL2 / PLd 50
7.9.10.2 SIL CL3 / PLe Dual Channel control 51
7.10 Shock-hazard Protection 52
7.10.1 Leakage current 52
7.10.2 Residualcurrent protectivedevice(RCD) 52
7.10.3 Isolating transformers 52
8 Mechanical Installation 53
8.1 Important Notes 53
8.2 Guide to MechanicalInstallation 53
8.3 Dimensions 54
8.3.1 Device with heat sink 54
8.3.2 Device with Coldplate 55
8.4 Assembly 56
8.4.1 Mounting the shieldingplate 56
8.4.2 Backplane mounting - devices with heat sink 57
8.4.3 Backplane mounting - devices with Coldplate 58
9 Electrical Installation 59
9.1 Important Notes 59
9.2 Guide to electricalinstallation 60
9.3 Wiring 61
9.3.1 Shielding connection to the front panel 62
9.3.2 Technicaldata for connecting cables 63
9.4 Components of a servo system 64
9.5 Blockdiagram 65
9.6 Connector assignments 66
9.7 Connection diagram (Overview) 67
9.8 Voltage supply 68
9.8.1 Connection to various mainssupply networks 68
9.8.2 Mainssupplyconnection (X0) 69
9.8.3 24V auxiliary supply (X4) 69
9.9 DC bus link (X8) 70
9.9.1 DC Bustopology 71
9.9.2 External brake resistor (X8) 71
9.9.3 Capacitor Module KCM (X8) 72
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9.10 Motor connection 73
9.10.1 Motor power connection (X8) 73
9.10.2 Motor holding brake connection (X8, X9) 74
9.11 Feedback systems 74
9.12 Primary and secondary feedbacktypes 75
9.12.1 SFD3 (X1), singlecable connection 76
9.12.2 HIPERFACE DSL (X1), single cable connection 77
9.12.3 Resolver (X2) 78
9.12.4 Sine Encoder with BiSS analog (X1) 79
9.12.5 Encoder with BiSS digital (X1) 80
9.12.6 Sine Encoder with EnDat 2.1 (X1) 81
9.12.7 Encoder with EnDat 2.2 (X1) 82
9.12.8 Sine Encoder with HIPERFACE (X1) 83
9.12.9 Sine Encoder with SSI(X1) 84
9.12.10 Sine Encoder without data channel(X1) 85
9.12.11 Sine Encoder with Hall(X1) 86
9.12.12 ROD (AquadB) 5V, 1.5MHz (X1) 87
9.12.13 ROD (AquadB) 5V, 350kHz(X1) 88
9.12.14 ROD (AquadB) 5V, 350kHzwith Hall(X1) 89
9.12.15 ROD (AquadB) 24V (X3) 90
9.12.16 ROD (AquadB) 24V withHall (X3, X1) 91
9.12.17 SSI absolute Encoder (X1) 92
9.12.18 Hall sensors (X1) 93
9.13 ElectronicGearing, Master-Slave operation 94
9.13.1 Encoder control types 94
9.13.2 Connection to stepper motor controllers (step and direction) 95
9.13.2.1 Step / Direction with 5 V signal level (X1) 95
9.13.2.2 Step / Direction with 24 V signal level (X3) 95
9.13.3 Master-Slave operation 96
9.13.3.1 Connection to an S700 master, 5V signal level (X1) 96
9.13.3.2 Connection to an S700 Master, 5V signal level (X5) 96
9.14 Encoder Emulation,position output 97
9.14.1 Incremental encoder output - A quad B(X1) 97
9.14.2 SSI encoder output (X1) 98
9.15 Digitaland analog inputs and outputs 99
9.15.1 Analog Inputs (X3B) 99
9.15.2 DigitalInputs (X3A, X3B, X4) 100
9.15.2.1 Connector X3A, X3B 100
9.15.2.2 Connector X4 101
9.15.3 DigitalOutputs (X3A, X3B,X4) 102
9.15.3.1 Connectors X3A, X3B 103
9.15.3.2 Connector X4 103
9.16 RS232 interface, PC connection (X6) 104
9.17 CAN-bus interface (X6) 105
9.18 EtherNet interface (X7) 106
9.19 Memory card 107
10 Setup 108
10.1 Important notes 108
10.2 Setup software 109
10.2.1 Use as directed 109
10.2.2 Software description 109
10.2.3 Hardware requirements, operating systems 110
10.2.4 Installation under WINDOWS 110
10.3 Quickstart, initialdrive test 111
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S748-772 Instructions Manual | Table of Contents
10.3.1 Preparation 111
10.3.2 Connect 113
10.3.3 Important Screen Elements 114
10.3.4 Setup Wizard 115
10.3.4.1 BasicSetup 115
10.3.4.2 Units/Mechanical 116
10.3.4.3 Motor (rotary) and Feedback 117
10.3.4.4 Motor (linear) / Feedback(Encoder) 117
10.3.4.5 Save Parameters and Restart 118
10.3.5 Motion Service (Jog Mode) 118
10.3.6 More Setup Screens 119
10.4 Multi axis system 120
10.5 Keypad operation and LED display 120
10.5.1 Operation 121
10.5.2 Status display 121
10.5.3 Standard menu structure 121
10.5.4 Advancedmenu structure 122
10.6 Error messages 123
10.7 Warning messages 124
10.8 Trouble shooting 125
11 Expansions 126
11.1 Expansion cards for slot 1 126
11.1.1 Guideto installation of expansioncards inslot 1 126
11.1.2 Expansion card -I/O-14/08- 127
11.1.2.1 Technical data 127
11.1.2.2 LEDs 127
11.1.2.3 Entering a motionblock number (example) 127
11.1.2.4 Connector assignments 128
11.1.2.5 Connection diagram (default) 129
11.1.3 Expansion card -PROFIBUS- 130
11.1.3.1 Connection technology 130
11.1.3.2 Connection diagram 130
11.1.4 Expansion card -SERCOS- 131
11.1.4.1 LEDs 131
11.1.4.2 Connection technology 131
11.1.4.3 Connection diagram 132
11.1.4.4 Setup 132
11.1.5 Expansion card - DEVICENET - 133
11.1.5.1 Connection technology,Connection diagram 133
11.1.5.2 Combined module statusand network statusLED 134
11.1.5.3 Setup 134
11.1.5.4 Bus cable 135
11.1.6 Expansion card -SYNQNET- 136
11.1.6.1 NODE ID Switch 136
11.1.6.2 NODE LED table 136
11.1.6.3 SynqNet Connection, Connector X21B /X21C (RJ-45) 136
11.1.6.4 Digital inputs and outputs, connector X21A (SubD 15-pin, socket) 137
11.1.6.5 Connection diagram digital inputs and outputs, connector X21A 137
11.1.7 Expansion card - FB-2to1 - 138
11.1.7.1 Pinout 138
11.1.7.2 Wiring example with BiSS digital(primary) and SinCos (secondary) 139
11.1.8 Expansion module-2CAN- 140
11.1.8.1 Installation 140
11.1.8.2 Connection technology 140
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S748-772 Instructions Manual | Table of Contents
11.1.8.3 Connector assignments 141
11.1.8.4 Setup of Station Address and Baud Rate 141
11.2 Expansion cards for slot 2 142
11.2.1 Guideto installation of expansioncards inslot 2 142
11.2.2 Option"F2", controlled Fan 142
11.2.3 Expansion cards "PosI/O" & "PosI/O-Monitor" 143
11.2.3.1 Feedback 144
11.2.3.1.1 ROD (AquadB) 5V (X5, X1) 144
11.2.3.1.2 ROD (AquadB) 5V with Hall (X5, X1) 145
11.2.3.1.3 SSI Encoder (X5, X1) 146
11.2.3.1.4 Sine Encoder with SSI(X5, X1) 147
11.2.3.2 Electronic gearing, Master-Slave operation (X5) 148
11.2.3.2.1 Connectionto a S700 master, 5V signal level (X5) 148
11.2.3.2.2 Connectionto stepper motor controllers with 5 V signal level (X5) 148
11.2.3.3 Encoder-Emulation (X5) 149
11.2.3.3.1 Incremental encoder output - A quad B (X5) 149
11.2.3.3.2 SSI encoder output (X5) 150
11.2.3.4 Analoge Inputs and Outputs 151
11.2.3.4.1 Analog OutputsANALOG-OUT 1 and 2 151
11.2.3.4.2 Analog Inputs ANALOG-IN 3 and 4 151
11.3 Expansion cards for slot 3 152
11.3.1 Guideto installation of expansioncards inslot 3 152
11.3.2 Option"F2", controlled Fan 152
11.3.3 Expansion cards "PosI/O" & "PosI/O-Monitor" 152
11.3.4 Expansion card "Safety 2-2" (S4) 153
11.3.4.1 Safe drive functions S2-2 153
11.3.4.2 Safety Notes S2-2 153
11.3.4.3 Wiring supply voltage 24 V for digitaloutputs 154
11.3.4.4 Safe inputsand outputs S2-2 154
11.3.5 Expansion card "Safety 1-2" (S3) 155
11.3.5.1 SSafe drive functions S1-2 155
11.3.5.2 Safety NotesS1-2 155
11.3.5.3 External encoder S1-2 156
11.3.5.4 Wiring supply voltage 24 V for digitaloutputs S1-2 156
11.3.5.5 Safe inputsand outputs S1-2 156
12 Appendix 157
12.1 Glossary 157
12.2 Order codes 159
12.2.1 Servo amplifiers 159
12.2.2 Memory Card 159
12.2.3 Expansion cards 160
12.2.3.1 Covers for Option Slots 160
12.2.3.2 Slot 1 160
12.2.3.3 Slot 2 160
12.2.3.4 Slot 3 160
12.2.4 Mating connectors 160
13 Index 161
14 Record of Document Revisions 165
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S748-772 Instructions Manual |
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2 General
2.1 About this manual
This manual describes the S748-S772 series of digital servo amplifiers (standardversion:
48A ...72A rated current). S701 to S724amplifiers are described in an additional manuals.
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.
More background information can be found in our "Kollmorgen Developer Network" kdn.koll-
morgen.com.
S748-772 Instructions Manual | 2 General
2.2 Using the PDF Format
This document includes several features for ease of navigation
Cross References Table of contents and index include active cross references.
Table of contents and
index
Page/chapter numbers
in the text
Lines are active cross references. Click on the line and the appropriate page is accessed.
Page/chapternumbers with cross references areactive links.
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S748-772 Instructions Manual | 2 General
2.3 Symbols Used
Warning Symbols
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 result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Indicates situations which, if not avoided, could result in property damage.
This symbol indicates important notes.
Warning of a danger (general). The type of danger is specified
by the text next to the symbol.
Warning of danger from electricity and its effects.
Warning of danger from hot surface.
Warning of danger from suspended loads.
Warning of danger from automatic start.
Drawing symbols
Symbol Description Symbol Description
Signal ground Diode
Chassis ground Relay
Protective earth Relay switch off delayed
Resistor Normally open contact
Fuse Normally closed contact
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2.4 Standards used
Standard Content
ISO 4762 Hexagon socket head cap screws
ISO 12100 Safety of machinery: Basic concepts, general principles for design
ISO 13849 Safety of machinery: Safety-related parts of control systems (former EN 954)
IEC 60085 Electrical insulation - Thermal evaluationand 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 Electrical equipment of industrial machines – Serial data link for real-time com-
IEC 61508 Functional safety of electrical/electronic/programmable electronic safety-
IEC 61800 Adjustable speed electrical power drive systems
IEC 62061 Functional safety of electrical/electronic/programmable electronic safety-
IEC 82079 Preparation of instructions for use - Structuring, content and presentation
UL 840 UL Standard for Safety for Insulation Coordination
UL 508C UL Standard for Safety Power Conversion Equipment
S748-772 Instructions Manual | 2 General
munications between controls and drives.
related systems
related systems
IEC: International Electrotechnical Commission
ISO: International Organization for Standardization
UL: Underwriters Laboratories
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S748-772 Instructions Manual | 2 General
2.5 Abbreviations Used
Abbrev. Meaning
(➜ # xx) See page xx. Example (➜ # 53): see page 53.
AGND Analog ground
BTB/RTO Ready to operate
CAN Fieldbus (CANopen)
CLK Clock signal
COM Serial interface for a PC-AT
DGND Digital ground
Disk Magnetic storage (diskette, hard disk)
EEPROM Electrically erasable programmable memory
EMC Electromagnetic compatibility
EMI Electromagnetic interference
ESD Electrostatic discharge
F-SMA Fiber Optic Cable connector according to IEC 60874-2
INC Incremental Interface
LED Light-emitting diode
MB Megabyte
NI Zero pulse
PC Personal computer
PELV Protected low voltage
PL Performance Level
PLC Programmable logic controller
PWM Pulse width modultation
RAM Volatile memory
RB Brake (regen) resistor
RBext External brake resistor
RBint Internal brake resistor
RES Resolver
ROD A quad B encoder
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
SRAM Static RAM
SS1 Safe stop
SS2 Safe operational stop
SSI Synchronous serial interface
SSR Safe speed range
STO Safe Torque Off
V AC AC voltage
V DC DC voltage
VDE Verein deutscher Elektrotechniker
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3 Safety
This section helps you to recognize and avoid dangers to people and objects.
3.1 You should pay attention to this
Specialist staff required!
Only properly qualified personnel are permitted to perform such tasks as transport, installation and setup. Qualified specialist staff are persons with expertise in transport, installation,
assembly, commissioning and operation of electrotechnical equipment.
Transport, storage, unpacking: only by personnel with knowledge of handling electrostatically sensitive components.
Mechanical installation: only by personnel with mechanical expertise.
Electrical installation: only by personnel with expertise in electrical engineering.
Basic tests / setup: only by personnel with expertise in electrical engineering and drive
technology.
The qualified personnel must know and observe ISO 12100 / IEC 60364 / IEC 60664and
national accident prevention regulations.
S748-772 Instructions Manual | 3 Safety
Read the documentation!
Read the available documentation before installation andcommissioning. Improper handling
of the devices can cause harm to people or damage to property. The operator of systems
using the drive system must ensure that all personnel who work with the drive read and understand the manual before using the drive.
Check Hardware Revision!
Check the HardwareRevision Number of the product (see product label). This number is the
link between your product andthe manual. The product Hardware Revision Number must
match the Hardware Revision Number on the cover page of the manual.
Pay attention to the technical data!
Adhere to the technical data andthe specifications on connection conditions. If permissible
voltage values or current values are exceeded, the devices can be damaged. Unsuitable
motor or wrong wiring will damage the system components. Check the combinationof drive
andmotor. Compare the rated voltage and current of the units.
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.
Observe electrostatically sensitive components!
The devices contain electrostatically sensitive components which may be damaged by incorrect handling. Electrostatically discharge your body before touching the device. Avoid contact with highly insulating materials (artificial fabrics, plastic film etc.). Place the device on a
conductive surface.
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S748-772 Instructions Manual | 3 Safety
Automatic Restart!
The drive might restart automatically after power on, voltage dip or interruption of the supply
voltage, depending on the parametersetting. Risk of death or serious injury for humans working in the machine. If the parameter AENA is set to 1, then place a warningsign 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 anundervoltage protection device, you must observe EN 60204-1.
Hot surface!
Drives may have hot surfaces during operation. The housing can reach temperatures above
80°C. Risk of minor burns! Measure the temperature, and wait until the housing has cooled
down below 40 °C before touching it.
Earthing!
It is vital that you ensure that the drive is 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.
Leakage Current!
Since the leakage current to PE is more than 3.5 mA, in compliance with IEC61800-5-1 the
PE connection must either be doubled or a connecting cable with a cross-section >10 mm²
must be used. Deviating measures according to regional standards might be possible.
High voltages!
The equipment produces high electric voltages up to 900V. Do not open or touch the equipment duringoperation. Keepall covers closed.
Duringoperation, S700may have uncovered live sections, according to their level of enclosureprotection.
Lethal danger exists at live parts of the device. Built-in protection measures such as insulation orshielding may not be removed. Work on the electrical installation may only be performed by trained andqualified personnel, in compliance with the regulations for safety at
work, and only with switched off mains supply, and secured against restart.
Never undo any electrical connections to the S700while it is live. There is a danger of electrical arcing with damage to contacts and personal injury. Wait at least 10 minutes after disconnecting the product from the supply voltages (mains supply and 24V supply) before
touching potentially live sections of the equipment (such as contacts) or removing any connections.
Always measure the voltagein the DC bus link and wait until the voltage is below 50 V
before handling components.
Functional Safety
The STO safety implementation on the S700 is certified. The assessment of the safety functions according to EN13849 or EN 62061 must finally be doneby the user.
Reinforced Insulation
Thermal sensors, motor holding brakes and feedback systems built into the connected motor
must have reinforced insulation (according to IEC61800-5-1) against system components
with power voltage, according to the required application test voltage. All Kollmorgen components meet these requirements.
Never modify the drive!
It is not allowed to modify the drive hardware without permission by the manufacturer. Opening the housing causes loss of warranty.
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3.2 Warning notes placed on the product
S748/772
Residual Voltage.
Wait 10 minutes
after removing power.
If these signs are damaged, they must be replaced immediately.
S748-772 Instructions Manual | 3 Safety
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S748-772 Instructions Manual | 3 Safety
3.3 Use as Directed
The servo amplifiers are components which arebuilt into electrical equipment or machines,
andcan only be used as integral components of such equipment. If the servo amplifiers are
used in residential areas, or in business or commercial premises, then additional filter measures must be implemented by the user.
Cabinet and Wiring
The servo amplifiers may only be operated in a closed switchgear cabinet, taking into
account the ambient conditions (➜ # 32) and the dimensions (➜ # 54). Ventilation or cooling may be necessary to prevent enclosure ambient from exceeding 40°C (104°F).
Use only copper wire. Wire size may be determined from EN 60204 (or table310-16 of the
NEC 60°C or 75°C column for AWG size).
Power supply
Servo amplifiers in the S700 series can besupplied from 1-phase or 3-phase grounded
(earthed) industrial supply networks (TN-system, TT-system with grounded neutral point,
no more than42kA symmetrical rated current).
S7480/S7720: In case of mains voltageasymmetry >3% a mains choke must be used.
Periodic overvoltages betweenouter conductor (L1, L2, L3) and housing of the servo amplifier may not exceed 1000V (peak value). Transient overvoltages (< 50µs) between the
outer conductors may not exceed 1000V. Transient overvoltages (< 50µs) between outer
conductors and housingmay 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 protection*,
wire size, wire voltage rating, fuse protection, system dielectric requirements, overvoltage
andinput** current rating.
In case of DC supplied drives the built-in EMC filter will not work. The useris 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 ratingdrives to avoid the
smaller drives becoming the effective ‘fuse’ rather than the circuit protective fuse.
**The power supply system design must ensureinrush current protection by limiting input current during power up. DC supply polarity must be properly wired. Improper polarity of DC
powerwill damage the drive and void warranty.
Motors
The S700 family of servo amplifiers is only intended to drive specific brushless synchronous servomotors, with closed-loop control of torque, speed and/or position. The
rated voltage of the motors must be at least as high as the DC bus link voltage of the
servo amplifier.
Functional Safety
Consider the specific "use as directed" information (➜ # 41) when you use the safety
function STO.
To achieve PL e or SIL CL3, the safe switching of the pulse inhibitor must be tested periodically by analyzing the feedback signal from the safety control.
Observe the user documentation for safety cards S1-2(S3) / S2-2(S4) when you use a
safety expansion card.
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3.4 Prohibited Use
Otheruse than that described in chapter “Use as directed”is not intended and can lead to personnel injuries and equipment damage.
The use of the servo amplifier in the following environments is prohibited:
potentially explosive areas,
environments with corrosive and/orelectrically conductive acids, alkaline solutions, oils,
vapors, dusts,
directly on non-grounded supply networks or on asymmetrically grounded supplies with a
voltage >240V,
ships or offshoreapplications.
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,
does not comply with the Low Voltage Directive.
The control of holding brakes by the S700 alone may not be used in applications, where functional safety is to be ensured with the brake.
S748-772 Instructions Manual | 3 Safety
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S748-772 Instructions Manual | 4 Product life cycle handling
4 Product life cycle handling
4.1 Transport
Only by qualifiedpersonnel in the manufacturer’s original recyclable packaging
Avoid shocks
Temperature: –25 to +70°C, max. 20K/h rate of change, class 2K3 acc. to EN61800-2,
EN60721-3-1
Humidity: max. 95% relative humidity, no condensation, class 2K3 acc. to EN61800-2,
EN60721-3-1
If the packaging is damaged, check the unit for visible damage. In this case, inform the
shipper and the manufacturer.
The servo amplifiers contain electrostatically sensitive components which can be damaged
by incorrect handling. Discharge yourself before touching the servo amplifier. Avoid contact
with highly insulating materials (artificial fabrics, plastic films etc.). Place the servo amplifier
on a conductive surface.
4.2 Packaging
The S700 packaging consists of recyclable cardboard with inserts.
Dimensions S748/S772: (HxWxD) 390x600x400 mm
Labeling : nameplate outside at the box
4.3 Storage
Storage only in the manufacturer’s original recyclable packaging
Max. stacking height S748...S772: 3 cartons
Storage temperature: -25 to +55°C, max. rate of change 20K/h, class 1K4 acc. to
EN61800-2, EN60721-3-1
Storage humidity: 5 ... 95% relative humidity, no condensation, class 1K3 acc. to
EN61800-2, EN60721-3-1
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 andapply single-phase 230V AC
for about 30 minutes to the terminals L1 / L2.
4.4 Decommissioning
Only professional staff who are qualified in electrical engineering are allowed to decommission parts of the system.
DANGER: Lethal Voltages!
There is a danger of serious personal injury or death by electrical shock or electrical arcing.
Switch off the mainswitch of the switchgear cabinet.
Secure the system against restarting.
Block the main switch.
Wait at least 10 minutes after disconnecting.
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4.5 Maintenance and cleaning
The device does not require maintenance. Openingthe device voids the warranty. The inside
of the unit can only be cleaned by the manufacturer.
Do not immerse orspray the device. Avoid that liquid enters the device.
To clean the device exterior:
1. Decommission the device (see chapter 4.4 "Decommissioning").
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.
4.6 Disassembly
Only professional staff who are qualified in electrical engineering are allowed to disassemble
parts of the system.
1. Decommission the device (see chapter 4.4 "Decommissioning").
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.
S748-772 Instructions Manual | 4 Product life cycle handling
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S748-772 Instructions Manual | 4 Product life cycle handling
4.7 System 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 mul-
tiple 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 the device
Only the manufacturer can repair the device. Opening the device voids the warranty.
1. Decommission the device (see chapter 4.4 "Decommissioning").
2. Demount the device (see chapter 4.6 "Disassembly").
3. Send the device to the manufacturer.
4. Install a new device as described in this manual.
5. Setup the system as described in this manual.
Exchange of other drive system parts
If parts of the drive system (for example cables) must be replaced, proceed as follows:
4.8 Disposal
1. Decommission the device (see chapter 4.4 "Decommissioning").
2. Exchange the parts.
3. Check all connections for correct fastening.
4. Setup the system as described in this manual.
To dispose the unit properly, contact a certified electronic scrapdisposal merchant.
In accordance with the WEEE-2012/19/EC guideline and similar, the manufactureraccepts
returns of old devices and accessories for professional disposal. Transport costs are the
responsibility of the sender.
Contact Kollmorgen and clarify the logistics.
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5 Approvals
Certificates (CE, functional safety) can be found at the Kollmorgen Website.
5.1 Conformance with UL
The servo amplifiers are listed under UL file number E217428.
UL-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S. stand-
ards (in this case UL 840 and UL 508C). The UL certification relates only to the mechanical
andelectrical construction design of the device. This standard describes the fulfillment by
designof minimum requirements for electrically operated powerconversion equipment, such
as frequency converters and servo amplifiers, which is intended to eliminate the risk of fire,
electric shock, or injury to persons, being caused by such equipment. The technical conformance with the U.S. standard is determinedby an independent UL inspector through the
type testing and regular checkups. 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 insulationcreepage spacings
for electrical equipment and printed circuit boards.
S748-772 Instructions Manual | 5 Approvals
UL Markings
Use 60°C or 75°C copper wire only.
Tightening torque for field wiring terminals:
X0 8-2 AWG, TQ Lb In. 40.
X8 8-2 AWG, TQ Lb In. 40.
Use in a pollution degree 2 environment.
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 providedin 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 symmetrical
amperes for a max. voltage of 480 Vac.
Supply circuit protection:
Model Fuse class Rating Voltage/SCCR Max. Fuse Rating
S7480 RK5, CC, J, T 600VAC 200kA 60A
S7720 RK5, CC, J, T 600VAC 200kA 80A
For use on a solidly grounded wye source only.
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S748-772 Instructions Manual | 5 Approvals
5.2 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 installationdescribed in this documentation
means that you will be responsible for carrying out new measurements to ensure conformance with regulatory requirements.
Kollmorgen declares the conformity of the products S748 and S772 with the following directives
EC Machinery Directive 2006/42
EC EMC Directive 2014/30/EC
EC Low VoltageDirective 2014/35/EC
Concerning noise immunity the servo amplifier meets the requirements to the 2nd environmental category (industrial environment). For noise emission the amplifier meets the
requirement to a product of the category C2 (motor cable up to 10 m). With a motor cable
length from 10 m onwards, the servo amplifier meets the requirement to the category C3.
This product can cause high-frequency interferences in non industrial environments which
can require measures for interference suppression.
5.2.1 European Directives and Standards for the machine builder
Servo amplifiers aresafety components that are intended to be incorporated into electrical
plant and machines for industrial use. When the servo amplifiers arebuilt 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 VoltageDirective (2014/35/EC)
Standards to be applied for conformance with 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 manufacturer must check whether other standards or EC Directives must be
applied to the machine.
Standards to be applied for conformance with EC Low Voltage Directive(2014/35/EC)
IEC 60204-1 (Safety and Electrical Equipment in Machines)
IEC 60439-1 (Low-voltage switchgear and controller assemblies)
Standards to be applied for conformance with 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 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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S748-772 Instructions Manual | 5 Approvals
5.2.2 Functional Safety Conformance according to EC Machinery Directive
STO (Safe Torque Off)
The S700 servo amplifier offers a two channel STO function (Safe Torque Off). The function
blocks the triggerpulses 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 S700 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, PFHD and TM.
Device
STO1/2 Enable single channel PLd, Cat.3 SIL CL 2 7.05E-08 20
STO1-Enable+
STO2-Enable
STO1-Enable+
STO2-Enable+
STO-Status
SIL2 / PLd solutions can be implemented with single-channel or dual-channel control with
simple safety switching devices.
SIL3 / PLe solutions requires a safety control that periodically tests the safe switching of the
pulse inhibitor by analyzing the feedback signal.
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.
Operation mode EN 13849-1 EN 62061 PFHD [1/h] TM [Year]
dual channel PLd, Cat.3 SIL CL 2 7.05E-08 20
dual channel +
periodical testing
PLe, Cat.4 SIL CL 3 1.38E-09 20
5.3 Conformance with RoHS
The device is manufactured in conformance with RoHS Directive 2011/65/EC with delegated
directive 2015/863/EC for installation into a machine.
5.4 Conformance with REACH
EU Regulation no. 1907/2006 deals with the registration, evaluation, authorization and restriction of chemical substances 1 (abbreviated to "REACH").
The device does not containany substances (CMR substances, PBTsubstances, vPvB substances and similar hazardous substances stipulated in individual cases based on scientific
criteria) above 0.1 mass percent per product that are included on the candidate list.
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S748-772 Instructions Manual | 5 Approvals
5.5 Conformance with EAC
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 device has passed all required conformity procedures in a memberstate of the Eurasian Customs Union, and that the device meets all technical requirements requested in the member states of the Eurasian Customs Union:
Low voltage (TP TC 020/2011)
Electromagnetic Compatibility (TP TC 004/2011)
Contact: Intelisys LLC. , Bakuninskaya Str. d 14, Building 10, RU-105005 Moskau
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6 Package
6.1 Package supplied
When an amplifier from the S700 series is ordered (order numbers (➜ # 159)), the following
is supplied:
Servo amplifier S700 with shielding plate and shield clamps
Product Safety Guide S700 (printed)
Online documentation and setup software on CD-ROM
Mating connectors X3A, X3B, X4, X9A, X9B
The mating SubD connectors are not part of the package!
Accessories : (must be orderedseparately, if required; description see accessories
manual)
Hybrid motor cable (prefabricated)for single cable connection
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 BAS(U)
Communication cable to the PC (➜ # 104) 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
S748-772 Instructions Manual | 6 Package
6.2 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.
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S748-772 Instructions Manual | 6 Package
6.3 Part number scheme
Use the part number scheme for product identification only, not for the order process,
because not all combinations of features are possible, always.
Example 1: S77202-EIF2PM-NA-000 Example 2: S7480C-EIF2S4-NA-000
S7
S700
72
72A rated current
0
208...480V rated voltage
2
no electr./mech. option
EI
I/O expansion card in Slot 1
F2
Expansion card Controlled Fan in Slot 2
PM
PosI/O expansion card in Slot 3
NA
Standard (EtherCAT&CANopen onboard)
000
no customer specific specials
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S7
S700
48
48A rated current
0
208...480V rated voltage
C
Coldplate
EI
I/O expansion card in Slot 1
F2
Expansion card Controlled Fan in Slot 2
S4
Safety Card S2-2 in Slot 3
NA
Standard (EtherCAT&CANopen onboard)
000
no customer specific specials
S748-772 Instructions Manual | 7 Technical description
7 Technical description
7.1 The S700 family of digital servo amplifiers
Standard version
Large supply voltage range: 3 x 208V
(with mains voltage below 300V set parameters NONBTB=3 and VBUSBAL=1)
Overvoltage category III acc. to IEC 61800-5-1
CANopen on board
EtherCAT on board
RS232 and 24V pulse direction interface on board
Resolver-, Encoder-, AquadB Encoder-, ComCoder- evaluation on board
Position controller on board
Safe Stop STO on board (upto SIL CL3, PLe)
3 front side slots for expansion cards
Memory Card slot on board
Synchronous servomotors, linear motors, asynchronous motors andDC motors can be
used
Power section
-10%
... 480V
+10%
Directly on grounded mains supply, 3x208V-10% … 3x480V+10%, 50/60Hz
(with mains voltage below 300V set parameters NONBTB=3 and VBUSBAL=1)
TN-network or TT-network with grounded neutral point, 42kA max. symmetrical current
rating, connection to other supply types only via isolating transformer (➜ # 68)
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...900V DC, can be connected in parallel.
Interference suppression filters are integrated for the electrical supply feed and the 24 V
auxiliary supply voltage (with motor cable 10 m for C2 as per IEC 61800-3, with motor
cable > 10 m for C3 as per IEC 61800-3).
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S748-772 Instructions Manual | 7 Technical description
Integrated safety
Appropriate insulation and creepage distances and electrical isolation ensure safe electrical separation, as per IEC 61800-5-1, betweenthe power input / motor connections and
the signal electronics.
Soft-start, overvoltage detection, short-circuit protection, phase-failure monitoring.
Temperaturemonitoring of the servo amplifier andmotor (if our motors and prefabricated
cables are used).
Safe stop (up to SILCL3 acc. to IEC 62061, PLe acc. to ISO13849-1), (➜ # 41)
Slot for safety card with more safety functions for the safe drive operation, (➜ # 153)
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 holdingbrake 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 and write access to parameter records andfirmware via smartcard.
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 125 μs)
Integrated 24V step/direction interface for connecting a servomotor to a stepper controller
Inputs and Outputs
programmable analog inputs (➜ # 99)
programmable analog inputs (➜ # 100)
2 programmable digital inputs/outputs (direction selectable)(➜ # 100)
Programmable logical combinations of digital signal
1 input Enable (➜ # 100)
2 inputs STO Enable (➜ # 101)
2 STO-Status Outputs (➜ # 102)
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S748-772 Instructions Manual | 7 Technical description
Expansions
Slot 1
Expansioncards in slot 1 can be combined with F2 Optionin slot 2. More combinations of
slot 1 and slot 2 expansion cards are not possible.
I/O-14/08 expansion card, (➜ # 127)
PROFIBUS expansion card, (➜ # 130)
sercos® II expansion card, (➜ # 131)
DeviceNet expansion card, (➜ # 133)
SynqNet expansion card, (➜ # 136)
FB-2to1 expansion card, (➜ # 138)
-2CAN- expansion module, separated connectors for CAN bus and RS232, (➜ # 140)
Slot 2
PosI/O expansion card,(➜ # 143)
PosI/O-Monitor expansion card, (➜ # 143)
F2 Option, controlled fan, later insertion not possible,(➜ # 152), can be combined with
expansion cards in slot 1.
Slot 3
PosI/O expansion card, (➜ # 152)
PosI/O-Monitor expansion card, (➜ # 152)
F2 Option, controlled fan, later insertion not possible, (➜ # 152)
Safety expansion card (S3) S1-2 (SIL CL3), (➜ # 155)
Safety expansion card (S4) S2-2 (SIL CL2), (➜ # 153)
Several third-party expansion cards (ModBus, LightBus, FIP-IO etc. please contact the manufacturer for further information)
Macro programming
More information can be foundin our KDN Makro-Programming.
62.5μs / 250μs / 1ms / 4ms / 16ms / IDLE / IRQ
128kByte memory
IEC 61131 structured text
400easy instructions every 62.5 μs
CAN objects for multi axis control
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S748-772 Instructions Manual | 7 Technical description
7.2 Technical data
7.2.1 Rated data
Electrical data DIM S74802 S77202
Rated supply voltage(grounded supply.
phase to phase) (L1.L2.L3)
Rated input power for cont. operation kVA 35 50
Permitted switch on/off frequency 1/h 30
Auxiliary voltage supply — (➜ # 31)
Maximum DC bus link voltage V= 900
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 max. 5s. ± 3%) Arms 96 140
Switching frequency of output stage kHz 8
- at reduced current (50%) kHz 16
Voltage rise speed dU/dt, (measured without connected motor, (➜ # 73))
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 — (➜ # 35)
Threshold for overvoltage switch-off VDC (➜ # 35)
Motor inductance min. at 3x208V mH 0.38 0.26
Motor inductance min. at 3x230V mH 0.42 0.29
Motor inductance min. at 3x400V mH 0.74 0.51
Motor inductance min. at 3x480V mH 0.88 0.61
Motor inductance max. mH Consult our support
Form factor of the output current (rated con-
ditions, min. load inductance)
Bandwidth of current controller kHz > 1.2 (up to 5)
Residual voltage drop at rated current V 6
Thermal dissipation, output stage disabled W 24
Thermal dissipation at rated current (without brake dissipation)
at 3x230V W 555 855
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/with connectors & shielding plate mm 386/505
Width mm 190
Depth, without/with connectors mm 244/285
V~ 3 x 208V-10% … 3 x 480V+10%.
50/60 Hz
— 1.01
* In case of mains voltage below 300V, set parameters NONBTB=3 and VBUSBAL=1.
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