Kollmorgen SERVOSTAR 300, S300 Users manual

SERVOSTAR 300
Digital Servo Amplifier S300
Instructions Manual
Edition: May 2020
Translation of the original instructions.
Valid for Hardware Revision 04.20
For safe and proper use, follow these instructions. Keep them for future reference.
Record of Document Revisions:
Revision Rermarks
... Table with life cycle information of this document see (# 141)
04/2018 X1 connector (male->female), HR table updated, Wiki links migrated to KDN, ventilation corrected
11/2018 Layout of the warning notes updated, user expertise updated, new readers note on cover page
05/2020 Layout updated, chapter "Used Standards" removed, motor temperatur sensor generalized, chapter
normal operation added, RoHS,REACH, EAC, PROFINET expansion card
Hardware Revision (HR)
Hardware Rev. Firmware Rev. Export Clas-
sification
02.01
02.10 (03.01) 3.75 - 4.99 AL-3A225 AS->STO, new approval
04.00 5.18 - 5.99 AL-3A225 New CPU, front label S300
04.10 5.18_ND0 - 5.99_ND0 - New data structure
04.20 ≥ 6.00_ND0 - SFD3/DSL support
2.18 - 3.74 AL-3A225
Remarks
Start HR
Trademarks
WINDOWS is a registered trademark of Microsoft Corp.
HIPERFACE is a registered trademark of Max Stegmann GmbH SERCOS s a registered trademark of sercos® international e.V. PROFIBUS and PROFINET are registered trademarks of PROFIBUS and PROFINET International (PI). 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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S300 Instructions Manual | Table of Contents

1 Table of Contents

1 Table of Contents 3
2 General 9
2.1 General 9
2.2 Using the PDF Format 9
2.3 SymbolsUsed 10
2.4 Abbreviations Used 11
3 Safety 12
3.1 You should payattention to this 12
3.2 Warning notes placed on the product 14
3.3 Use asDirected 15
3.4 Prohibited Use 15
4 Product life cycle handling 16
4.1 Transport 16
4.2 Packaging 16
4.3 Storage 16
4.4 Installation, setup and normal operation 16
4.5 Decommissioning 17
4.6 Maintenance and cleaning 17
4.7 Disassembly 17
4.8 System Repair 18
4.9 Disposal 18
5 Approvals 19
5.1 Conformance with UL/cUL 19
5.2 Conformance with CE 20
5.2.1 European Directivesand Standards for the machine builder 20
5.2.2 Functional Safety Conformance (STO) according to EC Machinery Directive 21
5.2.3 Conformance with RoHS 21
5.2.4 Conformance with REACH 21
5.3 Conformance with EAC 21
6 Package 22
6.1 Package Supplied 22
6.2 Nameplate 22
6.3 Part Number Scheme 23
7 Technical description 24
7.1 The SERVOSTAR 300 familyof digital servo amplifiers 24
7.2 Technical Data 26
7.2.1 TechnicalData 110 / 230 V (Types S3_ _6_) 26
7.2.2 TechnicalData 230V ... 480 V (types S3_ _0_) 27
7.2.3 Inputs / outputs, Auxiliary voltage 28
7.2.4 Connectors 28
7.2.5 Recommended Tightening Torques 28
7.2.6 Fusing 28
7.2.7 Ambient Conditions, Ventilation and Mounting Position 29
7.2.8 Conductor cross-sections 29
7.3 Motor holding brake 30
7.4 LED display 31
7.5 Grounding system 31
7.6 Dynamic braking (brake circuit) 31
7.7 Switch-on and switch-off behavior 33
7.7.1 Behavior in standard operation 34
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S300 Instructions Manual | Table of Contents
7.7.2 Behavior in the event of an error (with standard setting) 35
7.8 Stop-, Emergency Stop-, Emergency Off Function to IEC 60204 36
7.8.1 Stop 36
7.8.2 Emergency Stop 37
7.8.3 Emergency Off 37
7.9 Safe Torque Off ( STO) 38
7.9.1 Safety characteristic data 38
7.9.2 Safety Notes 39
7.9.3 Use as directed 40
7.9.4 Prohibited Use STO 40
7.9.5 Technicaldata and pinning 40
7.9.6 Enclosure 40
7.9.7 Wiring 40
7.9.8 Functional description 41
7.9.8.1 Safe operation sequence 41
7.9.8.2 Control circuit 42
7.9.8.3 Functional test 43
7.9.8.4 Mains supply circuit 43
7.10 Shock-hazard Protection 44
7.10.1 Leakage current 44
7.10.2 Residual current protective device (RCD) 44
7.10.3 Isolating transformers 44
8 Mechanical Installation 45
8.1 Important Notes 45
8.2 Guide to MechanicalInstallation 45
8.3 Mounting 46
8.4 Dimensions 47
9 Electrical Installation 48
9.1 Important Notes 48
9.2 Guide to electricalinstallation 49
9.3 Wiring 50
9.3.1 Shielding connection to the front panel 51
9.3.2 Technicaldata for cables 52
9.4 Components of a servo system 53
9.5 Blockdiagram 54
9.6 Connector assignment 55
9.7 Connection overview 56
9.8 Voltage supply 58
9.8.1 Connection to various mainssupply networks 58
9.8.2 24V auxiliary supply (X4) 59
9.8.3 Mainssupply connection ( X0), three phase 59
9.8.4 Mainssupply connection ( X0), two phase without neutr al 59
9.8.5 Mainssupply connection ( X0), single phase with neutral 60
9.9 DC bus link (X8) 61
9.9.1 External brake resistor (X8) 61
9.9.2 Capacitor Module KCM (X8) 62
9.10 Motor power and motor holding brake connection (X9) 64
9.11 Feedback systems 65
9.12 Primary and secondary feedback types 66
9.12.1 SFD3 (X1), single cable connection 67
9.12.2 HIPERFACE DSL (X1), single cable connection 68
9.12.3 Resolver (X2) 69
9.12.4 Sine Encoder with BiSS analog (X1) 70
9.12.5 Encoder with BiSS digital(X1) 71
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S300 Instructions Manual | Table of Contents
9.12.6 Sine Encoder with EnDat 2.1 (X1) 72
9.12.7 Encoder with EnDat 2.2 (X1) 73
9.12.8 Sine Encoder with HIPERFACE (X1) 74
9.12.9 Sine Encoder with SSI (X5, X1) 75
9.12.10 Sine Encoder without data channel(X1) 76
9.12.11 Sine Encoder with Hall (X1) 77
9.12.12 ROD (AquadB) 5V, 1.5MHz (X1) 78
9.12.13 ROD (AquadB) 5V, 350kHz(X1) 79
9.12.14 ROD (AquadB) 5V, 350kHzwith Hall (X1) 80
9.12.15 ROD (AquadB) 5V (X5, X1) 81
9.12.16 ROD (AquadB) 5V with Hall (X5, X1) 82
9.12.17 ROD (AquadB) 24V (X3) 83
9.12.18 ROD (AquadB) 24V with Hall (X3, X1) 84
9.12.19 SSI Encoder (X5, X1) 85
9.12.20 Hall sensors (X1) 86
9.13 ElectronicGearing, Master-Slave operation 87
9.13.1 Encoder control types 87
9.13.2 Connection to stepper motor controllers (step and direction) 88
9.13.2.1 Step / Direction with 5 V signal level ( X1) 88
9.13.2.2 Step / Direction with 24 V signal level (X3) 88
9.13.2.3 Step / Direction with 5 V signal level ( X5) 89
9.13.3 Anschlussfür Master-Slave Betrieb 89
9.13.3.1 Master-Slave 5V (X1) 89
9.13.3.2 Master-Slave 5V (X5) 89
9.14 Encoder Emulation, position output 90
9.14.1 Incremental encoder output (AquadB) (X5) 90
9.14.2 SSI encoder output (X5) 91
9.15 Digital and analog inputs and outputs 92
9.15.1 Analog Inputs (X3) 92
9.15.2 DigitalInputs (X3/X4) 93
9.15.3 DigitalOutputs ( X3) 94
9.16 RS232 interface, PC connection (X6) 95
9.17 CAN-bus interface (X6) 96
10 Setup 97
10.1 Important Notes 97
10.2 Setup software 98
10.2.1 Use as directed 98
10.2.2 Software description 98
10.2.3 Hardware requirements, operating systems 99
10.2.4 Installation under WINDOWS 99
10.3 Quickstart, initial drive test 100
10.3.1 Preparation 100
10.3.2 Connect 102
10.3.3 Important Screen Elements 103
10.3.4 Setup Wizard 104
10.3.4.1 BasicSetup 104
10.3.4.2 Units/Mechanical 105
10.3.4.3 Motor (r otary) and Feedback 106
10.3.4.4 Motor (linear) / Feedback(Encoder) 106
10.3.4.5 Save Parameters and Restart 107
10.3.5 Motion Service(Jog Mode) 107
10.3.6 More Setup Screens 108
10.4 Multi axis system 109
10.5 Keypad operation and LED display 109
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S300 Instructions Manual | Table of Contents
10.5.1 Operation 110
10.5.2 Status display 110
10.5.3 Standard menu structure 110
10.5.4 Advanced menu structure 111
10.6 Error messages 112
10.7 Warning messages 113
10.8 Trouble shooting 114
11 Expansions 115
11.1 Guide to installation of expansion cards 115
11.2 Expansion card -I/O-14/08- 116
11.2.1 Technicaldata 116
11.2.2 LEDs 116
11.2.3 Entering a motion blocknumber (example) 116
11.2.4 Connector assignments 117
11.2.5 Connection diagram (default) 118
11.3 Expansion card -PROFIBUS- 119
11.3.1 Connection technology 119
11.3.2 Connection diagram 119
11.4 Expansion card -SERCOS- 120
11.4.1 LEDs 120
11.4.2 Connection technology 120
11.4.3 Connection diagram 121
11.4.4 Setup 121
11.5 Expansion card - DEVICENET - 122
11.5.1 Connection technology 122
11.5.2 Connection diagram 122
11.5.3 Combined module status and network status LED 123
11.5.4 Setup 123
11.5.5 Bus cable 124
11.6 Expansion card -SYNQNET- 125
11.6.1 NODE ID Switch 125
11.6.2 NODE LED table 125
11.6.3 SynqNet Connection, Connector X21B / X21C (RJ-45) 125
11.6.4 Digitalinputs and outputs, connector X21A (SubD 15-pin, socket) 126
11.6.5 Connection diagram digital inputs and outputs, connector X21A 126
11.7 Expansion card - F B-2to1 - 127
11.7.1 Pinout 127
11.7.2 Wiring example with BiSS digital (primary) and SinCos (secondary) 128
11.8 Expansion card -PROFINET- 129
11.8.1 Device master file 129
11.8.2 LED 129
11.8.3 Connection technology 129
11.8.4 Connection examples 130
11.9 Expansion module -2CAN- 131
11.9.1 Installation 131
11.9.2 Connection technology 131
11.9.3 Connector assignments 132
11.9.4 Setup of Station Address and Baud Rate 132
11.10 Option"EtherCAT" 133
11.10.1 NODE LED table 133
11.10.2 Connection diagram 133
11.11 Option "FAN", ventilator control 134
12 Appendix 135
12.1 Glossary 135
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S300 Instructions Manual | Table of Contents
12.2 Order codes 137
13 Index 139
14 Record of document revisions 141
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S300 Instructions Manual |
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2 General

2.1 General

S300 Instructions Manual | 2 General
This manual describes the digital servo amplifiers of the SERVOSTAR 300 (S300, standard version, 1.5 to 10 A nominal current).
A more detailed description of the expansion cards that are currently available and the digital connection to automation systems can be found, together with our 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.

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/chapter numbers with cross references are active links.
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S300 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 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
SIL Safety Integrity Level
SIL CL Safety Integrity Level Claim Limit
SRAM Static RAM
SSI Synchronous serial interface
STO Safe Torque Off
V AC AC voltage
V DC DC voltage
S300 Instructions Manual | 2 General
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S300 Instructions Manual | 3 Safety

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 60664 and national accident prevention regulations.
Read the documentation!
Read the available documentation before installation and commissioning. 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 Hardware Revision Number of the product (see product label). This number is the link between your product and the 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 and the 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 combination of drive and motor. Compare the rated voltage and current of the units.
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.
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.
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S300 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 parameter setting. Risk of death or serious injury for humans work­ing in the machine. If the parameter AENA is set to 1, then place a warning 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.
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 during operation. Keep all covers closed.
During operation, S300 may have uncovered live sections, according to their level of enclos­ure protection.
Lethal danger exists at live parts of the device. Built-in protection measures such as insu­lation or shielding may not be removed. 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 switched off mains supply, and secured against restart.
Never undo any electrical connections to the S300 while it is live. There is a danger of elec­trical arcing with damage to contacts and personal injury. Wait at least 5 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 voltage in the DC bus link and wait until the voltage is below 50 V before handling components.
Functional Safety
The STO safety implementation on the S300 is certified. The assessment of the safety func­tions according to EN13849 or EN 62061 must finally be done by 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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S300 Instructions Manual | 3 Safety

3.2 Warning notes placed on the product

Residual Voltage.
Wait 5 minutes
after removing power.
If these signs are damaged, they must be replaced immediately.
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3.3 Use as Directed

The servo amplifiers are components which are built into electrical equipment or machines, and can 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 (# 29) and the dimensions (# 47). 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 table 310-16 of the NEC 60°C or 75°C column for AWG size).
Power supply
The SERVOSTAR 300 family of servo amplifiers (overvoltage category III acc. to EN 61800-5-1) can be connected directly to symmetrically earthed (grounded) three-phase industrial mains supply networks [TN-system, TT-system with earthed (grounded) neutral point, not more than 42,000 rms symmetrical amperes,110V ctively 208V see (# 58). Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo amp­lifier may not exceed 1000V (peak value). Transient overvoltages (< 50µs) between the outer conductors may not exceed 1000V. Transient overvoltages (< 50µs) between outer conductors and housing may not exceed 2000V.
-10%
...480V
S300 Instructions Manual | 3 Safety
...230V
+10%
maximum]. Connection to different mains supply networks
-10%
+10%
resped-
Motors
The SERVOSTAR 300 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 (# 38) when you use the safety function STO.

3.4 Prohibited Use

Other use than that described in chapter “Use as directed” is not intended and can lead to per­sonnel injuries and equipment damage. The servo amplifier may not be used with a machine that does not comply with appropriate national directives or standards. The use of the servo amplifier in the following environments is also prohibited:
potentially explosive areas environments with corrosive and/or electrically conductive acids, alkaline solutions, oils, vapors, dusts ships or offshore applications
The control of holding brakes by the S300 alone may not be used in applications, where func­tional safety is to be ensured with the brake.
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S300 Instructions Manual | 4 Product life cycle handling

4 Product life cycle handling

4.1 Transport

Transport the SERVOSTAR 300 in accordance with IEC 61800-2 as follows:
Only by qualified personnel in the manufacturer’s original recyclable packaging Avoid shocks Temperature: –25 to +70°C, max. 20K/hr rate of change, class 2K3 acc. to EN61800-2, EN 60721-3-1 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 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 S300 packaging consists of recyclable cardboard with inserts.
Dimensions (HxWxD): 115x365x275mm Labeling : nameplate outside at the box

4.3 Storage

Store the S300 in accordance with IEC 61800-2 as follows:
Storage only in the manufacturer’s original recyclable packaging Max. stacking height 8 cartons Storage temperature: -25 to +55°C, max. rate of change 20°C / hour class 1K4 acc. to EN61800-2, EN 60721-3-1 Storage humidity: 5 ... 95% relative humidity, no condensation class 1K3 acc. to EN61800-2, EN 60721-3-1 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 and apply single-phase 230V AC for about 30 minutes to the terminals L1 / L2.

4.4 Installation, setup and normal operation

In normal operation, the cabinet door must be closed and the device must not be touched. Installation and setup information are given in
Chapter Mechanical installation (# 45) Chapter Electrical installation (# 48) Chapter Setup (# 97)
Normal operation tested for environmental class 3K3 according to IEC 61800-2 (# 29). The manufacturer of the machine defines the necessary end user expertise based on the risk assessment for the machine and describes the requirements for normal operation based on the application.
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4.5 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 main switch of the switchgear cabinet. Secure the system against restarting. Block the main switch. Wait at least 5 minutes after disconnecting.

4.6 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 4.5 "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.
S300 Instructions Manual | 4 Product life cycle handling

4.7 Disassembly

Only professional staff who are qualified in electrical engineering are allowed to disassemble parts of the system.
1. Decommission the device (see chapter 4.5 "Decommissioning").
2. Check temperature.
3. Remove the connectors. Disconnect the potential earth connection last.
4. Demount: loosen the fastening screws. Remove the device.
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).
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S300 Instructions Manual | 4 Product life cycle handling

4.8 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 4.5 "Decommissioning").
2. Demount the device (see chapter 4.7 "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:

4.9 Disposal

1. Decommission the device (see chapter 4.5 "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 scrap disposal merchant.
In accordance with the WEEE-2012/19/EU guideline and similar, the manufacturer accepts 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/cUL

This servo amplifier is listed under UL file number E217428.
UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S. and Canadian standard (in this case UL 840 and UL 508C). The UL certification relates only to the mechanical and electrical construction design of the device.
This standards describe 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, electric shock, or injury to persons, being caused by such equipment. The technical conformance with the standards is determined by 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 (cUL)-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.
S300 Instructions Manual | 5 Approvals
Markings Marquages
Use 60°C or 75°C copper wire only. Use Class 1 wire only. Tightening torque for field wiring ter­minals. X0, X8, X9: 0.5 - 0.6Nm (4.43 to
5.31 lbf in). 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 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 sym­metrical amperes for a max. voltage of 480 Vac. The drives may be connected together via the “common bus” (DC bus link) based on the instructions on (# 61) ff. The devices may also be grouped from the AC input side based on the max. input fuse (e.g. 3xS346 with one com­mon 6A fuse in line).
Utilisez un fil en cuivre 60°C ou 75 °C min.. Utilisez seulement un fil de classe 1. Couples de serrage recommandée. X0, X8, X9: 0.5 - 0.6Nm (4.43 to 5.31 lbf in). Utilisation dans un environnement de pol­lution de niveau 2. Ces variateurs offrent une protection contre les surcharges de moteur à semi-con­ducteur à 130 % du courant FLA nominal. Une protection de court-circuit à semi-con­ducteur intégrale ne fournit pas de pro­tection de la dérivation. Il convient de garantir une protection de la dérivation con­forme au NEC (National Electrical Code) et aux réglementations locales en vigueur, ou aux directives équivalentes applicables. Ces variateurs n’offrent pas de capteurs de température excessive. Ce produit est conçu pour une utilisation sur un circuit capable de fournir 42 000 ampères symétriques (rms) maximum pour 480V. Les variateurs peuvent être reliés entre eux via le “bus commun CC” sur la base des instructions (# 61) ff. Les variateurs peuvent être groupés d'entrée AC basé sur le max. fusible d’entrée (par exemple 3xS346 avec un fusible de 6A commune).
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S300 Instructions Manual | 5 Approvals

5.2 Conformance with CE

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 conformance with reg­ulatory requirements.
Kollmorgen declares the conformity of the products SERVOSTAR 300(S300) with the fol­lowing directives
EC Machinery Directive 2006/42/EU EC EMC Directive 2014/30/EU EC Low Voltage Directive 2014/35/EU
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 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/EU) EC EMC Directive (2014/30/EU) EC Low Voltage Directive (2014/35/EU)
Standards to be applied for conformance with EC Machinery Directive (2006/42/EU)
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 the Low Voltage Directive(2014/35/EU)
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 the EMC Directive (2014/30/EU)
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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S300 Instructions Manual | 5 Approvals

5.2.2 Functional Safety Conformance (STO) according to EC Machinery Directive

The S300 servo amplifier offers a single channel STO function (Safe Torque Off) that can be used as a functional safe restart lock.
The safetys concept is certified. The safety circuit concept for realizing the safety function "Safe Torque Off" in the servo amplifiers S300 is suited for SIL CL 2 according to IEC 62061 and PLd 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 Operation mode EN 13849-1 EN 62061 PFHD [1/h] TM [Year]
STO-Enable
single channel PLd SIL CL 2 1.50E-07 20

5.2.3 Conformance with RoHS

The device is manufactured in conformance with RoHS Directive 2011/65/EU with delegated directive 2015/863/EU for installation into a machine.

5.2.4 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 contain any 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.

5.3 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 mem­ber state 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: SERVOSTAR LLC. , Bld.1, Semyonovskaya nab. 2/1, RU-105094 Moskau
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S300 Instructions Manual | 6 Package

6 Package

6.1 Package Supplied

When you order a SERVOSTAR 300 series amplifier (Order codes (# 137)), you will receive:
S3xx Mating connectors X0, X3, X4, X8 Mating Connector X9 (with SERVOSTAR 303-310 only ) (S3xx6) S300 Safety Notes printed All documentation in PDF format on CD-ROM Setup software DRIVE.EXE on CD-ROM
The mating SubD connectors are not part of the package!
Accessories: (must be ordered separately; description see accessories manual)
l Hybrid motor cable (prefabricated) for single cable connection l motor cable (prefabricated) with special shield clamp, or both power connectors sep-
arately, with the motor cable as a cut-off length
l feedback cable (prefabricated) or both feedback connectors separately, with the feedback
cable as a cut-off length
l motor choke 3YL/3YLN, for motor cables longer than 25 meters l external brake resistor BAR(U), capacity module KCM l communication cable to the PC (# 95) for setting parameters from a PC l power cable, control cables, fieldbus cables (as cut-off lengths)

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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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.
S300 Instructions Manual | 6 Package
Expansions and device options cannot be combined.
Comparison device name -> part number
Device Name Part Number
SERVOSTAR 303 S30361-NA
SERVOSTAR 306 S30661-NA
SERVOSTAR 310 S31061-NA
SERVOSTAR 341 S30101-NA
SERVOSTAR 343 S30301-NA
SERVOSTAR 346 S30601-NA
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S300 Instructions Manual | 7 Technical description

7 Technical description

7.1 The SERVOSTAR 300 family of digital servo amplifiers

Standard version
Two voltage classes with large nominal voltage range 1 x 110 V 3 x 208 V
… 3 x 230 V
-10%
… 3 x 480 V
-10%
+10%
(SERVOSTAR 303-310, S3xx6)
+10%
(SERVOSTAR 341-346, S3xx0) Overvoltage category III acc. to EN 61800-5-1 Shielding connection directly on the servo amplifier Two analog inputs onboard CANopen onboard (default: 500 kBaud), for integration in CAN-bus systems and for set­ting parameters for several drives via the PC interface of one of the amplifiers Slot for an expansion card RS232 and pulse direction interface onboard Restart lock STO for functional safety onboard (# 38) Intelligent position controller onboard Multi feedback support Synchronous servomotors, linear motors, asynchronous motors, high frequency spindles and DC motors can be used
Power section
Directly on grounded 3-phase supply, 110V
-10%
or 230V
up to 480V
-10%
+10%
TN-network or TT-network with grounded neutral point, 42kA max. symmetrical current rating, connection to other supply types only via isolating transformer, (# 58) 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 regenerated power between several amp­lifiers on the same DC bus link circuit. Internal brake resistor as standard, external brake resistors if required. DC bus link voltage 135 … 450 V DC or 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 EN 61800-3, with motor cable > 10m for C3 as per EN 61800-3).
Integrated safety
Appropriate insulation/creepage distances and electrical isolation ensure safe electrical separation, as per EN 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 prefabricated cables are used).
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S300 Instructions Manual | 7 Technical description
Auxiliary supply voltage 24V DC
Electrically isolated, internal fusing, from an external 24V DC power supply unit with, for instance, isolating transformer or uninterruptible power supply.
Operation and parameter setting
With our user-friendly setup software, 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.
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) Integrated step/direction interface for connecting a servomotor to a stepper controller Evaluation of resolver signals and sine-cosine signals of high-resolution encoders Encoder emulation (incremental, compatible with A quad B or SSI)
Comfort functions
2 programmable analog inputs 4 programmable digital inputs 2 programmable digital outputs programmable logical combinations of digital signals
Device Options
Option EtherCAT, cannot be inserted later, (# 133) Option FAN, ventilator control, cannot be inserted later, (# 134)
Expansions
I/O-14/08 expansion card,, (# 116) PROFIBUS DP expansion card,, (# 119) sercos® II expansion card,, (# 120) DeviceNet expansion card,, (# 122) SynqNet expansion card,, (# 125) FB-2to1 expansion card,, (➜ # 127) PROFINET expansion card, (# 129)
-2CAN- expansion module, separated connectors for CAN-bus and RS232, (# 131) Several third-party expansion cards (ModBus, LightBus, FIP-IO etc. please contact the manufacturer for further information)
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S300 Instructions Manual | 7 Technical description

7.2 Technical Data

7.2.1 Technical Data 110 / 230 V (Types S3_ _6_)

Rated data DIM S303 S306 S310
Order code - S30361 S30661 S31061
Rated supply voltage (L1,L2,L3) (grounded system, phase-phase)
V~
1 x 110V 3 x 110V
-10%
-10%
... 230V ... 230V
Rated installed load for continuous operation at 230V kVA 1.1 2.4 4
Permitted switch on/off frequency 1/h 30
Max DC bus link voltage V= 450
Rated output current (rms value, ± 3%)
at 1x115V (observe (# 60)) Arms 3.5* 8* 10*
at 1x230V (observe (# 60)) Arms 3* 6* 10*
at 3x115V Arms 3.5 8 10
at 3x230V Arms 3 6 10
Peak output current (max. ca. 5s, ± 3%)
at 1x115V, 1x230V (observe (# 60)) Arms 9* 15* 20*
at 3x115V, 3x230V Arms 9 15 20
Clock frequency of the output stage kHz 8 /16 with 50% derating
Voltage rise speed dU/dt (observe notes on page (➜ # 64))
at 1x115V kV/µs 3.0
at 1x230V kV/µs 3.3
at 3x115V kV/µs 3.0
at 3x230V kV/µs 3.3
Technical data for brake circuit - (# 31)
Overvoltage protection threshold at 115 V / 230 V V 235 / 455
Motor inductance min.
at 1x115V mH 3.7 3.7 3.7
at 1x230V mH 4.3 4.3 4.3
at 3x115V mH 2.1 1.3 1.0
at 3x230V mH 4.3 2.6 1.9
Motor inductance max. mH Consult our customer support
Form factor of the output current (rated conditions, min. load inductance)
- 1.01
Bandwidth of subordinate current controller kHz > 1.2
Residual voltage drop at rated current V 4
Quiescent dissipation, output stage disabled W 12
Dissipation at rated current (incl. power supply losses, without brake dissipation)
W 35 60 90
Noise emission max. dB(A) 25 45
Mechanical
Weight kg 2.7
Height without connectors mm 270 279
Width mm 70
Depth without/with connectors mm 171 / <200
+10%
+10%
, 50/60 Hz , 50/60 Hz
*in single-phase applications nom./peak current is limited to value below nominal value. This depends on motor constant Kt and motor speed (➜ # 60).
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S300 Instructions Manual | 7 Technical description

7.2.2 Technical Data 230V ... 480 V (types S3_ _0_)

Rated data DIM S341 S343 S346
Order code - S30101 S30301 S30601
Rated supply voltage (L1,L2,L3) (grounded system, phase-phase)
V~
3 x 208V
-10%
... 480V
Rated installed load for continuous operation at 400V kVA 1.2 2.5 5
Permitted switch on/off frequency 1/h 30
Max DC bus link voltage V= 900
Rated output current (rms value, ± 3%)
at 3x208V Arms 2 5 6
at 3x230V Arms 2 5 6
at 3x400V Arms 1.5 4 6
at 3x480V Arms 1.5 3 6
Peak output current (max. ca. 5s, ± 3%)
at 3x208V...3x480V Arms 4.5 7.5 12
Clock frequency of the output stage kHz 8 /16 with 50% derating
Voltage rise speed dU/dt (observe notes on page (➜ # 64))
at 3x208V kV/µs 3.0
at 3x230V kV/µs 3.3
at 3x400V kV/µs 5.7
at 3x480V kV/µs 6.9
Technical data for brake circuit - (# 31)
Overvoltage protection threshold
at 3x230V V 455
at 3x400V V 800
at 3x480V V 900
Motor inductance min.
at 3x208V mH 7.7 4.6 2.9
at 3x230V mH 8.5 5.1 3.2
at 3x400V mH 14.8 8.9 5.6
at 3x480V mH 17.8 10.7 6.7
Motor inductance max. mH Consult our customer support
Form factor of the output current (rated conditions, min. load inductance)
- 1.01
Bandwidth of subordinate current controller kHz > 1.2
Residual voltage drop at rated current V 5
Quiescent dissipation, output stage disabled W 12
Dissipation at rated current (incl. power supply losses, without brake dissipation)
W 40 60 90
Noise emission max. dB(A) 25 45
Mechanical
Weight kg 2.7
Height without connectors mm 270 279
Width mm 70
Depth without/with connectors mm 171 / <230
+10%
, 50/60 Hz
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S300 Instructions Manual | 7 Technical description

7.2.3 Inputs / outputs, Auxiliary voltage

Interface Electr. data
Analog inputs 1, 2 (resolution 14/12 bit) ±10V
Max. common-mode voltage ±10V
Digital control inputs as per EN 61131-2 type1, max. 30VDC
Digital control outputs, active high open Emitter, max. 30VDC, 10mA
BTB/RTO output, relay contacts
Auxiliary supply voltage, electrically isolated, without motor brake / fan
Auxiliary supply voltage, electrically isolated, with motor brake / fan
Min./max. output current to brake 0.15A / 1.5A

7.2.4 Connectors

max. 30VDC, max 42VAC
500mA
20V - 30V
1A
24V (-0% +15%)
2.5A (check voltage drop !)
Connector Type max. cross
Control signals X3, X4 Mini-Combicon 1.5 mm² 4 A 160 V
S303-310: Power X0,X8,X9 Classic-Combicon 2.5 mm² 12 A 630V
S341-346: Power X0, X8, X9 Power-Combicon 4 mm² 16 A 1000 V
Resolver input X2 SubD 9pin (female) 0.5 mm² 1 A <100 V
Encoder input X1 SubD15pin (female) 0.5 mm² 1 A <100 V
PC interface, CAN X6 SubD 9pin (male) 0.5 mm² 1 A <100 V
Encoder emulation X5 SubD 9pin (male) 0.5 mm² 1 A <100 V
*1 single-line connection *2 single-line connection with recommended conductor cross section (# 29) *3 rated voltage with pollution level 2

7.2.5 Recommended Tightening Torques

Connector Recommended torque
X0, X8, X9 0.5 to 0.6 Nm (4.43 to 5.31 in lbf)
Ground bolt 3.5 Nm (31 in lbf)

7.2.6 Fusing

Internal Fusing
section
*1
permitted
current
permitted
*2
tension
*3
Circuit internal fuse
Auxiliary supply 24V 3.15 A
Brake resistor electronic
External fusing
Fusible cutouts or similar S303 / S341 / S343 S306 / S310 / S346
AC supply F
24V supply F
Brake resistor F
N1/2/3
H1/2/3
B1/2
European fuses: gRL or gL 400V/500V, T means time-delay, US fuses: class RK5/CC/J/T, 600VAC 200kA, time-delay * for example Bussmann FWP-xx
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6 A 10 A
max. 8 A
6 A* 6 A*
S300 Instructions Manual | 7 Technical description

7.2.7 Ambient Conditions, Ventilation and Mounting Position

Storage, hints (# 16)
Transport, hints (# 16)
Mains power supply
Aux. power supply
without brake and fan with brake or fan
Surrounding air tem­perature in operation
Humidity in operation rel. humidity 85%, no condensation, class 3K3
Site altitude up to 1000m a.m.s.l. without restriction
Pollution level Pollution level 2 to EN 60664-1
Vibrations Class 3M2 according to IEC 60721-3-3
Enclosure protection IP 20 according to EN60529
Mounting position generally vertical (# 46)
Ventilation
S303 und S341 all other types
S303-S310:
1x110V-10% …1x230V+10%, 50/60 Hz 3x110V-10% …3x230V+10%, 50/60 Hz
S341-S346:
3x208V-10% ...3x 480V+10%, 50/60 Hz
20 V DC ... 30 V DC 24 V DC (-0% +15%),check voltage drop
0 to +40°C (32 to 104°F) at rated data +40 to +55°C (113 to 131°F) with power derating 2.5% / K
1000 — 2500m a.m.s.l. with power derating 1.5%/100m
natural convection built-on fan (optionally controlled, Option FN (# 134))
Make sure that there is sufficient forced ventilation within the switchgear cabinet.

7.2.8 Conductor cross-sections

Recommendations for cables (material and construction (# 52)):
Interface Cross section Techn. Requirements
ACconnection 1.5 mm² 600V,80°C
DDC bus link Brake resistor
Motor cables up to 25m, motor choke
Motor cables 25m to 50 m, motor choke 3YL/3YLN
Resolver, motor thermal control
Encoder, motor thermal control 7x2x0.25 mm², max. 50m* twisted pairs, shielded
ComCoder, motor thermal control 8x2x0.25 mm², max. 25m twisted pairs, shielded
Setpoints, AGND 0.25 mm², max. 30m twisted pairs, shielded
Control signals, BTB, DGND 0.5 mm², max. 30m
Holding brake (motor) min. 0.75 mm²
+24 V / DGND max. 2.5 mm² check voltage drop
2.5 mm²
1..1.5 mm², max. 25 m
1 mm², 25 - 50m*
4x2x0.25 mm², max.100m*
For multi-axis systems, observe the specific operating conditions for your system. To reach the max. permitted cable length, observe cable requirements (# 52).
1000V, 80°C,
shielded for lengths >0.20m
600V,80°C, shielded, capacitance <150pF/m
600V,80°C,shielded, capacitance<150pF/m
twisted pairs, shielded, capacitance<120pF/m
600V, 80°C, shielded, check voltage drop
* Kollmorgen North America supplies cables up to 39 meters, Europe up to max. length
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S300 Instructions Manual | 7 Technical description

7.3 Motor holding brake

A 24V / max.1.5A holding brake in the motor can be controlled directly by the amplifier.
No functional safety!
Danger by falling load (in case of suspended load, vertical axes). An additional mechanical brake is required for funktional safety, which must be safely operated.
The brake only works with sufficient voltage level (# 28). 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.
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 seconds (EMRGTO).
The release delay time (tbrH) and the engage delay time (tbrL) of the holding 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 (# 64).
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