Page 1
www.DanaherMotion.com
Digital Servo Amplifier
®
SERVOSTAR
400
Assembly, Installation, Setup
Edition 07/05
File sr400_d.xxx
Order No.: 102530
Page 2
Previous editions
Edition Comments
10/01 First edition
02/02 new layout
07/03 new layout, technical data adapted to new hardware, equipment matching removed
07/05
SSI Simulation updated (Multiturn), UL/cUL information updated,
typographical changes, chapter 1 new sorted, several corrections
PC-AT is a registered trademark of International Business Machines Corp.
WINDOWS is a registered trademark of Microsoft Corp.
HIPERFACE is a registered trademark of Max Stegmann GmbH
EnDat is a registered trademark of Dr.Johannes Heidenhain GmbH
SERVOSTAR is a registered trademark of Kollmorgen Corporation
Technical changes to improve the performance of the equipment may be made without notice !
Printed in the Federal Republic of Germany
All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm
or any other method) or processed, copied or distributed by electronic means without the written permission
of Danaher Motion.
Page 3
Kollmorgen 07/05 Contents
1 General
1.1 About this manual ....................................................................... 5
1.2 Symbols used in this Manual ............................................................... 5
1.3 Abbreviations used in this Manual ........................................................... 6
2 Technical description
2.1 Safety Instructions ....................................................................... 7
2.2 Use as directed ......................................................................... 8
2.3 European Directives and Standards.......................................................... 9
2.4 CE Conformity .......................................................................... 9
2.5 UL and cUL- Conformance................................................................ 10
2.6 Nameplate ............................................................................ 11
2.7 Equipment description ................................................................... 11
2.7.1 Package as supplied ............................................................... 11
2.7.2 Digital servo amplifiers in the series SERVOSTAR 400..................................... 12
2.8 Components of a servo system ............................................................ 14
2.9 Technical data ......................................................................... 15
2.9.1 Rated data ....................................................................... 15
2.9.2 Connections...................................................................... 16
2.9.3 Recommended tightening torques ..................................................... 16
2.9.4 Fusing .......................................................................... 16
2.9.4.1 Internal fusing ................................................................. 16
2.9.4.2 External fusing ................................................................ 16
2.9.5 Permissible ambient conditions, ventilation, mounting position ............................... 17
2.9.6 Conductor cross-sections............................................................ 17
2.10 Motor holding brake control ............................................................... 18
2.11 Regen circuit .......................................................................... 19
2.11.1 LED display ...................................................................... 19
2.12 Grounding system ...................................................................... 19
2.13 Switch-on/-off behaviour.................................................................. 20
2.13.1 Stop function as per EN 60204 (VDE 0113).............................................. 20
2.13.2 Emergency stop methods ........................................................... 21
3 Installation
3.1 Important notes ........................................................................ 23
3.2 Guide to installation/wiring ................................................................ 24
3.3 Mounting ............................................................................. 25
3.3.1 Dimensions ...................................................................... 26
3.4 Wiring................................................................................ 27
3.4.1 Wiring diagram master ............................................................. 28
3.4.2 Wiring diagram axis module.......................................................... 29
3.4.3 Example of connections for multi-axis system ............................................ 30
3.4.4 Connector assignments ............................................................. 31
3.4.5 Connection techniques.............................................................. 32
3.4.5.1 Shield connection on the front panel ................................................ 32
3.4.5.2 Requirements to cables.......................................................... 33
3.5 Setup software......................................................................... 34
3.5.1 General ......................................................................... 34
3.5.1.1 Use as directed ................................................................ 34
3.5.1.2 Software description ............................................................ 34
3.5.1.3 Hardware requirements.......................................................... 35
3.5.1.4 Operating systems ............................................................. 35
3.5.2 Installation under WINDOWS 98 / 2000 / ME / NT / XP..................................... 35
SERVOSTAR®400 Installation Manual 3
Page 4
Contents 07/05 Kollmorgen
4 Interfaces
4.1 Block diagram ......................................................................... 36
4.2 Power supply, master only................................................................ 37
4.2.1 Mains supply connection (X0) ........................................................ 37
4.2.1.1 Three-phase supplies ........................................................... 37
4.2.1.2 Single-phase supplies ........................................................... 37
4.2.2 24V auxiliary voltage (X0) ........................................................... 38
4.3 DC Bus link/DC-bus (X0) ................................................................. 38
4.4 Motor connection with brake (X6)........................................................... 38
4.5 External regen resistor (X0), master only..................................................... 39
4.6 Feedback ............................................................................. 39
4.6.1 Resolver connection (X5)............................................................ 39
4.6.2 Encoder connection (X2) ............................................................ 40
4.7 Control signals ......................................................................... 41
4.7.1 Analog setpoint input (X3) ........................................................... 41
4.7.2 Digital control inputs (X3)............................................................ 42
4.7.3 Digital control outputs (X3)........................................................... 43
4.7.4 Digital control signals on the Master (X1)................................................ 44
4.8 Encoder simulations..................................................................... 45
4.8.1 Incremental encoder output (X4) ...................................................... 45
4.8.2 SSI output (X4) ................................................................... 46
4.8.3 Input encoder control for master-slave operation.......................................... 47
4.8.3.1 Connection to SERVOSTAR 400 master, 5V level (X4) ................................. 47
4.8.3.2 Connection to encoder with 24V signal level (X3) ...................................... 48
4.8.3.3 Connection for Sin/Cos encoder (X2) ............................................... 48
4.9 Interface for stepper motor controls (pulse/direction)............................................ 49
4.9.1 Connection of stepper motor controls with 5V signal level (X4) ...............................50
4.9.2 Connection of stepper motor controls with 24V signal level (X3) ..............................50
4.10 RS232 interface, PC connection (X8), master only............................................. 51
4.11 Fieldbus connection ..................................................................... 52
4.11.1 CANopen interface (X7)............................................................. 52
4.11.2 PROFIBUS interface (X7), option ..................................................... 53
4.11.3 SERCOS interface (X7), option ....................................................... 54
4.11.3.1 Light emitting diodes (LEDs) ...................................................... 54
4.11.3.2 Connection diagram ............................................................ 54
5Setup
5.1 Important notes ........................................................................ 55
5.2 Guide to setup ......................................................................... 56
5.3 Parameterization ....................................................................... 57
5.3.1 Multi-axis systems ................................................................. 57
5.3.2 Key pad controls and status displays................................................... 58
5.3.2.1 Operating .................................................................... 58
5.3.2.2 Status display on the axis module.................................................. 58
5.3.2.3 Status display on the master ...................................................... 59
5.4 Error messages ........................................................................ 60
5.5 Warning messages ..................................................................... 61
6 Accessories
6.1 External PSU 24V DC / 5A................................................................ 63
6.2 External PSU 24V DC / 20A............................................................... 64
6.3 External regen resistor BAR(U)xyz ......................................................... 65
6.4 Add-on fan ............................................................................ 66
7 Appendix
7.1 Transport, storage, maintenace, disposal .................................................... 67
7.2 Fault-finding ........................................................................... 68
7.3 Glossary.............................................................................. 70
7.4 Order numbers......................................................................... 72
7.5 Index ................................................................................ 74
4 SERVOSTAR®400 Installation Manual
Page 5
Kollmorgen 07/05 General
1 General
1.1 About this manual
This manual describes the digital servo amplifiers of the SERVOSTAR 400 series.
In this manual you can find information about:
General Chapter 1
l
Technical description Chapter 2
l
Assembly / installation Chapter 3
l
Interfaces Chapter 4
l
Commissioning Chapter 5
l
Accessories Chapter 6
l
Transport, storage, maintenance, disposal Chapter 7
l
A more detailed description of the field bus interfaces and the digital connection to auto
mation systems can be found on the accompanying CD-ROM in PDF format (system
requirements: WINDOWS 95 or higher, Internet browser, Acrobat Reader) in several
language versions.
You can print out this documentation on any standard printer. A printed copy of the docu
mentation is available from us at extra cost.
This manual makes the following demands on qualified personnel :
Transport: only by personnel with knowledge of handling
electrostatically sensitive components.
Installation: only by electrically qualified personnel
Commissioning: only by qualified personnel with extensive knowledge of
electrical engineering / drive technology
1.2 Symbols used in this Manual
danger to personnel
from electricity
and its effects
ð p.
see page (cross-refer
ence)
-
-
general warning
general instructions
mechanical hazard
-
l special emphasis
Keys on the master:
press once : move up one menu item, increase number by one
U
U
U
press twice in rapid succession : increase number by ten
press once : move down one menu item, decrease number by one
press twice in rapid succession : decrease number by ten
U
hold right key pressed, and then press left key as well :
to enter number, Return function
SERVOSTAR®400 Installation Manual 5
Page 6
General 07/05 Kollmorgen
1.3 Abbreviations used in this Manual
The abbreviations used in this manual are explained in the table below.
Abbrev. Meaning
AGND Analog ground
BTB/RTO Ready to operate
CAN Fieldbus (CANopen)
CE Communité Europeenne (=EC)
CLK Clock signal
COM Serial interface for a PC-AT
DGND Digital ground
DIN Deutsches Institut für Normung
Disk Magnetic storage (diskette, hard disk)
EEPROM Electrically erasable memory
EMC Electromagnetic compatibility
EMI Elektromagnetic interference
EN European standard
ESD Electrostatic discharge
IEC International Electrotechnical Commission
IGBT Insulated gate bipolar transistor
INC Incremental Interface
ISO International Standardization Organization
LED Light-emitting diode
MB Megabyte
NI Zero pulse
NSTOP Limit-switch input, rot. dir. CCW (left)
PC Personal Computer
PELV Protected low voltage
PLC Programmable logic controller
PSTOP Limit-switch input, rot. dir. CW (right)
PSU Power supply unit
PWM Pulse-width modulation
RAM Volatile memory
RBallast Regen resistor
RBext External regen resistor
RBint Internal regen resistor
RES Resolver
ROD 426 A quad B Encoder
SRAM Static RAM
SSI Synchronous serial interface
SW/SETP. Setpoint
UL Underwriter Laboratory
V AC AC voltage
V DC DC voltage
VDE Verein deutscher Elektrotechniker
6 SERVOSTAR®400 Installation Manual
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Kollmorgen 07/05 Technical description
2 Technical description
2.1 Safety Instructions
Only properly qualified personnel are permitted to carry out activities
l
such as transport, installation, commissioning and maintenance.
Properly qualified persons are those who are familiar with the transport,
assembly, installation, commissioning and operation of the product, and
who have the appropriate qualifications for their job. The qualified
personnel must know and observe the following standards and
regulations:
IEC 364 and CENELEC HD 384 or DIN VDE 0100
IEC Report 664 or DIN VDE 0110
national accident prevention regulations or BGV A2
The manufacturer of the machine must produce a hazard analysis for the
l
machine and take appropriate measures to ensure that unforeseen
movements do not result in personal injury or material damage.
Read this documentation before carrying out the installation and
l
commissioning. Incorrect handling of the servo amplifier can lead to
personal injury or material damage. It is vital that you keep to the
technical data and information on connection requirements (nameplate
and documentation).
Do not open or touch the equipmen during operationt. Keep all covers
l
and cabinet doors closed during operation. Touching the equipment is
allowed during installation and commissioning for properly qualified
persons only. Otherwise, there are deadly hazards, with the possibility
of death, severe injury or material damage.
— During operation, servo amplifiers may have uncovered live
components, depending on their level of enclosure protection.
— Control and power connections may be live, even though the
motor is not rotating.
— Servo amplifiers may have hot surfaces during operation.
Surface can reach temperatures above 80°C.
l
Discharge your body before touching the servo amplifier. The servo
amplifiers contain electrostatically sensitive components which may be
damaged by incorrect handling. Avoid contact with highly insulating
materials (artificial fabrics, plastic film etc.). Place the servo amplifier on
a conductive surface.
l
Never undo any electrical connections to the servo amplifier while it is
live. There is a danger of electrical arcing with damage to contacts and
personal injury.
Wait at least five minutes after disconnecting the servo amplifier from
the main supply power before touching potentially live sections of the
equipment (e.g. contacts) or undoing any connections. Capacitors can
still have dangerous voltages present up to five minutes after switching
off the supply power. To be sure, measure the voltage in the DC Bus link
and wait until it has fallen below 40V.
SERVOSTAR®400 Installation Manual 7
Page 8
Technical description 07/05 Kollmorgen
2.2 Use as directed
The servo amplifiers are components which are built into electrical equipment or machi
nes, and can only be commissioned as integral components of such equipment.
The manufacturer of the machine must produce a hazard analysis for the machine
and take appropriate measures to ensure that unforeseen movements do not result
in personal injury or material damage.
The servo amplifier should only be used with power supplies with a maximum
symmetrical rated current of 5000A and a voltage of 115/230V AC (SERVOSTAR
40xM) or 400V AC (SERVOSTAR 44xM).
Mains voltage Servo amplifier
1 x 115V AC only SERVOSTAR 40xM, unearthed operation is permissible
3 x 115V AC only SERVOSTAR 40xM, unearthed operation is permissible
1 x 230V AC only SERVOSTAR 40xM, unearthed operation is permissible
3 x 230V AC all types, unearthed operation is permissible
3 x 400V AC
If the servo amplifiers are used in residential areas, or in business or commercial premi
ses, then additional filter measures must be implemented by the user.
The SERVOSTAR 400 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.
only SERVOSTAR 44xM, TN-system or TT-system with earthed
neutral point, max. 5000A symmetrical rated current
-
-
The servo amplifiers may only be operated in a closed control cabinet, taking into
account the ambient conditions defined on page 17. Ventilation or cooling measures may
be required to keep the temperature below 45°C.
Use only copper-cored cables for wiring. The conductor cross-sections can be taken from
the European standard EN 60204 (or Table 310-16 of NEC for 60°C or 75°C in the
column for AWG cross-sections).
We can only guarantee that the system will conform to the standards cited on page 9 if
the components used are exclusively those supplied by us (servo amplifier, motor, cables
etc.).
8 SERVOSTAR®400 Installation Manual
Page 9
Kollmorgen 07/05 Technical description
2.3 European Directives and Standards
Servo amplifiers are components that are intended to be incorporated into electrical plant
and machines for industrial use. When the servoamplifiers are built into machines or
plant, the intended operation of the amplifier is forbidden until it has been established that
the machine or plant fulfills the requirements of the EC Machinery Directive 98/37/EG and
the EC Directive on EMC (89/336/EEC) and the Low Voltage Directive 73/23/EEC.
To fulfill the EC Machinery directive 98/37/EG, the following standards have to be applied:
EN 60204-1 (Safety and electrical equipment of machines)
EN 292 (Safety of machines)
The manufacturer of the machine must produce a hazard analysis for the machine
and take appropriate measures to ensure that unforeseen movements do not result
in personal injury or material damage.
To fulfill the Low Voltage Directive 73/23/EEC, the following standards have to be applied:
EN 60204-1 (Safety and electrical equipment of machines)
EN 50178 (Equipment of high voltage plant with electronic devices)
EN 60439-1 (Low-voltage switchgear and controlgear assemblies)
To fulfill the EC EMC regulations 89/336/EEC, the following standards have to be applied:
EN 61000-6-1 or EN 61000-6-2 (noise immunity within the
domestic range/industrial range)
EN 61000-6-3 or EN 61000-6-4 (noise emission within the
domestic range/industrial range)
The manufacturer of the machine or plant is responsible for ensuring that they meet the
limits required by the EMC regulations. Advice on the correct installation for EMC – such
as shielding, grounding, arrangement of connectors and cable routing – can be found in
this documentation.
The machine / plant manufacturer must examine whether with its machine / plant
still further or other standards or EEC guidelines are to be used.
2.4 CE Conformity
Conformity with the EC Directive on EMC 89/336/EEC and the Low Voltage Directive
73/23/EEC is mandatory for servoamplifiers supplied within the European Union.
To fulfill the EMC directive, the standard EN 61800-3 is applied.
In the reference to noise immunity the servoamplifier fulfills the requirement to the cate
gory second environment (industrial environment). For the range of the noise emission
the rvo amplifier fulfills the requirement to a product of the category reduced availability.
This is a product with reduced availability according to IEC 61800-3. This product
can cause interferences within domestic range; if required you must accomplish
appropriate measures.
The servo amplifiers have been tested by an authorized testing laboratory in a defined
configuration with the system components which 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 that the
regulatory requirements are fulfilled.
To fulfill the Low Voltage Directive, the standard EN 50178 has to be applied.
-
SERVOSTAR®400 Installation Manual 9
Page 10
Technical description 07/05 Kollmorgen
2.5 UL and cUL- Conformance
UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S.
and Canadian standard (in this case UL 840 and UL 508C).
This standard describes the fulfilment by design of minimum requirements for electrically
operated power conversion equipment, such as frequency converters and servo ampli
fiers, which is intended to eliminate the risk of fire, electric shock, or injury to persons,
being caused by such equipment.
-
UL(cUL) regulations also specify the minimum technical requirements of electrical devi
ces, in order to take the necessary measures against the risk of fire, which can be trigge
red by electrically operated devices. The technical conformance with the U.S. and Cana
dian standard is determined by an independent UL (cUL) 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 fulfilment by design of minimum requirements for electrically ope
rated 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 fulfilment by design of air and insulation creepage spacings for
electrical equipment and printed circuit boards.
UL File Number
This servo amplifier is listed under UL file number E217428.
-
-
-
-
10 SERVOSTAR®400 Installation Manual
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Kollmorgen 07/05 Technical description
2.6 Nameplate
The nameplate depicted below is attached to the side of the servo amplifier.
Danaher Motion GmbH
Wacholderstr. 40-42
D-40489 Düsseldorf
www.DanaherMotion.com
Typenbezeichnung
Spannungsversorgung
Umgebungstemp.
Ambient temp.
008102106842
Barcode
Serial Number
2.7 Equipment description
2.7.1
Package as supplied
If you order a SERVOSTAR 400 series amplifier from us, you will receive:
Customer Support
Europe Tel. +49 (0)203 / 99790
Italy 3 36 594260
North America 1 8 -3
Model Number
Power Supply
Tel. + 9 (0) 2 /
Tel. + ( 15) 226 148
Ser. Nr
Nennstrom
Ser. No.
Nom. Current
E217428
Bemerkung
Schutzart
5.76
U
CUS
L
®
LISTED
IND. CONT. EQ.
1VD4
Barcode
Firmware
Comment
Encl.Rating
— SERVOSTAR 4xxM (master)
— Mating connectors for X0, X1, X3, X6
— Protective cover for the axis-side (required only once per system)
— Assembly and Installation Instructions
— Setup software DRIVE.EXE and online documentation on CD-ROM
alternatively
— SERVOSTAR 4xxA (axis module)
— Mating connector for X3, X6
— Short-form instructions
The mating SubD connectors are not part of the package supplied!
Accessories:
(must be ordered separately if required)
— Electrical add-on fan (for max. 2 axes, required for SERVOSTAR 4x6)
— Synchronous servomotor (linear or rotary)
— Motor lead (pre-assembled), or motor cable as cut-off length + loose connectors
(motor- and amplifier-side)
— Feedback cable (pre-assembled) or both feedback connectors, loose with
feedback cable as cut-off length
— External regen resistor (ð p.65)
— Communication cable to PC (ð p.51) for parameterizing the master and any
attached axis modules
— Power cable, control cables, fieldbus cables (as lengths)
SERVOSTAR®400 Installation Manual 11
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Technical description 07/05 Kollmorgen
2.7.2 Digital servo amplifiers in the series SERVOSTAR 400
Minimum complexity
up to 8 axes in a single system
l
only one power supply feed and one auxiliary voltage supply per system
l
shield connection directly on the servo amplifier
l
all axes in a system can be parameterized through a single interface
l
strongly reduced wiring expenditure by modular structure
l
simple mechanical structure on DIN rails
l
Standard version
2 supply voltage versions: SERVOSTAR 40xM up to 3x230VAC and
l
SERVOSTAR 44xM up to 3x400VAC
one size for the master and axis modules each, see page 26
l
analog input
l
fieldbus interface is integrated (standard: CANopen)
l
RS232 is integrated
l
pulse-direction interface is integrated
l
Supply power
directly off electrical supply input (master only, B6 rectifier bridge,
l
integral power input filter and inrush circuit):
1 x 115V AC (SERVOSTAR 40xM only, unearthed operation is permitted)
3 x 115V AC (SERVOSTAR 40xM only, unearthed operation is permitted)
1 x 230V AC (SERVOSTAR 40xM only, unearthed operation is permissible)
3 x 230V AC (all types, unearthed operation is permissible)
3 x 400V AC (SERVOSTAR 44xM only, TN-system or TT-system with
earthed neutral point)
l
fusing (e.g. fusible cutout) provided by the user
l
interference suppression filter for the supply input (for reduced availability according
to EN61800-3) is integrated
l
interference suppression filter for the 24V auxiliary supply (for general availability
according to EN 61800-3) is integrated
l
all shielding connections directly on the amplifier
l
output stage IGBT module with isolated current measurement
Clock frequency can be switched from 8 to 16 kHz with
ASCII command (with power reduction, please contact
our customer support)
l
regen circuit internal regen resistor as standard,
external regen resistor if required
l
DC Bus link voltage 160...310V DC for SERVOSTAR 40xM
310...560V DC for SERVOSTAR 44xM
160...560V DC for SERVOSTAR 4xxA
12 SERVOSTAR®400 Installation Manual
Page 13
Kollmorgen 07/05 Technical description
Integrated safety
safe electrical separation to EN 50178 between the power input / motor connections
l
and the signal electronics, provided by appropriate creepage distances and complete
electrical isolation
Soft-start, overvoltage detection, short-circuit protection, phase-failure monitoring
l
temperature monitoring of servo amplifier and motor (when using our motors with our
l
pre-assembled cables)
Auxiliary voltage 24V DC
electrically isolated via an external 24V DC PSU, e.g. with isolating transformer
l
Operation and parameter setting
with the comfortable setup software, via the serial interface of a PC to a single con
l
nection for all axes in a system
station address setting through two keys and a 3-digit LED status display on the
l
master
fully programmable via RS232 interface
l
-
Completely digital control
digital current controller (space vector pulse-width modulation, 62.5 µs)
l
freely programmable digital speed controller (62.5 µs or 250 µs)
l
integral position controller, with adaptation possibilities for every application (250 µs)
l
l
integrated pulse direction interface, for connection of a servomotor to a
stepper-motor control
l
evaluation of the resolver signals or sine/cosine signals from a high-resolution
encoder
l
encoder simulation (incremental ROD 426-compatible or SSI)
Comfort functions
l
adjustable setpoint ramps
l
4 programmable digital inputs
(two are normally defined as limit-switch inputs)
l
2 programmable digital outputs
l
freely programmable combinations of all digital signals
Options
l
PROFIBUS DP interface instead of CANopen, see page 53
l
SERCOS interface instead of CANopen, see page 54
SERVOSTAR®400 Installation Manual 13
Page 14
Technical description 07/05 Kollmorgen
2.8 Components of a servo system
PC
Control / PLC
24V supply
SERVOSTAR 400
fuses
drive contactor
terminals
motor
14 SERVOSTAR®400 Installation Manual
Page 15
Kollmorgen 07/05 Technical description
2.9 Technical data
2.9.1
Rated data
max. 230VAC max. 400VAC
SERVOSTAR SERVOSTAR
Rated data DIM 403M 406M 403A 406A 443M 446M 403A 406A
Rated supply voltage V~
Max. installed load for S1 operation
(in a multi-axis system)
kVA 7 — 12 —
1 x 115V
to
3 x 230V
-10%
—
+10%
3 x 230V
to
3 x 400V
-10%
—
+10%
Rated DC Bus link voltage V= 160 - 310 310 - 560
Rated output current
(rms value, ± 3%, @ 8kHz)
Peak output current
(max. ca. 5s, ± 3%, @ 8kHz)
Arms
Arms
36*36*36*36*
9 12* 9 12* 9 12* 9 12*
Clock frequency of output stage kHz 8 (can be switched to 16, see page 12)
Overvoltage switch-off threshold V 450 — 750 —
maximum load inductance mH 75 40 75 40 75 40 75 40
minimum load inductance mH 12 7.5 12 7.5 12 7.5 12 7.5
Form factor of the output current (rated
conditions and min. load inductance)
Bandwidth of subordinate current
controller
— 1.01 1.01
kHz > 1.2 > 1.2
Residual voltage drop at rated current V < 5 < 5
Quiescent dissipation, output stage disabled W 12 15 12 15 12 15 12 15
Dissipation at rated current
(without regen dissipation)
W3560304035603040
Inputs/outputs
Analog input, 14-bit resolution V
common-mode voltage max. V
input resistance
kW
Digital control inputs
low 0...7 / high 12...36V,
±10 ±10
±10 ±10
20 20
low 0...7 / high 12...36V,
7mA
7mA
Digital control outputs, open emitter max. 30V, 10mA max. 30V, 10mA
BTB/RTO output, relay contacts
DC max. 30,
V
AC max 42
—
DC max. 30,
AC max 42
—
mA 500 500
Auxiliary supply, electrically isolated,
without holding brake, without fan
Auxiliary supply, electrically isolated,
with holding brake or fan
(check voltage drop !)
V 20...30
A 0.5 0.5
V
24
(-0% +15%)
—
—
20...30
24
(-0% +15%)
A 2.5 2.5
—
—
Max. output current for holding brake A 1,5 1,5
Mechanical
Weight kg 3 1.7 3 1.7
Height, without connectors mm 230 267* 230 267* 230 267* 230 267*
Width mm 100 50 100 50
Depth, without connectors mm 240 240
* with add-on ventilation, see page 66
SERVOSTAR®400 Installation Manual 15
Page 16
Technical description 07/05 Kollmorgen
2.9.2 Connections
Function Connector type
Control signals Combicon spring terminal
Power supply Power Combicon
Motor Combicon
Resolver input SubD 9pol. (socket)
Incremental encoder input SubD 15pol. (socket)
PC interface SubD 9pol. (plug)
Encoder simulation, ROD/SSI SubD 9pol. (plug)
2.9.3 Recommended tightening torques
Connector Tightening torque
X1, X3, X6 0.3 Nm
X0 1.3 Nm
Earthing bolts 3.5 Nm
lower mounting bolt 3.5 Nm
2.9.4 Fusing
2.9.4.1 Internal fusing
Function
Auxiliary supply 24V 20 AM
Regen resistor electronical
2.9.4.2 External fusing
Function Fusible cutouts or similar
AC supply F
24V supply F
regen resistor F
N1/2/3
H1/2
B1/2
16 A slow
20 A slow
6 A slow
16 SERVOSTAR®400 Installation Manual
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2.9.5 Permissible ambient conditions, ventilation, mounting position
Storage temp. /humidity/duration
Transport temperature/humidity
ð p.67
ð p.67
Supply voltage tolerances
main power
SERVOSTAR 40xM
SERVOSTAR 44xM
min 1x115V
min 3x115V
min 3x230V
AC / max 1x230V
-10%
AC / max 3x230V
-10%
AC / max 3x400V
-10%
+10%
, 50/60 Hz
+10%
, 50/60 Hz
+10%
, 50/60 Hz
auxiliary supply
w/o brake and w/o fan
with brake or with fan
Ambient temperature in operation
Humidity in operation
Site altitude
20 VDC ... 30 VDC
24 VDC (-0% +15%)
0...+45
o
C at rated conditions
+45...+55°C with power derating 2.5% / K
rel. humidity 85%, no condensation
up to 1000m amsl without restrictions
1000...2500m amsl with derating 1.5% / 100m
Pollution level Pollution level 2 as per EN 60204 / EN 50178 Enclosure rating IP 20 Mounting position
Ventilation
normally vertical ð p.25
SERVOSTAR4x3: free convection
SERVOSTAR4x6: add-on fan (ð p.66)
Make sure that there is adequate forced ventilation
within the closed control cabinet.
2.9.6 Conductor cross-sections
Following EN 60204-1, we recommend :
AC connection 1.5 mm², depending on the system fusing
Motor cables
Resolver, motor thermostat
Encoder, motor thermostat
Analog signals 0.25 mm² , twisted pairs, shielded
Control signals, BTB, DGND 0.5 mm²
Holding brake (motor) 0.75 mm², shielded, check voltage drop
+24 V / XGND max. 2.5 mm², check voltage drop
Technical requirements to cables ð p.33.
1 mm², shielded, capacitance <150pF/m,
max. 25m
4x2x0.25 mm², twisted pairs, shielded, max.100m,
capacitance <120pF/m
7x2x0.25 mm², twisted pairs, shielded, max. 50m,
capacitance <120pF/m
SERVOSTAR®400 Installation Manual 17
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2.10 Motor holding brake control
A motor holding brake (24V / max.1.5A) can be controlled directly by the servo amplifier.
This function does not ensure personnel safety!
The brake function must be enabled through the BRAKE parameter (on the screen page
for Motor): the setting is WITH.
In the diagram below you can see the timing and functional relationships between the
ENABLE signal, speed setpoint, speed and braking force.
During the internal enable delay time of 100ms the speed setpoint of the servo amplifier is
internally driven down a 10ms ramp to 0V. The brake output is switched on when 3% of
the final speed is reached, at the latest after 1 second.
The rise (f
) and fall (f
brH
) times of the holding brakes that are built into the motors vary
brL
for the different types of motor (see motor manual).
A description of the interface can be found on page 38.
Personnel-safe operation of the holding brake requires an additional “make” contact in
the brake circuit and a spark suppressor device (e.g. a varistor) in the recommended
brake circuit:
SERVOSTAR
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2.11 Regen circuit
During braking with the aid of the motor, energy is fed back to the servo amplifier. This
energy is converted into heat in the regen resistor. The regen resistor is switched in and
out by the regen circuit. The switching thresholds for the regen circuit are adjusted to suit
the supply voltage with the aid of the setup software.
Our customer support can help you with the calculation of the regen power which is requi
red. A description of the interface can be found on page 39 .
Internal regen resistor 33 W
External regen resistor 33 W
Functional description
The regen circuit starts to respond when the DC Bus link voltage reaches the set value.
If the energy which is fed back from the motor, as an average over time or as a peak
value, is higher than the preset regen power, then the servo amplifier will output the sta
tus regen power exceeded and the circuit will be switched off.
-
-
At the next internal check of the DC Bus link voltage (after a few milliseconds) an overvol
tage will be detected and the servo amplifier will be switched off, with the error message
overvoltage (ð p.60).
The BTB/RTO contact (terminals X1/1,2) will be opened simultaneously (ð p.44).
Technical data
Supply voltage Rated data DIM Value
Upper switch-on threshold for regen circuit V 400
Switch-off threshold for regen circuit V 380
)W55
Bint
) max. kW 0,4
W
33
3 x 230 V
Continuous int. power in regen circuit (R
Continuous ext. power in circuit (R
Pulse power, internal (R
Pulse power, external (R
max. 1s) kW 4.8
Bint
Bext
Bext
max. 1s) kW 4.8
External regen resistor
Upper switch-on threshold for regen circuit V 720
Switch-off threshold for regen circuit V 680
)W80
Bint
) max. kW 0,6
W
33
3 x 400 V
Continuous int. power in regen circuit (R
Continuous ext. power in circuit (R
Pulse power, internal (R
Pulse power, external (R
max. 1s) kW 16
Bint
Bext
Bext
max. 1s) kW 16
External regen resistor
-
2.11.1 LED display
A 3-digit LED display indicates the amplifier status after switching on the 24V supply
(ð p.59).
2.12 Grounding system
AGND – ground reference for analog signals, internal analog ground
DGND – ground reference for digital signals and auxiliary supply voltage,
optically isolated
PGND — ground reference for position output
The electrical isolation is indicated in the block diagram (ð p.36).
SERVOSTAR®400 Installation Manual 19
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2.13 Switch-on/-off behaviour
The diagram below illustrates the correct functional sequence for switching the servo
amplifier on and off.
2.13.1 Stop function as per EN 60204 (VDE 0113)
If a fault occurs (ð p.60), the output stage of the servo amplifier is switched off and the
BTB/RTO contact is opened. In addition, a global error signal can be given out at one of
the digital outputs (terminals X3/8 and X3/9) (see the Online help in the setup software).
These signals can be used by the higher-level control to terminate the current PLC cycle
or to shut down the drive (through an additional brake or similar means).
Instruments with a selected Brake function use a special sequence for switching off the
output stage (ð p.18). The Stop functions are defined in EN 60204 (VDE 0113), Paras.
9.2.2 and 9.2.5.3.
Categories of
Category 0: Shut down by immediate switch-off of the supply of energy to the
Category 1: A controlled shut-down, during which the supply of energy to the
Category 2: A controlled shut-down, where the supply of energy to the drive
Every machine must be equipped with a Stop function to Category 0.
Categories 1 and/or 2 must be provided if the safety or functional requirements of the
machine make this necessary.
Stop functions
drive machinery (i.e. an uncontrolled shut-down)
drive machinery is maintained to perform the shut-down, and where
the supply is only interrupted when standstill has been reached
machinery is maintained
Implementation of the Stop function :
You can find wiring recommendations in our application note
“Stop and Emergency Stop functions with SERVOSTAR”
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Kollmorgen 07/05 Technical description
2.13.2 Emergency stop methods
The Emergency Stop function is defined in EN 60204 (VDE 0113), Para. 9.2.5.4.
In addition to the requirements for Stop, the Emergency Stop must fulfill the following
requirements:
it must have priority over all other functions and controls in all operating situations
l
the energy supply to any drive machinery that could cause dangerous situations
l
must be switched off as fast as possible, without causing any further hazards (e.g. by
using
mechanical latching devices that do not require an external supply of energy, by
counter-current braking in Stop Category 1)
the reset must not initiate a restart
l
If necessary, provision must be made for the additional connection of emergency stop
devices (see EN 60204 Requirements for emergency stop devices).
The Emergency Stop must be effective as a stop of either Category 0 or Category 1.
The Emergency Stop Category must be determined by a risk evaluation of the machine.
Category 0
Only hard-wired electromechanical components may be used for an Emergency Stop
function to Category 0. The action must not depend on switching logic (hardware or soft
ware) or on the transmission of commands through a communications network or a data
connection.
In multi-axis systems (several SERVOSTAR 400-systems or combinations of
SERVOSTAR 400 and SERVOSTAR 300 or 600) using a coupled DC Bus link the motor
cable must also be disconnected by a changeover switch (a contactor, such as Siemens
type 3RT1516-1BB40) and short-circuited by resistors wired in a star configuration.
-
Category 1
For Emergency Stop Category 1 the final disconnection of the energy supply to the drive
machinery must be ensured by electromechanical components. Supplementary Emergency Stop devices may be plugged in.
Implementation of the Emergency Stop function :
You can find wiring recommendations in our application note
“Stop and Emergency Stop functions with SERVOSTAR”
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This page has been deliberately left blank.
22 SERVOSTAR®400 Installation Manual
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3 Installation
3.1 Important notes
Protect the servo amplifier from impermissible stresses. In particular, do not let any
l
components become bent or any insulation distances altered during transport and
handling. Avoid contact with electronic components and contacts.
Check the combination of servo amplifier and motor. Compare the rated voltage and
l
current of the units. Carry out the wiring according to the instructions on page 27.
Make sure that the maximum permissible rated voltage at the terminals for L1, L2, L3
l
and +R
conditions (see EN 60204-1 Section 4.3.1). An excessive voltage on these terminals
can lead to destruction of the regen circuit and the servo amplifier.
Use the SERVOSTAR 44x only on an earthed 3-phase supply system. Use the am
plifier only to drive a synchronous servomotor.
The fusing of the AC supply input and the 24V supply is installed by the user
l
(ð p.16).
Take care that the servo amplifier and motor are properly earthed. Do not use pain
l
ted (non-conductive) mounting plates.
, –DC is not exceeded by more than 10%, even in the most unfavourable
Bext
-
-
Route power and control cables separately. We recommend a separation of at least
l
20 cm. This improves the interference immunity required by EMC regulations. If a
motor power cable is used which includes cores for brake control, the brake control
cores must be separately shielded. Earth the shielding at both ends (ð p.28).
Install all heavy-current cables with an adequate cross-section, as per EN 60204-1
l
(ð p.17).
l
Wire the BTB/RTO contact in series into the safety circuit of the installation.
Only in this way is the monitoring of the servo amplifier assured.
l
Install all shielding with large area (low impedance) connections, with metallised connector housings or shield connection clamps where possible.
Notes on connection techniques can be found on page 32.
l
Ensure that there is an adequate flow of cool, filtered air into the bottom of the control
cabinet. Note the conditions on page 17 .
l
It is permissible to alter the servo amplifier settings by using the operator software.
Any other alterations will invalidate the warranty.
Caution
Never disconnect the electrical connections to the servo amplifier while it is live.
Residual charges in the capacitors can have dangerous levels up to 300 seconds
after switching off the mains supply voltage. Measure the voltage in the DC Bus
link (+R
/-DC) and wait until the voltage has fallen below 40V.
Bext
Control and power connections can still be live, even when the motor is not
rotating.
SERVOSTAR®400 Installation Manual 23
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Installation 07/05 Kollmorgen
3.2 Guide to installation/wiring
The following notes should assist you to carry out the installation in a sensible sequence,
without overlooking anything important:
In a closed control cabinet. Observe page 17.
Site
Ventilation
Mounting
Cable selection Select cables according to EN 60204-1, ð p.17
The site must be free from conductive or corrosive materials.
For the mounting position within the cabinet ð p.25
Check that the ventilation of the servo amplifier is unimpeded
and keep within the permitted ambient temperature ð p.17 .
Keep the required space clear above and below the
servo amplifier ð p.25.
Mount the servo amplifier on mounting rails (DIN-rails) on the
conductive, earthed mounting plate in the control cabinet and
mount the necessary add-on fans (ð p.66)
Grounding,
Shielding
Wiring
EMC-conform shielding and grounding (ð p.28) Earth the moun
ting plate, motor housing and CNC-GND of the controls. Notes
on connection techniques are on page 32
— Route power leads separately from control cables
— Wire the BTB/RTO contact in series into the safety loop
— Connect the digital control inputs to the servo amplifier
— Connect up AGND
— Connect the analog setpoint, if required
— Connect the feedback unit (resolver or encoder)
— If required, connect the encoder simulation
— If required, connect the fieldbus
— Connect the motor cable
Connect shielding to EMC connectors at the motor end, and
the shielding lug at the amplifier end
— Connect motor-holding brake, with shielding to EMC
connector at the motor end, and to shielding lug at the
amplifier end
— If required, connect the external regen resistor (with fusing)
— Connect the auxiliary supply
(maximum permissible voltages ð p.17)
— Connect main power supply
(maximum permissible voltages ð p.17)
— Connect PC (ð p.51).
-
Check
Make a final check of the wiring carried out against the wiring
diagrams that have been used
24 SERVOSTAR®400 Installation Manual
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Kollmorgen 07/05 Installation
3.3 Mounting
Material: 2 mounting rails to EN60715, min. length = system width + 40mm,
make sure there is a conductive connection to the mounting plate
Mount the protective cover (7mm) on the left side of the system.
Tools required: Screwdriver with approx. 5 mm blade width
SERVOSTAR 400
SERVOSTAR®400 Installation Manual 25
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Installation 07/05 Kollmorgen
3.3.1 Dimensions
SERVOSTAR 400M
SERVOSTAR 400A
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Kollmorgen 07/05 Installation
3.4 Wiring
Only professional staff who are qualified in electrical engineering are allowed to
install the servo amplifier.
The installation procedure is described as an example. A different procedure may be
appropriate or necessary, depending on the application of the equipment.
We provide further know-how through training courses (on request).
Caution !
Only install and wire up the equipment when it is not live, i.e. when neither the
mains power supply nor the 24 V auxiliary voltage nor the operating voltages of
any other connected equipment is switched on.
Take care that the cabinet is safely disconnected (lock-out, warning signs etc.).
The individual voltages will be switched on for the first time during commissioning.
Note !
The ground symbol
that you must take care to provide an electrically conductive connection with the
largest possible area between the unit indicated and the mounting plate in the
control cabinet. This connection is for the effective grounding of HF interference,
and must not be confused with the PE symbol W (protective earth to EN 60204).
Use the following wiring and connection diagrams :
— Power and control connections : Page 28
— Multiaxis systems : Page 30
— Resolver : Page 39
— High-resolution encoder : Page 40
— Encoder simulation ROD : Page 45
— Encoder simulation SSI : Page 46
— Master/slave interface : Page 47
— Pulse/direction interface : Page 49
— RS232 / PC : Page 51
— CAN interface : Page 52
— PROFIBUS interface : Page 53
— SERCOS interface : Page 54
X, which you will find in all the wiring diagrams, indicates
SERVOSTAR®400 Installation Manual 27
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3.4.1 Wiring diagram master
Follow the safety instructions (ð p.7)
and the use as directed (ð p.8) !
SERVOSTAR 400M
ð p.40
ð p.41
ð p.42
ð p.39
ð p.43
ð p.38
ð p.47
ð p.51
ð p.44
ð p.38
ð p.39
ð p.52
ð p.37
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3.4.2 Wiring diagram axis module
Follow the safety instructions (ð p.7)
and the use as directed (ð p.8) !
SERVOSTAR 400A
ð p.40
ð p.41
ð p.42
ð p.39
ð p.43
ð p.38
ð p.47
ð p.52
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3.4.3 Example of connections for multi-axis system
Follow the safety instructions (ð p.7)
and the use as directed (ð p.8) !
M
SERVOSTAR 400M
SERVOSTAR 400A
M
M
SERVOSTAR 400A
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3.4.4 Connector assignments
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Installation 07/05 Kollmorgen
3.4.5 Connection techniques
3.4.5.1 Shield connection on the front panel
The pre-assembled cables for
SERVOSTAR 400 are provided
with an overall metal ferrule at the
amplifier end that is electrically
connected to the shielding.
Thread a cable tie through each slot
in the shielding strip (front panel) of
the servo amplifier.
SERVOSTAR 400
SERVOSTAR 400
Tighten up the cable ties so that the
shielding ferrule and the sheathing
of the cable is pressed down tightly
against the shielding strip.
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3.4.5.2 Requirements to cables
Further information on the chemical, mechanical and electrical characteristics of the
cables can be obtained from our customer support.
Insulation material
Sheathing PUR (polyurethane, code 11Y)
Core insulation PETP (polyesteraphthalate, code 12Y)
Capacitance
Motor cable less than 150 pF/m
RES/encoder cable less than 120 pF/m
Technical data
— The brackets in the cable designation indicate the shielding.
— All cables are suitable for use as trailing cables.
— The technical data refer to the use as moveable cables.
operating life : 1 million bending cycles
— The permissible operating temperature range is from -30°C to +80°C.
— All cables are colour-coded according to IEC 757.
Cores
[mm²]
(4x1.0) 10 100 Motor cable, 25m max.
(4x1.0+(2x0.75)) 10.5 100
(4x2x0.25) 6.9 60
(10x2x0.14) 8.8 80
External diameter
[mm]
Bending radius
[mm]
Remarks
Motor cable with extra cores
for controls, 25m max.
twisted pairs(7x2x0.25) 9.9 80
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3.5 Setup software
3.5.1
General
This chapter describes the installation of the setup software DRIVE.EXE for the
SERVOSTAR 400 digital servo amplifiers.
We offer training and familiarization courses on request.
3.5.1.1 Use as directed
The operator software is intended to be used for altering and storing the operating para
meters for the SERVOSTAR 400 series of servo amplifiers. The attached servo amplifier
is commissioned with the assistance of the software - during this process the drive can be
controlled directly by the service functions.
Only professional personnel who have the relevant expertise described on page 5
are permitted to carry out online parameter setting for a drive which is running.
Sets of data which are stored on data media are not safe against unintended
alteration by other persons. After loading a set of data you must therefore check all
parameters thoroughly before enabling the servo amplifier.
3.5.1.2 Software description
The servo amplifiers must be adapted to the requirements of your installation. Usually you
will not have to carry out this parameter setting yourself on the amplifier, but on a PC,
with the assistance of the operator software. The PC is connected to the servo amplifier
by a null-modem (serial) cable. The setup software provides the communication between
the PC and SERVOSTAR 400.
-
You will find the setup software on the accompanying CD-ROM and in the download section of the Danaher Motion web appearance
With very little effort you can alter parameters and immediately observe the effect on the
drive, since there is a continuous (online) connection to the amplifier. At the same time,
important actual values are read out from the amplifier and displayed on the PC monitor
(oscilloscope function).
Any interface modules which may be built into the amplifier are automatically recognized,
and the additional parameters which are required for position control or motion-block defi
nition are made available.
Sets of data can be stored on data media (archived) and loaded again. You can also print
out the data sets.
We provide you with motor-specific default sets of data for all the reasonable combina
tions of servo amplifier and motor. In most applications you will be able to use these
default values to get your drive running without any problems.
.
-
-
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3.5.1.3 Hardware requirements
The PC interface (X6, RS232) of the master is connected to a serial interface on the PC
by a null-modem cable (not a null-modem link cable !)(ð p.51).
Connect / disconnect the interface cable only when the supply is switched off for
both the PC and the servo amplifier.
The interface in the servo amplifier is electrically isolated by an optocoupler, and is at the
same potential as the CANopen interface.
Minimum requirements for the PC:
Processor : Pentium I or higher
Operating system : WINDOWS 98 / 2000 / ME / NT4.0 / XP
Graphica adapter : Windows compatible, color
Drives : Hard disk (10 MB free space)
CD-ROM drive
Main memory : at least 8MB
Interface : one free serial interface (COM1:, 2:, 3: or 4:)
3.5.1.4 Operating systems
WINDOWS 98 / 2000 / ME / NT / XP
DRIVE.EXE can work under WINDOWS 98 / 2000 / ME / XP or WINDOWS NT 4.0.
Emergency operation is possible with an ASCII terminal-emulation.
Interface setting: 9600 bps, databit 8, stopbit 1,no parity, no handshake
Unix, Linux
DRIVE.EXE does not work under Unix and Linux.
3.5.2 Installation under WINDOWS 98 / 2000 / ME / NT / XP
The CD-ROM includes an installation program called SETUP.EXE that makes it easier to install the setup software on your PC.
Connection to the serial interface of the PC
Connect the interface cable to a serial interface on your PC and the PC interfaces (X8) of
the SERVOSTAR 400 (ð p.51).
Installation
Insert the CD-ROM into a free drive.
Autostart activated:
The start screen of the CD-ROM pops up. Click on the link to the Setup Software and
follow the instructions.
Autostart deactivated:
Click on START (task bar), then on Run. Enter the program call x:\start.exe (where x= is
the drive letter for the CD drive). Click on OK and follow the instructions.
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4 Interfaces
This chapter presents all the important interfaces, divided between master and axis
module. The precise location of the connectors and terminals can be seen on page 31.
4.1 Block diagram
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4.2 Power supply, master only
4.2.1
Mains supply connection (X0)
4.2.1.1 Three-phase supplies
Directly to earthed supply, filter is integrated, fusing (e.g. fusible cut-outs) to be provided
by the user (ð p.16).
SERVOSTAR 400
4.2.1.2 Single-phase supplies
Directly to supply, filter is integrated, fusing (e.g. fusible cut-outs) to be provided by the
user (ð p.16).
SERVOSTAR 400
for SERVOSTAR40xM
for SERVOSTAR44xM
for SERVOSTAR40xM
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4.2.2 24V auxiliary voltage (X0)
— Electrically isolated supply from an external 24V DC PSU, e.g. with isolating
transformer
— Required current rating (ð p.15)
— Integrated EMC filter for the 24V auxiliary supply
SERVOSTAR 400
4.3 DC Bus link/DC-bus (X0)
Can be connected in parallel with further, identical masters (via terminals -DC and RB
4.4 Motor connection with brake (X6)
Max. admisible length of the motor cable is 25 m.
SERVOSTAR 400
ext
).
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4.5 External regen resistor (X0), master only
Remove the plug-on link between terminals X0/5 (-RB) and X0/4 (+R
4.6 Feedback
4.6.1
Resolver connection (X5)
Our rotary servomotors have 2-pole hollow-shaft resolvers built in as a standard.
It is possible to connect 2- to 32-pole resolvers to SERVOSTAR 400. If lead lengths of
more than 25m are planned, please consult our customer support.
The thermostat contact in the motor is connected via the resolver cable to the
SERVOSTAR 400 and evaluated there.
SERVOSTAR 400
bint
).
SERVOSTAR 400
SubD9
12-pin round
SERVOSTAR®400 Installation Manual 39
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4.6.2 Encoder connection (X2)
As an option, the motors can be fitted with a single-turn or multiturn sine-cosine encoder.
Preferred types are the ECN1313 and EQN1325 encoders. The encoder is used by the
SERVOSTAR 400 as a feedback device for drive tasks that require highly precise positio
ning or extremely smooth running. If lead lengths of more than 25m are planned, please
consult our customer support.
The thermostat contact in the motor is connected via the encoder cable to the
SERVOSTAR 400 and evaluated there.
— Output voltage Up 5 V / max. 250 mA
— Output voltage Us 11V / max. 250 mA
-
SERVOSTAR 400
SubD15
17-pin round
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4.7 Control signals
4.7.1
Analog setpoint input (X3)
The servo amplifier has a programmable input for analog setpoints.
AGND (X3/1) must always be joined to the CNC-GND of the controls to provide a ground
reference.
Technical data
— Input voltage max. ± 10 V
— Resolution 1.25 mV
— Ground reference AGND, terminal X3/1
— Input resistance 20 kW
— Common mode voltage range for both inputs ± 10 V supplementary
SERVOSTAR 400
Analog input (terminals X3/2-3)
Input voltage max. ± 10 V, 14-bit resolution, scalable
Standard setting: Speed Setpoint
Fixing the direction of rotation
Standard setting: clockwise rotation of the motor shaft (looking at shaft end)
with positive voltage on terminal X3/3 (+ ) against X3/2(-)
To reverse the direction of rotation you can swap the connections to terminals X3/2-3 or
change the DIRECTION parameter in the SPEED screen.
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4.7.2 Digital control inputs (X3)
All digital inputs are electrically isolated through optocouplers.
Technical data
— Reference ground is digital-GND (DGND, terminal X1/4,5 on the master)
— The logic is dimensioned for +24V / 7mA (PLC-compatible)
— H-level from +12...36V / 7mA, L-level from 0...7V/0mA
SERVOSTAR 400
You can use the digital inputs PSTOP / NSTOP / DIGITAL-IN1 and DIGITAL-IN2 to
initiate pre-programmed functions that are stored in the servo amplifier.
You will find a list of the pre-programmed functions in the Online Help.
If an input has to be re-assigned to a pre-programmed function, then the data set must be
stored in the EEPROM of the servo amplifier, and the 24V auxiliary supply for the servo
amplifier must be switched off and then on again (to reset the amplifier software).
Limit-switches PSTOP / NSTOP
Terminals X3/6 and X3/7 are used to connect limit switches. They are deactivated upon
delivery. If these inputs are not needed for the connection of limit switches, then they can
be used for other input functions.
Limit-switch positive/negative (PSTOP / NSTOP, terminals X3/6 and X3/7), high level in
normal operation (fail-safe for cable break). A low signal (open) inhibits the corresponding
direction of rotation.
DIGITAL-IN 1 / DIGITAL-IN 2
You can link the digital inputs at terminals X3/4 (DIGITAL-IN 1) and X3/5 (DIGITAL-IN2)
with a pre-programmed function.
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4.7.3 Digital control outputs (X3)
Technical characteristics
— Ground reference is Digital-GND (DGND, terminal X1/4,5 on the master)
— Alle digital outputs are floating
— DIGITAL-OUT1 and 2 : Open-collector, max. 30V DC, 10mA
SERVOSTAR 400
Programmable digital outputs DIGITAL-OUT1/2:
You can use the digital outputs DIGITAL-OUT1 (terminal X3/8) and DIGITAL-OUT2
(terminal X3/9) to output messages from pre-programmed functions that are stored in the
servo amplifier.
A list of the pre-programmed functions can be found in the Online Help.
If an input is freshly assigned to a pre-programmed function, then the data set must be
stored in the EEPROM of the servo amplifier, and the 24V auxiliary supply of the servo
amplifier must be switched off and on again (to reset the amplifier software).
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4.7.4 Digital control signals on the Master (X1)
Technical characteristics
— Ground reference is Digital-GND (DGND, terminal X1/4,5)
— The logic is dimensioned for +24V / 7mA (PLC-compatible)
— H-level from +12...36V / 7mA, L-level from 0...7V/0mA
BTB/RTO: Relay output, max. 30V DC or 42V AC, 0.5A
SERVOSTAR 400
ENABLE input
The output stage of the servo amplifier is activated by the enable signal
(terminal X1/3, input 24V, active-high).
In the inhibited state (low signal) the motor which is attached does not have any torque.
Ready-to-operate contact BTB/RTO
Operational readiness (terminals X1/1 and X1/2 ) is signalled via a floating relay contact.
The contact is closed when all servo amplifiers in the system are ready for operation.
This signal is not influenced by the enable signal, the I²t- limit, or the regen threshold.
All faults cause the BTB/RTO contact to open and the output stage to switch off
A list of the error messages can be found on page 60.
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4.8 Encoder simulations
4.8.1
Incremental encoder output (X4)
The incremental-encoder interface is part of the package supplied. Select the encoder
function ROD (screen page “Encoder”, funktion ENCMODE). In the servo amplifier, the
position of the motor shaft is calculated from the cyclic-absolute signals of the resolver or
encoder.
Incremental-encoder compatible pulses are generated from this information. Pulses are
output as two signals, A and B, with 90° phase difference and a zero pulse. The resolu
tion (lines before quadrature) can be changed with the RESOLUTION parameter:
Encoder function Feedback system Resolution Zero position
Resolver 16...1024
ROD (1)
EnDat / HIPERFACE
ROD interpolation (3)
You can also adjust and store the position of the zero pulse within one mechanical turn
(parameter NI-OFFSET).
The ground reference for the interface is PGND. PGND must always be connected to
the control ground. The max. admissible cable length is 10 m.
Connections and signal description for the incremental-encoder interface :
Incremental encoders w/o
absolute data channel
16...4096 and
8192...524288 (2n)
4...128 TTL lines
per sine line
one per revolution
(only if A=B=1)
one per revolution
(only if A=B=1)
analog pass
through X1 to X5
-
SERVOSTAR 400
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4.8.2 SSI output (X4)
The SSI interface (synchronous serial absolute-encoder emulation) is part of the package
supplied. Select encoder function ROD (“Encoder” screen page).
The servo amplifier calculates the motor shaft position from the cyclic-absolute signals of
the resolver or encoder. From this information a SSI date (after Stegmann patent specifi
cation DE 3445617C2) is provided.
28 bits are transferred. The 12 leading data bits contains the number of revolutions. The
following max. 16 bits contain the resolution and are not variable.
The following table shows the allocation of the SSI date:
Revolution Resolution
111098765432101514131211109876543210
The signal sequence can be output in Gray code or in Binary (standard) code (parameter
SSI-CODE). The servo amplifier can be adjusted to the clock frequency of your SSI-eva
luation through the SSI-TIMEOUT parameter (1.3 µs or 10 µs).
The ground reference for the interface is PGND. PGND must always be connected to
the control ground.
-
-
Connection and signals for the SSI interface :
The count direction for the SSI interface is UP when the motor shaft is rotating clockwise
(looking at the end of the motor shaft).
SERVOSTAR 400
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4.8.3 Input encoder control for master-slave operation
This interface can be used to link several SERVOSTAR 400 amplifiers in master-slave
operation.
The parameters for the slave amplifier are set up with the aid of the setup software (elec
trical gearing). The resolution (no. of pulses/turn) can be adjusted. The analog setpoint
input is inactive.
AGND (terminal X3/1) must be connected to the ground of the control system!
Observe the limit frequency!
-
Please contact our customer support for information on connecting external SSI enco
ders.
Signal diagram (for encoders with RS422 or 24V outputs)
4.8.3.1 Connection to SERVOSTAR 400 master, 5V level (X4)
This interface can be used to link several SERVOSTAR 400 amplifiers in master-slave
operation. Up to 16 slave amplifiers can be controller by the master via the encoder output. The SubD connector X4 is used for this purpose.
-
Limit frequency: 1 MHz, transition speed tv £ 0.1µsec
AGND (terminal X3/1) must be connected to the ground of the control system!
SERVOSTAR 400
SERVOSTAR 400
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4.8.3.2 Connection to encoder with 24V signal level (X3)
You can use this interface to set up the SERVOSTAR 400 as a slave following an enco
der with a 24V signal level (master-slave operation). This application uses the digital
inputs DIGITAL-IN 1 and 2 on connector X3.
Limit frequency: 100 kHz, transition speed tv £ 0.1µsec
AGND (terminal X3/1) must be connected to the ground of the control system!
SERVOSTAR 400
4.8.3.3 Connection for Sin/Cos encoder (X2)
You can use this interface to set up the SERVOSTAR 400 as a slave following a sine/
cosine encoder (master-slave operation). This application uses the SubD connector X2.
Limit frequency: 250 kHz
-
AGND (terminal X3/1) must be connected to the ground of the control system!
SERVOSTAR 400
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4.9 Interface for stepper motor controls (pulse/direction)
This interface can be used to connect the servo amplifier to a third-party stepper-motor
controller. The parameters for the servo amplifier are set up with the aid of the setup soft
ware (electrical gearing). The number of steps can be adjusted, so that the servo ampli
fier can be adjusted to the pulse/direction signals of any stepper-motor controller. Various
monitoring signals can be output. The analog input is inactive.
AGND (terminal X3/1) must be connected to the ground of the control system!
Observe the limit frequency!
Speed profile and signal diagram
-
-
Note:
Connecting an A quad B encoder offers more EMI supression.
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4.9.1 Connection of stepper motor controls with 5V signal level (X4)
You can use this interface to connect the servo amplifier to a stepper motor control with a
5V signal level. The SubD connector X4 is used for this purpose.
Limit frequency: 1 MHz
AGND (terminal X3/1) must be connected to the ground of the control system!
SERVOSTAR 400
4.9.2 Connection of stepper motor controls with 24V signal level (X3)
You can use this interface to connect the servo amplifier to a stepper motor control with a
24V signal level. The digital inputs DIGITAL-IN 1 and 2 on connector X3 are used for this
purpose.
Limit frequency: 100 kHz
AGND (terminal X3/1) must be connected to the ground of the control system!
SERVOSTAR 400
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4.10 RS232 interface, PC connection (X8), master only
The setting of the operating, position control, and motion-block parameters, can be car
ried out by using the setup software on an ordinary commercial PC.
Connect the PC interface (X8) of the servo amplifier while the supply to the equipment
is switched off via a null-modem cable to a serial interface on the PC (do not use a
null-modem link cable!).
The interface has the same potential as the internal logic, and uses AGND as the ground
reference.
The interface is selected and set up in the setup software.
Further notes can be found on page 34 .
SERVOSTAR 400
-
Interface cable between the PC and servo amplifiers of the
(View: front view of the built-in SubD connectors, this corresponds to looking at the solder
side of the SubD connector on the cable.)
SERVOSTAR 400 series:
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4.11 Fieldbus connection
4.11.1
CANopen interface (X7)
The interface for connection to the CAN bus (default: 500 kbps). The master is fitted with
a CAN input. All axis modules in the system are connected to this through the internal
bus. The last axis module has a CAN output, where the CAN bus either continues to
other bus participants or is terminated by a termination resistor.
The integrated profile is based on the communication profile CANopen DS301 and the
drive profile DSP402. The following functions are available in connection with the integra
ted position controller: Jogging with variable speed, homing, start motion task, start direct
task, digital setpoint provision, data transmission functions and many others.
Detailed information can be found in the CANopen manual.
The interface is at the same potential as the internal logic, and uses AGND as the ground
reference.
AGND must be connected to the control system ground for potential equalization!
SERVOSTAR 400
-
CAN bus cable
To meet ISO 11898 you should use a bus cable with a 120 W characteristic impedance.
The maximum usable cable length for reliable communication decreases with increasing
transmission speed. As a guide, you can use the following values which we have measu
red, but they must not be assumed to be limits:
Cable data: Characteristic impedance 100-120 W
Cable capacitance max. 60 nF/km
Conductor loop resistance 159.8 W/km
Cable length, depending on the transmission rate
Transmission rate /
kbps
1000 20
500 70
250 115
Lower cable capacitance (max. 30 nF/km) and lower lead resistance (loop: 115 W/km)
make it possible to transmit over longer distances.
(Characteristic impedance 150 ± 5WÞterminating resistance 150 ± 5W).
For EMC reasons, the SubD connector housing must fulfill the following conditions:
— metal or metallized housing
— provision for connecting the cable shielding within the housing,
large-area connections
max. cable length / m
-
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4.11.2 PROFIBUS interface (X7), option
This section describes the PROFIBUS interface for SERVOSTAR 400.
Information on the range of functions and the software protocol can be found in the
manual “Communication profile PROFIBUS-DP”.
The selection of cables, cable routing, shielding, bus connectors, bus termination and
propagation times are described in the “Setup guidelines for PROFIBUS-DP/FMS” from
PNO, the PROFIBUS User Organization, Order No. 2.111.
SERVOSTAR 400
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4.11.3 SERCOS interface (X7), option
This section describes the SERCOS interface of the SERVOSTAR 400. Information on
the range of functions and the software protocol can be found in the manual “IDN Refer
ence Guide SERCOS”. For the optical fibre (LWL) connection, only use SERCOS compo
nents to the SERCOS Standard IEC 61491.
-
4.11.3.1 Light emitting diodes (LEDs)
RT: indicates whether SERCOS telegrams are being correctly received. In the final
Communication Phase 4 this LED should flicker, since cyclical telegrams are being
received.
TT: indicates that SERCOS telegrams are being transmitted. In the final Communi-c
ation Phase 4 this LED should flicker, since cyclical telegrams are being transmitted. Check the stations addresses for the controls and the servo amplifier if:
- the LED never lights up in SERCOS Phase 1 or
- the axis cannot be operated, although the RT LED is lighting up cyclically.
Err: indicates that SERCOS communication is faulty or suffering from interference.
If this LED is very bright, then communication is suffering strong interference, or is
non-existent. Check the SERCOS transmission speed for the controls and the
servo amplifier (BAUDRATE) and the fibre-optic connection. If this LED flickers,
this indicates a low level of interference for Sercos communication, or the optical
transmitting power is not correctly adjusted to suit the length of cable.
Check the transmitting power of the (physically) previous SERCOS station.
The transmitting power of the servo amplifier can be adjusted in the setup software
DRIVE.EXE on the SERCOS screen page, by altering the LWL length parameter
for the cable length.
-
4.11.3.2 Connection diagram
Layout of the SERCOS bus system in ring topology, with optical fibre cables (schematic).
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5 Setup
5.1 Important notes
Only professional personnel with extensive knowledge in the fields of electrical
engineering and drive technology are allowed to setup the servo amplifier.
The procedure for commissioning is described as an example. Depending on the applica
tion, a different procedure may be appropriate or necessary.
In multi-axis systems, commission each servo amplifier individually.
Before commissioning, the manufacturer of the machine must produce a hazard
analysis for the machine and take appropriate measures to ensure that unforeseen
movements do not result in personal injury or material damage.
Caution !
Check that all live connecting elements are protected from accidental contact.
Deadly voltages can be present, up to 800V.
Never disconnect any of the electrical connections to the servo amplifier while it is
live.
Capacitors can still have residual charges with dangerous levels up to 300 seconds
after switching off the supply power.
Heat sinks and front panels of the amplifier can reach a temperature of up to 80°C
in operation. Check (measure) the heat sink temperature. Wait until the heat sink
has cooled down below 40°C before touching it.
Warning !
If the servo amplifier has been stored for longer than 1 year, then the DC Bus link
capacitors will have to be re-formed.
To do this, disconnect all the electrical connections.
Supply the servo amplifier for about 30 min. from single-phase 230V AC to the
terminals L1 / L2. This will re-form the capacitors.
-
Further information on commissioning:
The adaptation of parameters and their effects on the control loop behaviour are
described in the online help of the setup software.
The commissioning of the fieldbus interface is described in the corresponding
manual.
We can provide further know-how through training courses (on request).
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5.2 Guide to setup
The following instructions should help you to carry out the commissioning in a sensible
order, without any hazards to people or machinery:
Check installation
See Chapter 3. Disconnect the servo amplifier from
the supply.
Negate enable signal 0V on terminal X1/3 (Enable)
Switch on 24V
aux. supply
Switch on PC, start
setup SW
Check the displayed
parameters, correct
them if necessary
24V DC on terminal 0/1, ground on terminal X0/2
After the initialization procedure (about 0.5 sec.) the sta
tus is shown in the LED display (ð p.58
Select the interface to which the servo amplifier is con
nected. The parameters which are stored in the SRAM of
the servo amplifier are transferred to the PC.
Check the parameters described below especially
carefully. If you ignore these basic data, system com
ponents may be damaged or destroyed.
Supply voltage: set to the actual mains supply voltage (vlimits ð p.15)
Rated motor voltage: at least as high as the nominal voltage of the amplifier
Motor pole-no.: must match the feedback unit in the motor
I
: maximum is the motor standstill current I0(nameplate)
RMS
I
: maximum is 4 x motor standstill current I
PEAK
0
Limit speed: maximum is the rated motor speed (nameplate)
Regen power: maximum is the rated dissipation for the regen resistor
Station address: unique address on the master
-
-
-
Check safety devices
Make sure that any unintended movement of the drive
cannot cause danger to machinery or personnel.
Switch on power through the ON/OFF button of the contactor control
Apply 0V setpoint apply 0V to terminals X3/2-3
(500 msec after switching on the supply power) 24V DC
Enable amplifier
on terminal X1/3 (Enable), motor is at rest with standstill
torque M
0
apply a small analog setpoint (about 0.5V is recommen
ded) to terminals X3/2-3.
Setpoint
If the motor oscillates, the Kp parameter in the screen
page Speed controller must be reduced – the motor is
in danger !
Optimization optimize the speed, current and position controllers
Commission fieldbus
see commissioning instructions in the corresponding
manual on the CD-ROM
-
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5.3 Parameterization
A default parameter set is loaded into your servo amplifier at the factory. This contains
valid and safe parameters for the current and speed controllers.
A database for motor parameters is stored in the servo amplifier. During commissioning
you must select the data set for the motor that is connected and store it in the servo
amplifier. For most applications these settings will already provide good to very good con
trol loop characteristics.
An exact description of all parameters and the options for optimizing the control loop cha
racteristics can be found in the online help of the setup software.
5.3.1 Multi-axis systems
All the axes in a system can be parameterized through the RS232 interface in the master.
To do this, there is an internal connection between the master and the axis modules. The
PC cable only has to be connected to the master.
The internal address assignment is carried out automatically, so that it is only necessary
to set up the basic station address for the master.
-
-
PC
Axismodule 1
Axismodule 2
Axismodule 3
Master
COMx
X8/PC
After changing the station address it is necessary to turn off the 24V auxiliary
supply, and then turn it on again.
Starting at the master, descending addresses are assigned automatically to the axis
modules. The following table shows an example with one master and three axis modules:
Axis Address Remark
Master 10 Master address, set by user
Axis module 3 9
assigned automaticallyAxis module 2 8
Axis module 1 7
RS232
The highest permitted master address is 128. When choosing the master address,
please consider that at least address 1 will be assigned to the last (leftmost) axis
module.
In CAN and PROFIBUS field bus systems the automatically assigned addresses
must not match the address of other nodes.
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5.3.2 Key pad controls and status displays
Two keys are fitted in the operating panel of the master. Here you can enter the basic
address for the system and call up status information on all the axes that are connected.
5.3.2.1 Operating
The two keys can be used to perform the following functions:
Key symbol Functions
press once : go up one menu item, increase number by one
U
U
U
U
press twice in rapid succession : increase number by ten
press once : go down one menu item, decrease number by one
press twice in rapid succession : decrease number by ten
press and hold right key, then press left key as well :
enters a number, return function
5.3.2.2 Status display on the axis module
Each axis module is fitted with 2 LEDs that provide a quick indication of the instrument
status.
LED
red green Interpretation
lit off axis is not ready for operation (fault)
blinking off a warning has been generated
off lit axis is ready for operation, and enabled
off blinking axis is ready for operation, but not enabled
blinking blinking axis is selected for editing by the master
A detailed display of the warnings and faults can be called up in the display on the master
( ð p.59).
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5.3.2.3 Status display on the master
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5.4 Error messages
Any errors that occur are shown in coded form by an error number in the LED display on
the front panel. All error messages result in the BTB/RTO contact being opened, and the
output stage of the amplifier being switched off (motor loses all torque). The motor-hol
ding brake is activated.
Designation Explanation
F00 no error no error in the selected axis module
F01* heat sink temperature
F02* overvoltage
F03* contouring error message from the position controller
F04 feedback cable break, short circuit, short to ground
F05* undervoltage
F06 motor temperature
F07 aux. voltage internal aux. voltage not OK
F08* overspeed motor runs away, speed is too high
F09 EEPROM checksum error
F10 Flash-EPROM checksum error
F11 brake cable break, short circuit, short to ground
F12 motor phase motor phase missing (cable break or similar)
F13* internal temperature internal temperature too high
F14 output stage fault in the output stage
F15 I²t max. I²t max value exceeded
F16* supply BTB/RTO 2 or 3 phases missing in the supply feed
F17 A/D converter error in the analog-digital conversion
F18 regen regen circuit faulty or incorrect setting
F19* supply phase a phase is missing in the supply power feed
F20 slot error slot error
F21 handling error software error on the expansion card
F22 earth/ground fault not valid for this device
F23 CAN bus off severe CAN bus communication error
F24 warning warning display is evaluated as fault
F25 commutation error commutation error
F26 limit-switch homing error (drove onto hardware limit-switch)
F27 AS-option not valid for this device
F28 reserve reserve
F29 SERCOS error only in SERCOS systems
F30 timeout timeout, leads to emergency stop
F31 reserve reserve
F32 system error system software nor responding correctly
* = these error messages can be cleared without a reset, by using the ASCII command
CLRFAULT. If only one of these errors is present and the RESET button or the I/O
RESET function is used, only the CLRFAULT command will be executed.
heat sink temperature too high
limit is set by manufacturer to 80°C
overvoltage in DC Bus link
limit depends on the mains supply voltage
undervoltage in DC Bus link
limit is set by manufacturer to 100V
motor temperature too high (or temp. sensor defect)
limit is set by manufacturer to145°C
-
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5.5 Warning messages
Faults which occur, but which do not cause a switch-off of the amplifier output stage
(BTB/RTO contact remains closed), are indicated in the LED display on the front panel by
a coded warning number.
Number Designation Explanation
n01 I²t I²t threshold exceeded
n02 regen power reached preset regen power limit
n03* S_fault exceeded preset contouring error limit
n04* response monitoring
n05 supply phase supply phase missing
n06* Sw limit-switch 1 passed software limit-switch 1
n07* Sw limit-switch 2 passed software limit-switch 2
n08 motion task error a faulty motion task was started
n09 no reference point no reference point set at start of motion task
n10* PSTOP PSTOP limit-switch activated
n11* NSTOP NSTOP limit-switch activated
n12 default values
n13* expansion card expansion card not operating correctly
n14 SinCos feedback SinCos commutation failure
n15 table fault fault as per speed/current table INXMODE 35
n16-n31 reserve reserve
n32 firmware beta version firmware version has not been released
* = these warning messages result in a controller shut-down of the drive (braking by
emergency stop ramp)
response monitoring (fieldbus) has been
activated
only for HIPERFACE
motor default values loaded
®
:
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This page has been deliberately left blank.
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6 Accessories
6.1 External PSU 24V DC / 5A
Technical data
Input voltage 120 / 230V
Input current 0.9 / 0.6A
Frequency 50/60Hz
Primary fusing 3.15AT
Output voltage 24V ± 1%
Max. output current 5A
Residual ripple <150mVss
Switching peaks <240mVss
Output fusing short-circuit proof
Temperature range 0 to +60°C
DIN-rail, vertical mounting
Mounting method
Weight 0.75kg
50mm free space required above and below the in
strument
-
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6.2 External PSU 24V DC / 20A
Mounting plate
Mounting plate
Technical data
Input voltage 3 x 400V AC ± 10%
Input current approx. 1.1A
Frequency 50/60Hz
Primary fusing none
Output voltage 24V ± 1%
Max. output current 20A
Residual ripple <0.1%
Output fusing short-circuit proof
Test voltage to VDE 0550
Temperature range -20 to +60°C
Mounting method
Weight 3.5kg
on mounting plate (supplied)
Keep space free
Keep space free!
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6.3 External regen resistor BAR(U)xyz
Caution:
Surface temperature may exceed 200°C.
Observe the requested free space.
Do not mount to combustible surface.
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6.4 Add-on fan
Electrical add-on fan for two axes to achieve rated power even under unfavourable
ambient conditions, required for SERVOSTAR4x6.
To mount the fan, just hook it in the designated slots at the bottom of the SERVOSTAR
and screw the fixing bolt into the thread in the housing. The electrical connection takes
place automatically when mounting the fan.
Please consider that a mounted fan increases the required space underneath the
amplifier! (Þ p. 25)
The drawing below shows, how the fan should be mounted. With an odd number of axes
(master included), the fan must also cover the power supply unit at the master.
Single master
Master with 1 Axis module
Master with 2 Axis modules
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7 Appendix
7.1 Transport, storage, maintenace, disposal
Transport: — only by qualified personnel
— only in the manufacturer’s original recyclable packaging
— avoid shocks
— temperature -25 to +70°C, max. rate of change 20°C/hour
— humidity max. 95% relative humidity, no condensation
— the servo amplifiers contain electrostatically sensitive components
— which can be damaged by incorrect handling. Discharge yourself
— before touching the servo amplifier. Avoid contact with highly
— insulating materials (artificial fabrics, plastic films etc.).
— Place the servo amplifier on a conductive surface.
— if the packaging is damaged, check the unit for visible damage.
— In such a case, inform the shipper and the manufacturer.
Packaging: — recyclable cardboard with inserts
— dimensions SERVOSTAR 4xxA (HxWxD) 100x300x270 mm
SERVOSTAR 4xxM (HxWxD) 150x300x270 mm
— labelling instrument label on outside of box
Storage : — only in the manufacturer’s original recyclable packaging
— the servo amplifiers contain electrostatically sensitive components
— which can be damaged by incorrect handling. Discharge yourself
— before touching the servo amplifier. Avoid contact with highly
— insulating materials (artificial fabrics, plastic films etc.).
— Place the servo amplifier on a conductive surface.
— max. stacking height: 8 cartons
— storage temp. –25 to +55°C, max. rate of change 20°C/hr
— humidity relative humidity max. 95%, no condensation
— storage duration < 1 year without restriction
> 1 year: capacitors must be re-formed before
the servo amplifier is commissioned.
To do this, remove all electrical connections and
supply the servo amplifier for about 30 min. from
230V AC, single-phase, on terminals L2 / L3.
Maintenance: — the instruments do not require any maintenance
— opening the instruments invalidates the warranty
Cleaning : — if the casing is dirty : cleaning with Isopropanol or similar
do not immerse or spray
— if there is dirt inside the unit : to be cleaned by the manufacturer
— dirty protective grill (fan) : clean with a dry brush
Disposal : — you can dismantle the servo amplifier into its principal components
— by screwing it apart (aluminium heat sink, steel housing sections,
— electronics boards)
— disposal should be carried out by a certified disposal company.
— We can give you suitable addresses on request.
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7.2 Fault-finding
The table below should be regarded as a “First-aid” box. Depending on the conditions in your installation,
there may be a wide variety of reasons for the fault. In multi-axis systems there may be further hidden cau
ses of a fault. Our customer support can give you further assistance with problems.
Fault possible causes Measures to remove the fault
HMI message:
communication
fault
F01 message:
heat sink
temperature
F02 message:
overvoltage
F04 message:
feedback unit
F05 message:
undervoltage
F06 message:
motor temperature
F07 message:
aux. voltage
F08 message:
motor runs away
(overspeed)
F11 message:
brake
F13 message:
int. temperature
F14 message:
output stage
fault
F16 message:
mains BTB/RTO
F17 message:
A/D converter
wrong cable used
—
cable plugged into wrong position in
—
servo amplifier or PC
wrong PC interface selected
—
permissible heat sink temperature ex
—
ceeded
regen power is insufficient. regen power
—
limit was reached and the regen resistor
was switched off. This causes excessive
voltage in the DC Bus link circuit.
supply voltage too high
—
feedback connector not inserted
—
feedback cable is damaged
—
supply voltage not present or too low
—
when servo amplifier is enabled
— motor thermostat has been activated
— feedback connector is loose or break in
feedback cable
— the aux. voltage produced by the servo
amplifier is incorrect
— motor phases swapped
— feedback set up incorrectly
—
faulty connection to feedback unit
—
short-circuit in the supply cable for the
motor-holding brake
—
motor-holding brake is faulty
—
fault in brake cable
—
no brake connected, although the brake
parameter is set to "WITH"
—
permissible internal temperature excee
ded
—
motor cable: short-circuit/ground short
—
motor has short-circuit / ground short
—
output module is overheated
—
output stage is faulty
—
short-circuit / short to ground in the ex
ternal regen resistor
—
enable was applied, although the supply
voltage was not present.
—
at least 2 supply phases are missing
—
error in the analog-digital conversion,
usually caused by excessive EMI
-
-
use null-modem cable
—
plug cable into the correct sockets on
—
the servo amplifier and PC
select correct interface
—
improve ventilation
—
shorten the braking time RAMP or use
—
an external regen resistor with a higher
power rating and adjust the regen power
parameter
use mains transformer
—
check connector
—
check cable
—
only enable the servo amplifier when the
—
mains supply voltage has been switched
on delay > 500 ms
— wait until motor has cooled down, then
check why it became so hot
— tighten connector or new feedback cable
— return the servo amplifier to the manu-
facturer for repair
— correct motor phase sequence
— set up correct offset angle
—
check connector
—
remove short-circuit
—
replace motor
—
check shielding of brake cable
—
brake parameter set to "WITHOUT"
-
—
improve ventilation
—
replace cable
—
replace motor
—
improve ventilation
—
return the servo amplifier to the manu
facturer for repair
—
remove short-circuit / ground short
—
only enable the servo amplifier when the
mains supply voltage is switched on
—
check electrical supply
—
reduce EMI, check screening and
grounding
-
-
68 SERVOSTAR®400 Installation Manual
Page 69
Kollmorgen 07/05 Appendix
Fault possible causes Measures to remove the fault
F25 message:
Commutation er
ror
motor does not
rotate
motor oscillates
drive reports
following error
motor overhea
ting
drive too soft
drive runs
roughly
axis drifts at
setpoint = 0V
n12 message:
Motor default va
lues loaded
n14 message:
Wake & shake
active
wrong cable
—
wrong phasing
—
-
servo amplifier not enabled
—
break in setpoint cable
—
motor phases swapped
—
brake not released
—
drive is mechanically blocked
—
no. of motor poles set incorrectly
—
feedback set up incorrectly
—
gain too high (speed controller)
—
shielding in feedback cable has a break
—
AGND not wired up
—
or I
I
—
rms
setpoint ramp is too long
—
I
—
-
rms/Ipeak
is set to low
peak
set too high
— Kp (speed controller) too low
— Tn (speed controller) too high
— PID-T2 too high
— T-Tacho too high
— Kp (speed controller) too high
— Tn (speed controller) too low
— PID-T2 too low
—
T-Tacho too low
—
offset not correctly adjusted for analog
setpoint provision
—
AGND not joined to the CNC-GND of
the controls
—
Motor number stored in sine encoders
EEPROM different than what drive is
-
configured for
—
Wake & shake not executed
check wiring
—
check resolver poles (RESPOLES) +
—
motor poles (MPOLES) + offset (MPHA
SE)
apply enable signal
—
check setpoint cable
—
correct motor phase sequence
—
check brake control
—
check mechanism
—
set no. of motor poles
—
set up feedback correctly
—
reduce Kp (speed controller)
—
replace feedback cable
—
join AGND to CNC-GND
—
increase I
—
rms
or I
(keep within mo
peak
tor data !)
shorten setpoint ramp +/-
—
reduce I
—
rms/Ipeak
— increase Kp (speed controller)
— use motor default value for Tn (speed
controller)
— reduce PID-T2
— reduce T-Tacho
— reduce Kp (speed controller)
— use motor default value for Tn (speed
controller)
— increase PID-T2
—
increase T-Tacho
—
adjust setpoint-offset (analog I/O)
—
join AGND and CNC-GND
—
If n12 is displayed, default values for the
motor are loaded. Motor number will be
automatically stored in EEPROM with
SAVE.
—
Enable the drive
-
-
SERVOSTAR®400 Installation Manual 69
Page 70
Appendix 07/05 Kollmorgen
7.3 Glossary
C clock Clock signal
common-mode voltage The maximum amplitude of a disturbance (on both
inputs) which a differential input can eliminate
continuous power of regen circuit Mean power which can be dissipated in the
regen circuit
20
counts Internal count pulses, 1 pulse = 1/2
current controller Regulates the difference between the current
setpoint
and the actual value to 0
Output : power output voltage
D DC Bus link Rectified and smoothed power voltage
disable Removal of the enable signal (0V or open)
E earth short electrical connection between a phase and
the protective earth (PE)
enable Enable signal for the servo amplifier (+24V)
F fieldbus interface CANopen, PROFIBUS, SERCOS
free convection Free movement of air for cooling
G GRAY-code Special format for representing binary numbers
H holding brake Brake in the motor, which should only be used
when the motor is at standstill
I I²t threshold Monitoring of the r.m.s. current that is actually
required
incremental encoder interface Position signalling by 2 signals with 90° phase
difference, not an absolute position output
input drift Temperature and age-dependent alteration of an
analog input
Ipeak, peak current The effective value of the peak current
Irms, effective current The r.m.s. value of the continuous current
K Kp, P-gain Proportional gain of a control loop
L limit speed Maximum value for speed normalization at ±10V
limit-switch Switch limiting the traverse path of the machine;
implemented as n.c. (break) contact
M machine The complete assembly of all connected parts or
devices, of which at least one is movable
motion-block Set of all the position control parameters
which are required for a motion task
multi-axis system Machine with several driven axes
N natural convection Free movement of air for cooling
O optocoupler Optical connection between two electrically
independent systems
turn
-1
70 SERVOSTAR®400 Installation Manual
Page 71
Kollmorgen 07/05 Appendix
P P-controller Control loop with purely proportional behaviour
phase shift Compensation for the lag between the electro-
magnetic and magnetic fields in the motor
PID-controller Control loop with proportional, integral and
differential behaviour
PID-T2 Filter time constant for the speed controller output
position controller Regulates the difference between the position
setpoint and the actual position to 0
Output : speed setpoint
potential isolation electrically decoupled
power contactor System protection device with phase monitoring
pulse power of the regen circuit Maximum power which can be dissipated in the
regen circuit
R regen circuit Converts superfluous energy, which is fed back
during braking, into heat in the regen resistor
reset New start of the microprocessor
reversing mode Operation with a periodic change of direction
ring core Ferrite rings for interference suppression
ROD-interface Incremental position output
S servo amplifier Control device for regulating the speed, torque
and position of a servomotor
setpoint ramps Limits for the rate of change of the speed
setpoint
short-circuit here: electrically conductive connection between
two phases
speed controller Regulates the difference between the speed
setpoint and the actual value to 0
Output : current setpoint
SSI-interface Cyclic-absolute, serial position output
supply filter Device to divert interference on the power supply
cables to PE
T T-tacho, tachometer time constant Filter time constant in the speed feedback of
the control loop
tachometer voltage Voltage proportional to the actual speed
thermostat Temperature-sensitive switch built into the
motor winding
Tn, I-integration time Integral section of a control loop
Z zero pulse Output once per turn from incremental encoders,
used to zero the machine
SERVOSTAR®400 Installation Manual 71
Page 72
Appendix 07/05 Kollmorgen
7.4 Order numbers
Product Order numbers Europa
SERVOSTAR 403M-CANopen 102111
SERVOSTAR 406M-CANopen 102117
SERVOSTAR 443M-CANopen 102832
SERVOSTAR 446M-CANopen 102833
SERVOSTAR 403A-CANopen 102112
SERVOSTAR 406A-CANopen 102118
SERVOSTAR 403M-PROFIFIBUS 102113
SERVOSTAR 406M-PROFIFIBUS 102119
SERVOSTAR 443M-PROFIFIBUS 102834
SERVOSTAR 446M-PROFIFIBUS 102835
SERVOSTAR 403A-PROFIFIBUS 102114
SERVOSTAR 406A-PROFIFIBUS 102120
SERVOSTAR 403M-SERCOS 102115
SERVOSTAR 406M-SERCOS 102121
SERVOSTAR 443M-SERCOS 102976
SERVOSTAR 446M-SERCOS 102977
SERVOSTAR 403A-SERCOS 102116
SERVOSTAR 406A-SERCOS 102122
Mating connector X0 -SR4X0- (part of delivery) 102583
Mating connector X1 -SR4X1- (part of delivery) 102584
Mating connector X3 -SR4X3- (part of delivery) 102585
Mating connector X6 -SR4X6- (part of delivery) 107466
SubD 15 poles, male (X2) on request
SubD 9 poles, male (X5) 81783
SubD 9 poles, female (X4, X7, X8) 81784
Add-on fan -SR4BV- 102582
RS232 cable 90067
Motor cables
Resolver cables
Encoder cables
Fieldbus cables
Power supply unit 24V/ 5A 83034
Power supply unit 24V/20A 81279
Regen resistor BAR(U)250-33 106254
Regen resistor BAR(U)500-33 106255
Product CDROM 90079
see accessories catalogue,
(in preparation - available from Nov 05)
see accessories catalogue,
(in preparation - available from Nov 05)
see accessories catalogue,
(in preparation - available from Nov 05)
see accessories catalogue,
(in preparation - available from Nov 05)
72 SERVOSTAR®400 Installation Manual
Page 73
Kollmorgen 07/05 Appendix
This page has been deliberately left blank.
SERVOSTAR®400 Installation Manual 73
Page 74
Appendix 07/05 Kollmorgen
7.5 Index
! 24V aux. supply, interface ......38
A abbreviations .............6
accessories .............63
AGND ................19
ambient conditions..........17
ambient temperature.........17
B block diagram ............36
brake .................18
BTB/RTO ..............44
C CANopen interface .........52
CE conformity .............9
commissioning ............55
conductor cross-sections ......17
connection techniques ........32
connector assignments .......31
control signals ............41
D DC Bus link, interface ........38
DGND ................19
dimensions..............26
display, LED .............19
disposal ...............67
E earthing
installation ............24
wiring diagram ..........28
emergency stop methods ......21
enclosure rating ...........17
encoder
interface .............40
master-slave interface ......47
encoder simulations .........45
equipment description ........11
error messages ...........60
F fault-finding .............68
fieldbus interface...........52
forming ................55
fusing ................16
G glossary ...............70
ground symbol ............27
grounding system ..........19
guide
installation / wiring ........24
setup ...............56
H hardware requirements .......35
humidity ...............67
I inputs
ANALOG IN ...........41
DIGI-IN 1/2 ............42
enable
encoder..............40
encoder for master-slave.....47
NSTOP ..............42
power supply ...........37
PSTOP ..............42
resolver ..............39
installation
hardware .............27
software .............35
interfaces ..............36
K key operation ............58
L LED display .............58
limit-switch inputs ..........42
M maintenance .............67
master-slave .............47
motor, interface ...........38
mounting ...............25
mounting position ..........17
multi-axis systems
connection example .......30
Multi-axis systems
parameterization .........57
N nameplate ..............11
NSTOP, interface ..........42
O operating systems ..........35
options ................13
order numbers ............72
outputs
BTB/RTO .............44
DIGI-OUT 1/2...........43
encoder simulations .......45
..............44
74 SERVOSTAR®400 Installation Manual
Page 75
Kollmorgen 07/05 Appendix
P package supplied ..........11
packaging ..............67
parameterization ...........57
PC connection ............51
PC interface cable ..........51
PGND ................19
pollution level ............17
PROFIBUS interface.........53
PSTOP, interface ..........42
PSU 24V
20A................64
5A ................63
pulse/direction, interface.......49
R regen circuit .............19
regen resistor
dimensions ............65
external interface. ........39
techn. data ............19
resolver ...............39
ROD, interface ............45
RS232/PC, interface .........51
S safety instructions ...........7
SERCOS interface..........54
setpoint input ............41
setup software ............34
SETUP.EXE .............35
shield connection ..........32
shielding
installation ............24
wiring diagram ..........28
site altitude..............17
SSI, interface ............46
stacking height............67
standards ...............9
status display ............58
stop function .............20
storage ................67
storage duration ...........67
storage temperature .........67
supply connection, interface .....37
supply voltage ............17
switch on/off behaviour .......20
symbols ................5
system components, summary . . . 14
T technical data ............15
ambient conditions ........17
cables ..............33
conductor cross sections .....17
connections............16
fusing ...............16
rated data.............15
tightening torques ........16
tightening torques, connectors . . . 16
transport ...............67
transport temperature ........17
U use as directed
servo amplifier ...........8
setup software ..........34
V ventilation
installation ............24
techn. data ............17
W warning messages..........61
wiring.................24
wiring diagram
axis module............29
master ..............28
SERVOSTAR®400 Installation Manual 75
Page 76
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