Kollmorgen ServoStar 400 Installation Manual
www.DanaherMotion.com
Digital Servo Amplifier
®
SERVOSTAR
400
Assembly, Installation, Setup
Edition 07/05
File sr400_d.xxx
Order No.: 102530
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.
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
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
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
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
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
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
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
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
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
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
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
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
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
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
Kollmorgen 07/05 Technical description
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
Technical description 07/05 Kollmorgen
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
18 SERVOSTAR®400 Installation Manual
Kollmorgen 07/05 Technical description
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
Technical description 07/05 Kollmorgen
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”
20 SERVOSTAR®400 Installation Manual
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”
SERVOSTAR®400 Installation Manual 21
Technical description 07/05 Kollmorgen
This page has been deliberately left blank.
22 SERVOSTAR®400 Installation Manual
Kollmorgen 07/05 Installation
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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