Kollmorgen SERVOSTAR 601, SERVOSTAR 620 Assembly And Installation Manual
www.DanaherMotion.com
Digital servo amplifier
®
SERVOSTAR
601...620
Assembly, Installation, Setup
Edition 03/04
Filesr601_e.xxx
EU order No.: 90162
NA: M-SS-004-0216
Previous versions :
Edition Remarks
05/98 First edition
08/98 a few corrections
09/98
01/99 614 added, various minor corrections
02/99 Interface relay for digital outputs (pages 26, 43)
06/99 various corrections, cables and connectors removed, choke box added
08/99 24V tolerance, encoder wiring, ventilation
11/99 Packaging, regen resistor
12/99 Option -AS- integrated, ground-bolt, master-slave
04/00 various corrections, setup software on CDROM only, motors 6SM27LL and 6SM37VL added
06/00 Wiring diagrams electr. gearing, warning and error messages, recommended torque
08/00 Wiring diagram in chapter III.9.2 corrected
07/01
02/02 Dimensions BARxxx corrected
06/02
07/03 several corrections, DeviceNet expansion card added, directives and standards page revised, new cover design
09/03 Ethernet expansion card and Single axis controller expansion card added
03/04 new regen resistors BAR(U), several corrections
various minor corrections, parameter description removed, parameter setting for multi-axis systems and on/off switching
behavior added, Installation/setup divided into two chapters
S610-30 and options -I/O-14/08- and -2CAN - incorporated, hardware-description incorporated for PROFIBUS and SER
COS, nameplate, motor list and connector assignment corrected, LED-display corrected, error messages expanded
Frontpage new design, corrections to US English, motor table removed, order numbers added,
last page new design and contents, new; connection to diff. mains supply networks, block diagram to ch.III
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PC-AT is a registered trademark of International Business Machines Corp.
MS-DOS is a registered trademark of Microsoft 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.
Manufactured under one or more of the following US patents:
4,434,389 4,447,771 4,456,934 4,463,299 4,479,078
4,490,661 4,504,755 4,508,988 4,532,461 4,538,080
4,541,575 4,543,520 4,551,646 4,559,485 4,562,399
4,572,999 4,579,012 4,633,151 4,644,199 4,647,824
4,661,756 4,670,696 4,675,547 4,679,313 4,682,093
4,686,437 4,698,537 4,729,160 4,763,049 4,763,056
4,763,057 4,733,149 4,782,272 4,797,592 4,857,816
4,868,475 4,868,970 4,912,381 4,926,063 4,935,080
4,943,760 4,954,739 4,992,716 5,051,634 5,144,183
5,173,651 5,194,786 5,399,908 5,435,517 5,530,396
5,574,636 5,606,791 5,625,265 5,633,793 5,646,467
5,715,590 5,736,916 5,739,648 5,754,732 5,789,841
5,829,118 5,912,638 5,949,202 5,949,359 5,998,905
6,002,234
Technical changes which improve the performance of the equipment may be made without prior 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 stored, processed, copied or distributed by electronic means without the written permission of Danaher Motion Corporation.
Kollmorgen 03/04 Contents
Drawing Page
Contents ...............................................3
Safety instructions ........................................6
European directives and standards..............................7
-/UL-conformance ......................................7
Abbreviations and symbols ...................................8
1 General
1.1 About this manual ..................................................................................11
1.2 Prescribed use (Use as directed) of the servo amplifier .....................................................12
1.3 Nameplate .......................................................................................13
1.4 Instrument description ..............................................................................13
1.4.1 Package supplied ............................................................................13
1.4.2 The digital servo amplifiers of the series SERVOSTAR 600 ............................................14
1.4.3 Operation directly from supply...................................................................14
1.4.4 Digital servo amplifier concept ..................................................................15
1.5 Connection to different mains supply networks ...........................................................16
1.6 Components of a servo system .......................................................................17
1.7 Technical data ....................................................................................18
1.7.1 External fusing...............................................................................18
1.7.2 Allowable ambient conditions, ventilation, mounting position ...........................................19
1.7.3 Conductor cross-sections ......................................................................19
1.7.4 Recommended torque .........................................................................19
1.7.5 LED display .................................................................................19
1.8 Grounding system..................................................................................20
1.9 Control for motor-holding brake .......................................................................20
1.10 Regen circuit ......................................................................................21
1.11 Switch-on and switch-off behavior .....................................................................22
1.11.1 Stop function to EN 60204 (VDE 0113)............................................................22
1.11.2 Emergency Stop strategies .....................................................................23
2 Installation
2.1 Important instructions ...............................................................................25
2.2 Assembly ........................................................................................26
2.2.1 Dimensions .................................................................................27
2.3 Wiring ...........................................................................................28
2.3.1 Connection diagram ..........................................................................30
2.3.2 Example of connections for multi-axis system ......................................................31
2.3.3 Pin assignments .............................................................................32
2.3.4 Notes on connection techniques .................................................................33
2.3.4.1 Shielding connection to the front panel ........................................................33
2.3.4.2 Technical data for connecting cables .........................................................34
2.4 Setup software ....................................................................................35
2.4.1 General ....................................................................................35
2.4.1.1 Use as directed ..........................................................................35
2.4.1.2 Software description ......................................................................35
2.4.1.3 Hardware requirements ....................................................................36
2.4.1.4 Operating systems........................................................................36
2.4.2 Installation under WINDOWS 95 / 98 / 2000 / ME / NT / XP ............................................36
- A.4.028.6/10
- A.4.031.1/52
- A.4.031.3/01, 1/35
- A.4.031.3/6
- A.4.031.4/15
- A.4.031.4/14
- A.4.031.1/02
- A.4.031.1/19
- A.4.031.4/21
- A.4.029.4/25
SERVOSTAR®601...620 Installation Manual 3
Contents 03/04 Kollmorgen
Drawing Page
3 Interfaces
- A.4.031.1/47
3.1 Power supply .....................................................................................38
3.1.1 Mains supply connection (X0) ...................................................................38
3.1.2 24V auxiliary supply (X4).......................................................................38
3.1.3 DC-link (X7) .................................................................................38
- A.4.031.1/21,25
3.2 Motor connection with brake (X9) ......................................................................39
3.3 External regen resistor (X8) ..........................................................................39
- A.4.031.1/17,18
3.4 Feedback ........................................................................................40
3.4.1 Resolver connection (X2) ......................................................................40
3.4.2 Encoder (X1) ................................................................................41
- A.4.031.1/26
- A.4.031.1/27
3.5 Control signals, monitor signals .......................................................................42
3.5.1 Analog inputs (X3) ............................................................................42
3.5.2 Analog outputs (X3)...........................................................................43
3.5.3 Digital control inputs (X3) ......................................................................44
3.5.4 Digital control outputs (X3) .....................................................................45
- A.4.031.1/23
- A.031.1/22
- A.4.031.1/24
- A.4.031.1/20
3.6 Encoder simulations ................................................................................46
3.6.1 Incremental encoder simulation - A quad B position output (X5) ........................................46
3.6.2 SSI encoder simulation - position output (X5) .......................................................47
- A.4.031.1/11
- A.4.031.1/12
3.6.3 Interface for master-slave operation, encoder input ..................................................48
3.6.3.1 Connection to a SERVOSTAR master, 5V signal level (X5) ........................................48
- A.4.031.1/16,3/2
3.6.3.2 Connection to encoders with 24V signal level (X3) ...............................................49
3.6.3.3 Connection to a sine-cosine encoder (X1)......................................................49
3.7 Interface for stepper-motor controls (pulse-direction) .......................................................50
- A.4.031.1/44,43
- A.4.031.3/2
3.7.1 Connection to stepper-motor controller with 5V signal level (X5)........................................51
3.7.2 Connection to stepper-motor controller with 24V signal level (X3).......................................51
3.8 RS232 interface, PC connection (X6) ...................................................................52
3.9 CANopen Interface (X6) .............................................................................53
- A.4.031.1/10,45
- A.4.031.1/13,14
- A.4.031.1/15, 1/36
4Setup
4.1 Important notes ....................................................................................55
4.2 Parameter setting ..................................................................................57
4.2.1 Multi-axis systems ............................................................................57
4.2.1.1 Node address for CAN-bus .................................................................57
4.2.1.2 Baud rate for CAN-bus ....................................................................57
- A.4.031.4/37
4.2.2 Key operation / LED display ....................................................................58
4.2.2.1 Key operation............................................................................58
4.2.2.2 Status display ...........................................................................58
- A.4.031.3/4
4.2.2.3 Standard menu structure ...................................................................59
4.2.2.4 Extended menu structure...................................................................59
- A.4.031.3/3
4.3 Error messages ...................................................................................60
4.4 Warning messages .................................................................................61
5 Extensions / Accessories
5.1 Option -AS-, restart lock for personal safety ..............................................................63
5.1.1 Advantages of the -AS- option ..................................................................63
5.1.2 Functional description .........................................................................63
5.1.3 Block diagram ...............................................................................64
5.1.4 Signal diagram (sequence) .....................................................................64
5.1.5 Installation / Setup ............................................................................65
5.1.5.1 Safety instructions ........................................................................65
5.1.5.2 Functional test ...........................................................................65
5.1.5.3 Connection diagram.......................................................................65
5.1.6 Application examples .........................................................................66
5.1.6.1 Moving single axes or axis-groups in setting-up operation .........................................66
5.1.6.2 Switching off grouped axes with separate working areas ..........................................66
5.1.6.2.1 Control circuit.......................................................................66
5.1.6.2.2 Mains supply circuit ..................................................................67
5.2 Expansion card -I/O-14/08-...........................................................................68
5.2.1 Fitting the expansion card ......................................................................68
5.2.2 Technical data ...............................................................................68
5.2.3 Light emitting diodes (LEDs) ....................................................................68
5.2.4 Position of the connectors ......................................................................69
5.2.5 Connector assignments........................................................................70
5.2.6 Select motion task number (Sample) .............................................................70
5.2.7 Connection diagram ..........................................................................71
- A.4.031.1/32,30
- A.4.031.1/30
- A.4.031.1/311
- A.4.031.3/05
- A.4.031.4/42
- A.4.012.4/33
4 SERVOSTAR®601...620 Installation Manual
Kollmorgen 03/04 Contents
Drawing Page
5.3 Expansion card -PROFIBUS- .........................................................................72
5.3.1 Position of the connectors ......................................................................72
5.3.2 Fitting the expansion card ......................................................................72
5.3.3 Connection technology ........................................................................73
5.3.4 Connection diagram ..........................................................................73
5.4 Expansion card -SERCOS-...........................................................................74
5.4.1 Position of the connectors ......................................................................74
5.4.2 Fitting the expansion card ......................................................................74
5.4.3 Light emitting diodes (LEDs) ....................................................................75
5.4.4 Connection technology ........................................................................75
5.4.5 Connection diagram ..........................................................................75
5.5 Expansion card -DeviceNet- ..........................................................................76
5.5.1 Position of the connectors ......................................................................76
5.5.2 Fitting the expansion card ......................................................................76
5.5.3 Connection technology ........................................................................77
5.5.4 Connection diagram ..........................................................................77
5.5.5 Combined Module/Network Status LED ...........................................................77
5.6 Expansion card- ETHERNET - ........................................................................78
5.6.1 Fitting the expansion card ......................................................................78
5.6.2 Connectors .................................................................................78
5.6.3 LEDs ......................................................................................78
5.6.4 Position of the connectors ......................................................................79
5.6.5 Connection diagram ..........................................................................79
5.7 Expansion card for Single Axis Controller -SAC- ..........................................................80
5.7.1 Fitting the expansion card ......................................................................80
5.7.2 Technical data ...............................................................................80
5.7.3 Position of the connectors ......................................................................81
5.7.4 Connector assignments........................................................................81
5.7.4.1 RS-232 communication X17 (SubD 9-pin, plug) .................................................81
5.7.4.2 RS-485 communication X17 (SubD 9-pin, plug) .................................................82
5.7.4.3 DeviceNet communication X16 (Phönix, 5-pin) ..................................................82
5.7.4.4 Digital inputs/outputs, connector X18 (SubD 26-pin, socket) .......................................83
5.8 Expansion module -2CAN- ...........................................................................84
5.8.1 Position of the connectors ......................................................................84
5.8.2 Fitting the expansion module ...................................................................84
5.8.3 Connection technology ........................................................................85
5.8.4 Connector assignments........................................................................85
5.8.5 Connection diagram ..........................................................................85
5.9 Accessories ......................................................................................86
5.9.1 External 24V DC / 5A supply ....................................................................86
5.9.2 External 24V DC / 20A supply ...................................................................87
5.9.3 External regen resistor BARxxx .................................................................88
5.9.4 External regen resistor BAR(U)xxx ...............................................................89
5.9.5 Motor choke box 3YL-20 .......................................................................90
6 Appendix
6.1 Transport, storage, maintenance, disposal...............................................................91
6.2 Removing faults/warnings............................................................................92
6.3 Glossary .........................................................................................94
6.4 Order numbers ....................................................................................96
6.5 Index ............................................................................................97
- A.031.4/62
- A.4.031.1/41
- A.4.031.4/69
- A.4.037.4/02
- A.031.4/62
- A.4.031.1/56
- A.4.045.4/14, 4/15
- A.4.045.4/10, 31.1/60
- A.4.031.1/58,61, 45.1/28
- A.4.031.4/70
- A.4.037.4/08
- A.4.037.4/07
- A.4.012.4/33
- A.4.947.4/22
- A.4.947.4/25
- A.4.030.4/10
SERVOSTAR®601...620 Installation Manual 5
Safety instructions 03/04 Kollmorgen
Safety Instructions
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Only properly qualified personnel are permitted to perform activities such as
transport, installation, setup and maintenance. Properly qualified persons
are those who are familiar with the transport, assembly, installation, setup
and operation of the product, and who have the appropriate qualifications
for their job. The qualified personnel must know and observe:
IEC 364 and CENELEC HD 384 or DIN VDE 0100
IEC-Report 664 or DIN VDE 0110
National Accident Prevention Regulations or BGV A2
Read this documentation before carrying out installation and setup.
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 (on the nameplate and in the
documentation).
The manufacturer of the machine must generate a hazard analysis for the
machine, and take appropriate measures to ensure that unforeseen
movements cannot cause injury or damage to any person or property.
The servo amplifiers contain electrostatically sensitive components which
may be damaged by incorrect handling. Ground yourself before touching the
servo amplifier by touching any unpainted metal surface. Avoid contact with
highly insulating materials (artificial fabrics, plastic film etc.). Place the
servo amplifier on a conductive surface.
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Do not open the units. Keep all covers and switchgear cabinet doors closed
during operation. Otherwise there are deadly hazards, with the possibility of
severe danger to health or material damage.
During operation, servo amplifiers, according to their degree of enclosure
protection, may have uncovered live components. Control and power
connections may be live, even if the motor is not rotating.
Servo amplifiers may have hot surfaces during operation. Since the front
panel is used for cooling, it can reach temperatures above 80°C (176°F).
Never undo the electrical connections to the servo amplifier while it is live.
There is a danger of electric arcing with damage to contacts and danger to
persons.
Wait at least five minutes after disconnecting the servo amplifier from the
mains supply voltage before touching live sections of the equipment (e.g.
contacts) or undoing connections. Capacitors can still have dangerous
voltages present up to five minutes after switching off the supply voltages.
To be sure, measure the voltage in the DC-link circuit and wait until it has
fallen below 40V.
6 SERVOSTAR®601...620 Installation Manual
Kollmorgen 03/04
European directives and standards
Servo amplifiers are components that are intended to be incorporated into electrical plant and machines for in
dustrial 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).
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 appropria
te measures to ensure that unforeseen movements do not result in personal injury or material dama
ge.
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.
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.
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In the reference to noise immunity and noise emission the servoamplifier fulfills the requirement to the catego
ry second environment (industrial environment).
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 in
stallation described in this documentation means that you will be responsible for carrying out new measure
ments to ensure that the regulatory requirements are fulfilled.
To fulfill the Low Voltage Directive, the standard EN 50178 has to be applied.
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SERVOSTAR®601...620 Installation Manual 7
-
-
Directives and standards 03/04 Kollmorgen
UL and cUL- Conformance
UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S. and Canadian stan
dard (in this case UL 840 and UL 508C).
This standard describes the fulfilment by design of minimum requirements for electrically operated power con
version equipment, such as frequency converters and servo amplifiers, which is intended to eliminate the risk
of fire, electric shock, or injury to persons, being caused by such equipment. The technical conformance with
the U.S. and Canadian standard is determined by an independent UL (cUL) inspector through the type testing
and regular check-ups.
Apart from the notes on installation and safety in the documentation, the customer does not have to observe
any other points in direct connection with the UL (cUL)-certification of the equipment.
UL 508C
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UL 508C describes the fulfilment by design of minimum requirements for electrically operated power conversi
on 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.
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8 SERVOSTAR®601...620 Installation Manual
Kollmorgen 03/04 Abbreviations / symbols
Abbreviations used in this manual
The abbreviations used in this manual are explained in the table below.
Abbrev. Meaning
AGND Analog ground
AS Restart Lock, option
BTB/RTO Ready to operate
CAN Fieldbus (CANopen)
CE Communité Européenne (EC)
CLK Clock signal
COM Serial interface for a PC-AT
DGND Digital ground
DIN German Institute for industrial Standards
Disk Magnetic storage (diskette, hard disk)
EEPROM Electrically erasable programmable memory
EMC Electromagnetic compatibility
EMI Electromagnetic 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
MS-DOS Operating system for PC-AT
Abbrev Meaning
NI Zero pulse
NSTOP Limit-switch input for CCW rotation (left)
PC-AT Personal computer with 80x86 Processor
PELV Protected low voltage
PGND Ground for the interface
PSTOP Limit-switch input for CW rotation (right)
PWM Pulse-width modulation
RAM Volatile memory
Rregen Regen resistor
RBext External regen resistor
RBint Internal regen resistor
RES Resolver
ROD 426 A quad B encoder
PLC Programmable logic controller
SRAM Static RAM
SSI Synchronous serial interface
UL Underwriters Laboratory
VAC AC voltage
VDC DC voltage
VDE Verein deutscher Elektrotechniker
XGND Ground for the 24V supply
Symbols used in this manual
danger to personnel from
electricity and its effects
ð p.
Keys on the servo amplifier panel :
U
U
see page (cross-ref.) l special emphasis
press once : move up one menu item, increase number by one
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
general warning
general instructions
mechanical hazard
SERVOSTAR®601...620 Installation Manual 9
03/04 Kollmorgen
This page has been deliberately left blank.
10 SERVOSTAR®601...620 Installation Manual
Kollmorgen 03/04 General
1 General
1.1 About this manual
This manual describes the digital servo amplifiers of the SERVOSTAR®600 series
(standard version, 1.5 to 20 Amps nominal current).
Note:
SERVOSTAR 601 is sold in Europe only
In this manual you can find information about:
Technical data of the servo amplifiers Chapter I
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Assembly / installation Chapter II
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Interfaces Chapter III
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Setup the servo amplifier Chapter IV
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Accessories Chapter V
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Transport, storage, maintenance, disposal of the servo amplifiers Chapter VI
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A more detailed description of the expansion cards which are currently available and the digital
connection to automation systems can be found on the accompanying CD-ROM in Acrobat-Reader
format (system requirements: WINDOWS > 95 with Internet browser, Acrobat Reader > 4.0) in
English, German Italian and French versions.
You can print this documentation on any standard printer. A printed copy of the documentation is
available from us at extra cost.
This manual makes the following demands on qualified personnel :
Transport : only by personnel with knowledge in handling electrostatically
sensitive components.
Installation : only by electrically qualified personnel
Setup : only by personnel with extensive knowledge of electrical
engineering / drive technology
SERVOSTAR®601...620 Installation Manual 11
General 03/04 Kollmorgen
1.2 Prescribed use (Use as directed) of the servo amplifier
The servo amplifiers are components which are built into electrical equipment or machines, and can
only be used as integral components of such equipment.
The manufacturer of the machine must generate a hazard analysis for the machine, and take
appropriate measures to ensure that unforeseen movements cannot cause injury or damage to any
person or property.
The SERVOSTAR 600 family of servo amplifiers can be connected directly to symmetrically earthed
(grounded) three-phase industrial mains supply networks [TN-system, TT-system with earthed
(grounded) neutral point, not more than 5000 rms symmetrical amperes, 480VAC maximum].
The servo amplifiers must not be operated directly on power supply networks >230V without an
earth (ground) or with an asymmetrical earth (ground).
Connection to different mains supply networks (with additional isolating transformer) ð p.16.
Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo amplifier may
not exceed 1000V (peak value).
Transient overvoltages (< 50µs) between the outer conductors may not exceed 1000V.
Transient overvoltages (< 50µs) between outer conductors and housing may not exceed 2000V.
If the servo amplifiers are used in residential areas, or in business or commercial premises, then
additional filter measures must be implemented by the user.
The SERVOSTAR 600 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 vol
tage of the motors must be at least as high as the DC-link voltage of the servo amplifier.
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The servo amplifiers may only be operated in a closed switchgear cabinet, taking into account the
ambient conditions defined on page 19 and the dimensions shown on page 26. Ventilation or cooling may be necessary to prevent enclosure ambient from exceeding 45°C (113°F).
Use only copper wire. Wire size may be determined from EN 60204 (or table 310-16 of the NEC
60°C or 75°C column for AWG size).
We only guarantee the conformance of the servo amplifiers with the standards for industrial areas
(page 7), if the components (motors, cables, amplifiers etc) are delivered by Danaher Motion.
Option -AS-, restart lock for personnel safety
The -AS- restart lock is exclusively intended to provide safety for personnel, by preventing the res
tart of a system. To achieve this personnel safety, the wiring of the safety circuits must meet the
safety requirements of EN60204, EN292 and EN 954-1.
The -AS- restart lock must only be activated,
— when the motor is no longer rotating (setpoint = 0V, speed = 0rpm, enable = 0V).
Drives with a suspended load must have an additional safe mechanical blocking
(e.g. by a motor-holding brake).
— when the monitoring contacts (KSO1/2 and BTB/RTO) for all servo amplifiers are
wired into the control signal loop (to recognize a cable break).
The -AS- restart lock may only be controlled by a CNC if the control of the internal safety relay is
arranged for redundant monitoring.
The -AS- restart lock must not be used if the drive is to be made inactive for the following reasons :
1. - cleaning, maintenance and repair operations
- long inoperative periods
In such cases, the entire system should be disconnected from the supply by the personnel,
and secured (main switch).
-
2. - emergency-stop situations
In an emergency-stop situation, the main contactor is switched off
(by the emergency-stop button or the BTB-contact in the safety circuit).
12 SERVOSTAR®601...620 Installation Manual
Kollmorgen 03/04 General
1.3 Nameplate
The nameplate depicted below is attached to the side of the servo amplifier.
The information described below is printed in the individual fields.
Danaher Motion GmbH
Wacholderstr. 40-42
D-40489 Düsseldorf
www.DanaherMotion.net
Typenbezeichnung
Spannungsversorgung
Model Number
Power Supply
Electrical supply
Installed load
1.4 Instrument description
1.4.1 Package supplied
Serial numberServo amplifier type
Customer Support
Europe Tel. +49 (0)203 / 99790
Italy 3 36 594260
North America 1 80 777-3786
Tel. + 9 (0) 2 /
Te l. + ( 0)
Ser. Nr
Nennstrom
Ser. No.
Nom. Current
Output current
in S1 operation
CONNECT-module
and options
Bemerkung
Schutzart
Enclosure Rating
Comment
Encl.Rating
When you order a SERVOSTAR 600 series amplifier, you will receive:
— SERVOSTAR 6xx
— mating connectors X3, X4, X0A, X0B, X7, X8
The mating SubD connectors and motor connector X9 are not part of the package!
— Assembly, Installation and Setup Instructions
— Online documentation on CD-ROM
— Setup software DRIVE.EXE on CD-ROM
Accessories:
— AC synchronous servomotor (linear or rotary)
— motor cable (pre-assembled), or both motor connectors separately, with motor cable as a
— feedback cable (pre-assembled, see application note “Cables and connectors”) or both
— motor choke 3YL-20 (ð p.90), for cable length above 25m
— external regen resistor (ð p.73)
— communications cable to the PC(ð p.52) or Y-adapter (ð p.57) for setting parameters of up
— power cable, control cables, fieldbus cables (as lengths)
(must be ordered separately)
cut-off length
feedback connectors separately, with feedback cable as length
to 6 servo amplifiers from one PC
SERVOSTAR®601...620 Installation Manual 13
General 03/04 Kollmorgen
1.4.2 The digital servo amplifiers of the series SERVOSTAR 600
Servoamplifiers of the SERVOSTAR 640/670 series are described in additional manuals.
Standard version
6 current ratings (1.5 A -Europe only-,3A,6A,10A,14A,20A)
l
three instrument widths : 70 mm for 1.5A up to 10A rated current
l
100 mm for 14A rated current
120 mm for 20A rated current
wide range of rated voltage (3x208V
l
shield connection directly at the servo amplifier
l
two analog setpoint inputs
l
integrated CANopen (default 500 kBaud), for integration into CAN bus systems and for
l
–10%
to 3x480V
setting parameters for several amplifiers via the PC-interface of one amplifier
integrated RS232, electrically isolated, integrated pulse-direction interface
l
Open architecture
open hardware and software architecture
l
slot for an expansion card
l
integrated macro language, including compiler
l
prepared for all conceivable customer-specific extensions
l
+10%
)
Options
l -AS- built-in safety relay (personnel-safety starting lock-out), ð p. 63
l I/O expansion card, ð p. 68
l PROFIBUS DP expansion card, ð p. 72
l SERCOS expansion card, ð p. 74
l DeviceNet expansion card, ð p. 76
l Ethernet expansion card, ð p. 78
l Single Axis Controller expansion card, ð p. 80
l
-2CAN- Expansion module, separated connectors for CAN bus and RS232, ð p. 84
l
Third party expansion cards (ModBus, FireWire, LightBus etc. - contact distributors for further
information)
1.4.3 Operation directly from supply
Electrical supply
l
Directly off grounded 3 phase system,
230V
208V
-10%
-10%
... 480V
... 480V
TN-system or TT-system with grounded neutral point, max. 5000 rms symmetrical amperes.
Connection to other mains supply networks only with insulating transformer ð p. 16
l
Fusing (e.g. fusible cutout) provided by the user
l
single-phase supply (e.g. for setup) is possible
+10%
+10%
,50Hz,
,60Hz
Auxiliary supply voltage 24VDC
l
Electrically isolated, internal fusing (3.15 AT), from an external 24VDC psu, e.g. with insulating
transformer
Power input filter
l
Interference suppression filter for the supply input (to Class A) is integrated
l
Interference suppression filter for the 24V aux. supply (to Class A) is integrated
14 SERVOSTAR®601...620 Installation Manual
Kollmorgen 03/04 General
1.4.4 Digital servo amplifier concept
Operation and parameter setting
With our user-friendly software for setup through the serial interface of a PC
l
Direct operation by means of two keys on the servo amplifier and a 3-character LED display
l
for status display in case there is no PC available
Fully programmable via RS232 interface
l
Power section
Power supply: B6 rectifier bridge, directly off 3-phase earthed (grounded)
l
supply system, integral power input filter and inrush circuit
All shielding connections directly on the amplifier
l
Output stage: IGBT- module with isolated current measurement
l
Regen circuit: with dynamic distribution of the regen power between several
l
amplifiers on the same DC-link circuit. Internal regen resistor as
standard, external regen resistors if required
DC-link voltage 260 — 900 VDC, can be switched in parallel
l
Completely digital control
Digital current controller (space vector pulse-width modulation, 62.5 µs)
l
digital speed controller adaptable to most different load conditions (65µs or 250 µs)
l
Integral position controller with adaptation possibilities for customer needs (250 µs)
l
l Pulse direction interface integrated for connection of a servomotor to a stepping motor
control
l Evaluation of the resolver signals and sine-cosine signals of a high-resolution encoder
l Encoder simulation (incremental or SSI)
Auxiliary functions
l Adjustable setpoint ramps
l 2 analog monitor outputs
l
4 programmable digital inputs (normally, two are defined as limit-switch inputs)
l
2 programmable digital outputs
l
Freely programmable combinations of all digital signals
Integrated safety
l
Safe electrical separation to EN 50178 between the power input / motor connections and the
signal electronics, provided by appropriate insulation/creepage distances and complete electri
cal isolation
l
Soft-start, overvoltage recognition, short-circuit protection, phase-failure monitoring
l
Temperature monitoring of servo amplifier and motor
(when using our motors with our pre-assembled cables)
-
SERVOSTAR®601...620 Installation Manual 15
General 03/04 Kollmorgen
1.5 Connection to different mains supply networks
On this page you'll find all possible connection variations to different mains supply networks.
An isolating transformer is always required for 400...480V mains networks without
earth(ground) and for networks with asymmetrical earth(ground).
208V with 60Hz only
SERVOSTAR
230...480V with 50Hz or 60Hz
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
16 SERVOSTAR®601...620 Installation Manual
Kollmorgen 03/04 General
1.6 Components of a servo system
PC
Control / PLC
24V supply
Option -AS-
terminals
SERVOSTAR 600
fuses
drive contactor
motor
SERVOSTAR®601...620 Installation Manual 17
General 03/04 Kollmorgen
1.7 Technical data
SERVOSTAR
Rated data DIM 601 603 606 610 610-30 614 620
Rated supply voltage (grounded system)
V~ 3 x 230V
V~ 3 x 208V
-10%
-10%
Rated installed load for S1 operation kVA 124771014
Rated DC-link voltage V= 260 - 675
A
Rated output current (rms value, ± 3%)
Peak output current (max. ca. 5s, ± 3%)
1.5 3 6 10 10 14 20
rms
A
3 6 12 20 30 (2s) 28 40
rms
Clock frequency of the output stage kHz 8 (16 with VDCmax=400V)
Technical data for regen circuit — ð p.21
Overvoltage protection threshold V 450...900
Max. load inductance mH 150 75 40 25 24 15 12
Min. load inductance mH 25 12 7,5 4 4 2,5 2
Form factor of the output current
(at rated data and min. load inductance)
— 1.01
Bandwidth of subordinate current controller kHz > 1.2
Residual voltage drop at rated current V 5
Quiescent dissipation, output stage disabled W 15
Dissipation at rated current (incl. power
supply losses, without regen dissipation)
W 30 40 60 90 90 160 200
Internal fusing (external fusing ð p.18)
Auxiliary supply 24V — internal 3.15 AT
Regen resistor — internal, electronic
Inputs
Setpoint ½, resolution 14bit/12bit V
Common-mode voltage max. V
Input resistance to AGND
kW
Digital inputs V according to IEC 1131
Digital outputs, open collector V according to IEC 1131
BTB/RTO output, relay contacts
Aux. power supply, electrically isolated without brake
Aux. power supply, electrically isolated with
brake (consider voltage loss!)
V DC max. 30, AC max. 42
mA 500
V 24 (-0% +15%)
A1
V 24 (-0% +15%)
A3
Max. output current, brake A 2
Connections
Control signals — Combicon 5.08 / 18 pole , 2,5mm²
Power signals — Power Combicon 7.62 / 4x4 + 1x6-pole, 4mm²
Resolver input — SubD 9pole (socket)
Sine-cosine encoder input — SubD 15pole (socket)
PC-interface, CAN — SubD 9pole (plug)
Encoder simulation, ROD (EEO) / SSI — SubD 9pole (plug)
Mechanical
Weight kg 4 5 7.5
Height without connectors mm 275
Width mm 70 100 120
Depth without connectors mm 265
... 480V
... 480V
±10
±10
20
+10%
+10%
,50Hz
,60Hz
1.7.1 External fusing
Fusible cutouts or similar
(Fuse UL time delay)
AC supply F
24V supply F
Regen resistor F
N1/2/3
H1/2/3
B1/2
(x=SorS-Rfor480V applications x=NorN-Rfor230V applications)
SERVOSTAR
601 / 603
SERVOSTAR
606 / 610
SERVOSTAR
614 / 620
6 AT (FRx-6) 10 AT (FRx-10) 20 AT (FRx-25)
max. 12 AF (max. FRx-12)
4 A (FRS-6) 6 A (FRS-6) 6 AF(FRS-10)
18 SERVOSTAR®601...620 Installation Manual
Kollmorgen 03/04 General
1.7.2 Allowable ambient conditions, ventilation, mounting position
Storage temperature/humidity, storage duration
Transport temperature / humidity
Supply voltage tolerances
Input power
Aux. power supply
Ambient temperature in operation
Humidity in operation
Site altitude
Pollution level Pollution level 2 to EN60204/EN50178 Enclosure protection IP 20 Mounting position Ventilation
Make sure that there is sufficient forced ventilation within the switchgear cabinet.
1.7.3 Conductor cross-sections
Following EN 60204 (for AWG: table 310-16 of the NEC 60°C or 75°C column), we recommend for
single-axis systems:
AC connection
DC-link
Motor cables up to 25 m length
Motor cables 25 to 100 m length,
with motor choke 3YL-20
(consult our customer service)
Resolver, thermostat-motor
Encoder, thermostat-motor
Setpoints, monitors, AGND 0.25 mm² (22 awg) twisted pairs, shielded
Control signals, BTB, DGND 0.5 mm² (20 awg)
Holding brake (motor) min. 0.75 mm² (18 awg), 600V,105°C (221°F), shielded, check voltage drop
+24 V / XGND max. 2.5 mm² (14 awg), check voltage drop
For multi-axis systems, please note the special operating conditions in your installation
Technical data for connection cables ð p.34 .Observe our application note “Cables and connectors”.
SERVOSTAR 601-610 : 1.5 mm² (14 awg)
SERVOSTAR 614/620 : 4 mm² (12 awg)
SERVOSTAR 601-610 : 1.5 mm² (14 awg)
SERVOSTAR 614/620 : 4 mm² (12 awg)
SERVOSTAR 601-610 : 1-1.5 mm² (14 awg)
SERVOSTAR 614/620 : 2.5 mm² (12 awg)
SERVOSTAR 601-606 : 1 mm² (14 awg)
SERVOSTAR 610-620 : 2.5 mm² (12 awg)
4x2x0.25 mm² (22awg) twisted pairs, shielded, max.100m,
capacitance <120pF/m
7x2x0,25 mm² (22 awg) twisted pairs, shielded, max.50m,
capacitance <120pF/m
ð p.91
ð p.91
min 3x 230V
min 3x 208V
24 VDC (-0% +15%)
0 to +45°C (32 to 113°F) at rated data
+45 to +55°C (113 to 131°F) with power derating
rel. humidity 85%, no condensation
up to 1000m a.m.s.l. without restriction
1000 — 2500m a.m.s.l. with power derating 1.5%/100m
generally vertical. ð p.26
forced convection by built-in fan
AC / max 3x 480V
-10%
AC / max 3x 480V
-10%
+10%
,50Hz
+10%
,60Hz
2.5% / K
600V,105°C (221°F),
twisted
600V,105°C (221°F),
shielded for lengths>20cm
600V,105°C (221°F),
shielded,
capacitance <150pF/m
600V,105°C (221°F),
shielded,
capacitance <150pF/m
1.7.4 Recommended torque
Connector Recommended torque
X3, X4 0.5 to 0.6 Nm (4.43 to 5.31 in lb)
X0A, X0B, X7, X8, X9 0.5 to 0.6 Nm (4.43 to 5.31 in lb)
Ground bolt 3.5 Nm (31 in lb)
1.7.5 LED display
A 3-character LED display shows the amplifier status after switching on the 24V supply
(ð p.58). During operation of the amplifier via the keys on the front panel, the parameter and
function numbers (ð p.59) are displayed, as well as the numbers of any errors which occur
(ð p.60).
SERVOSTAR®601...620 Installation Manual 19
General 03/04 Kollmorgen
1.8 Grounding system
AGND — ground for analog inputs/outputs, internal analog/µC ground
DGND — ground for digital inputs/outputs, optically isolated
XGND — ground for external 24V aux. voltage, optically and inductively isolated
PGND — ground for encoder simulation, RS232, CAN, optically isolated
The potential isolation is shown in the block diagram (ð p. 37).
1.9 Control for motor-holding brake
A 24V / max. 2A holding brake in the motor 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 (setting: WITH BRAKE). In the diagram below you can see the time and functio
nal 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. The rise (tbrH) and fall (tbrL) times of the holding brake which is built into the
motors are different for the various types of motor (see motor manual). A description of the
interface can be found on page 39 .
A safe (for personnel) operation of the holding brake requires an additional “make” (n.o.) contact in
the brake circuit and a suppressor device (varistor) for the recommended brake circuit diagram :
SERVOSTAR 600
20 SERVOSTAR®601...620 Installation Manual
Kollmorgen 03/04 General
1.10 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 circuit (thresholds) are adjusted to the supply
voltage with the help of the setup software.
Our customer service can help you with the calculation of the regen power which is required. A des
cription of the interface can be found on page 39 .
Internal regen resistor : SERVOSTAR 601/603 66 W
SERVOSTAR 606-620 33 W
External regen resistor : SERVOSTAR 601-620 33 W
Functional description :
1.- Individual amplifiers, not coupled through the DC-link (DC+, DC-)
The circuit starts to respond at a DC-link voltage of 400V, 720V or 840V (depending on the
supply voltage). 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 status “regen power exceeded” and the regen circuit will be switched off. At the next
internal check of the DC-link voltage (after a few ms) an overvoltage will be detected and the
Servo amplifier will be switched off with the error message “Overvoltage F02" (ð p.60). The
BTB/RTO contact (terminal X3/2,3) will be opened at the same time (ð p.45)
2.- Several servo amplifiers coupled through the DC-link circuit (DC+, DC-)
Thanks to the built-in regen circuit with its patented power distribution, several amplifiers
(even with different current ratings) can be operated off a common DC-link. This is achieved
by an automatic adjustment of the regen thresholds (which vary, because of tolerances).
The regen energy is distributed equally among all the amplifiers. The combined power of
all the amplifiers is always available, as continuous or peak power. The switch-off takes
place as described under 1. (above) for the servo amplifier with the lowest switch-off
threshold (resulting from tolerances). The RTO (BTB) contact of this amplifier (terminals
X3/2,3) will be opened at the same time (ð p.45).
-
Regen circuit: technical data SERVOSTAR
Supply voltage Rated data DIM 601 - 603 606 - 620
Upper switch-on level of regen circuit V 400 - 430
Switch-off level of regen circuit V 380 - 410
Overvoltage F02 V 450
3 x 230 V
3 x 400 V
3 x 480 V
Continuous power of regen circuit (R
Continuous power of regen circuit (R
Pulse power, internal (R
Pulse power, external (R
External regen resistor
Upper switch-on level of regen circuit V 720 - 750
Switch-off level of regen circuit V 680 - 710
Overvoltage F02 V 800
Continuous power of regen circuit (R
Continuous power of regen circuit (R
Pulse power, internal (R
Pulse power, external (R
External regen resistor
Upper switch-on level of regen circuit V 840 - 870
Switch-off level of regen circuit V 800 - 830
Overvoltage F02 V 900
Continuous power of regen circuit (R
Continuous power of regen circuit (R
Pulse power, internal (R
Pulse power, external (R
External regen resistor
max. 1s) kW 2.5 5
Bint
max. 1s) kW 5
Bext
max. 1s) kW 8 16
Bint
max. 1s) kW 16
Bext
max. 1s) kW 10.5 21
Bint
max. 1s) kW 21
Bext
) W 80 200
Bint
) max. kW 0.25 0.75
Bext
W
) W 80 200
Bint
) max. kW 0.4 1.2
Bext
W
) W 80 200
Bint
) max. kW 0.5 1.5
Bext
W
33
33
33
SERVOSTAR®601...620 Installation Manual 21
General 03/04 Kollmorgen
1.11 Switch-on and switch-off behavior
The diagram below illustrates the correct functional sequence for switching the servo amplifier on
and off.
DC-link
1.11.1 Stop function to 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 X3/16 and X3/17) (see online help for the setup software). These signals can be used by
the higher-level control to finish the current PLC cycle or to shut down the drive (with additional
brake or similar.).
Instruments which are equipped with a selected “Brake” function use a special sequence for
switching off the output stage (ð p.20).
The -AS- option can be used to switch off the drive via a positive-action (approved by the Trade
Liability Association) safety relay, so that personnel safety is ensured at the drive shaft (ð p.63).
The Stop functions are defined in EN 60204 (VDE 0113), Para. 9.2.2, 9.2.5.3.
There are three categories of Stop functions:
Category 0: Shut down by immediately switching off the supply of energy to the
drive machinery (i.e an uncontrolled shut-down);
Category 1: A controlled shut-down, during which the supply of energy to the drive
machinery is maintained to perform the shut-down, and where the energy
supply is only interrupted when the shut-down has been completed;
Category 2: A controlled shut-down, where the supply of energy to the drive machinery
is maintained.
Every machine must be equipped with a Stop function to Category 0. Stop functions to Categories 1
and/or 2 must be provided if the safety or functional requirements of the machine make this
necessary.
You can find additional information and implementation examples in our application note “Stop and
Emergency Stop functions with SERVOSTAR 600”.
22 SERVOSTAR®601...620 Installation Manual
Kollmorgen 03/04 General
1.11.2 Emergency Stop strategies
The Emergency Stop function is defined in EN 60204 (VDE 0113), Para. 9.2.5.4.
Implementation of the Emergency Stop function :
You can find wiring recommendations in our application note
“Stop and Emergency Stop functions with SERVOSTAR 600”
Category 0:
The controller is switched to “disable”, the electrical supply (400VAC) is disconnected.
The drive must be held by an electromagnetic holding device (brake).
In multiaxis systems with connected DC-link bus (intermediate circuit) the motor leads have
to be disconnected by a changeover switch (contactor, e.g. Siemens 3RT1516-1BB40) and
short-circuited by resistors connected in a star configuration.
Category 1:
If hazardous conditions can result from an emergency stop switch-off with an unbraked
run-down, then the drive can be switched off by a controlled shut-down.
Stop Category 1 permits electromotive braking with a switch-off when zero speed has
been reached. Safe shut-down can be achieved, when the loss of the mains supply is not
rated as a fault and the control takes over the disabling of the servoamplifier.
In the normal situation, only the supply power is switched off in a safe manner.
The 24V auxiliary supply remains switched on.
SERVOSTAR®601...620 Installation Manual 23
General 03/04 Kollmorgen
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24 SERVOSTAR®601...620 Installation Manual
Kollmorgen 03/04 Installation
2 Installation
2.1 Important instructions
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 current of
l
the units. Carry out the wiring according to the connection diagram on page 28.
Make sure that the maximum permissible rated voltage at the terminals L1, L2, L3 or +DC,
l
–DC is not exceeded by more than 10% even in the most unfavorable case
(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 600
servo amplifiers only on an earthed (grounded) 3-phased supply system, to drive a synchro
nous servomotor.
The fusing of the AC supply input and the 24V supply is installed by the user (ð p.18).
l
Take care that the servo amplifier and motor are earthed (grounded) properly. Do not use
l
painted (non-conductive) mounting plates.
Route power and control cables separately. We recommend a separation of at least 200mm.
l
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 (ground) the shielding at both ends (ð p.30).
l Install all heavy-current cables with an adequate cross-section, as per EN 60204. (ð p.19).
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 areas (low impedance), with metallised connector housings or
shield connection clamps where possible. Notes on connection techniques can be found on
page 33 and in the application note “Cables and connectors”.
l Ensure that there is an adequate flow of cool, filtered air into the bottom of the switchgear ca-
binet. Observe page 19 .
l It is permissible to alter the servo amplifier settings by using the setup software.
Any other alterations will invalidate the warranty.
-
Caution
Never disconnect the electrical connections to the servoamplifier while it is live. In un
favorable circumstances this could result in destruction of the electronics.
Residual charges in the capacitors can have dangerous levels up to 300 seconds after
switching off the mains supply voltage. Measure the bus voltage at the DC-link pins
(+DC/-DC), and wait until the voltage has fallen below 40V.
Control and power connections can still be live, even when the motor is not rotating.
SERVOSTAR®601...620 Installation Manual 25
Installation 03/04 Kollmorgen
2.2 Assembly
Material:2or4hexagon socket screws to DIN 912, M5
Tool required:4mmAllen key
SERVOSTAR
601-610
SERVOSTAR
601-610
SERVOSTAR
614
SERVOSTAR
620
SERVOSTAR 600
26 SERVOSTAR®601...620 Installation Manual
Kollmorgen 03/04 Installation
2.2.1 Dimensions
SERVOSTAR 601/603/606/610
SERVOSTAR 614
SERVOSTAR 620
SERVOSTAR®601...620 Installation Manual 27
Installation 03/04 Kollmorgen
2.3 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 sensible 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 (with a lock-out, warning signs etc.).
The individual voltages will be switched on for the first time during setup.
Note !
The ground symbol
X, which you will find in all the wiring diagrams, indicates that
you must take care to provide an electrically conductive connection with the largest
possible surface area between the unit indicated and the mounting plate in the switchgear cabinet.
This connection is for the effective grounding of HF interference, and must not be
confused with the PE- symbol W (a protective measure to EN 60204).
Use the following connection diagrams:
— Power and control connections : Page 30
— Multi-axis systems, example : Page 31
— Resolver : Page 40
— High-resolution encoder : Page 41
— Encoder simulation ROD : Page 46
— Encoder simulation SSI : Page 47
— Master-slave interface : Page 48
— Pulse direction interface : Page 50
— RS232 / PC : Page 52
— CAN-interface : Page 53
— Option -AS- : Page 65
— Expansion card -I/O-14/08- : Page 71
— Expansion card PROFIBUS : Page 73
— Expansion card SERCOS : Page 75
— Expansion card DeviceNet : Page 77
— Expansion card Ethernet : Page 79
— Expansion card SAC : Page 81
— Expansion module -2CAN- : Page 85
28 SERVOSTAR®601...620 Installation Manual
Kollmorgen 03/04 Installation
The following notes should assist you to carry out the installation in a sensible sequence, without
overlooking anything important.
Site
Ventilation
Assembly
Cable selection
Grounding
Shielding
Wiring
In a closed switchgear cabinet. Observe page 19 .
The site must be free from conductive or corrosive materials.
For the mounting position in the cabinet ð p.26
Check that the ventilation of the servo amplifier is unimpeded
and keep within the permitted ambient temperature ð p.19 .
Keep the required space clear above and below the servo amplifier
ð p.26.
Assemble the servo amplifier and power supply close together
on the conductive, grounded mounting plate in the cabinet.
Select cables according to EN 60204 ð p.19
EMC-compliant (EMI) shielding and grounding (ð p.30)
Earth (ground) the mounting plate, motor housing and CNC-GND
of the controls.
Notes on connection techniques are on page 33
— Route power leads and control cables separately
— Wire the BTB/RTO contact in series into the safety
— loop of the installation
— Connect the digital control inputs to the servo amplifier
Final check
— Connect up AGND (also if fieldbuses are used)
— Connect the analog setpoint, if required
— Connect up the feedback unit (resolver and/or encoder)
— Connect the encoder simulation, if required
— Connect the expansion card (see according notes from page 63)
— Connect the motor leads
— Connect shielding to EMI connectors at both ends
— Use motor chokes (3YL20) for lead lengths >25m
— Connect motor-holding brake, connect shielding to EMI
— connectors at both ends
— If required, connect the external regen resistor
— (with fusing)
— Connect aux. supply
— (for max. permissible voltage values ð p.19)
— Connect main power supply
— (for max. permissible voltage values ð p.19)
— Connect PC (ð p.52).
— Final check of the implementation of the wiring,
— according to the wiring diagrams which have been used.
SERVOSTAR®601...620 Installation Manual 29
Installation 03/04 Kollmorgen
2.3.1 Connection diagram
Reference Safety Instructions (ð p.6) and
Use As Directed (ð p.12) !
SERVOSTAR 600
ð p.42
ð p.41
ð p.43
ð p.40
ð p.39
ð p.44
ð p.39
ð p.38
ð p.38
ð p.45
ð p.46
ð p.47
ð p.48
ð p.50
ð p.53
ð p.52
ð p.38
30 SERVOSTAR®601...620 Installation Manual
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