Kollmorgen SERVOSTAR 601, SERVOSTAR 620 Assembly And Installation Manual

Download

Page 1

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

Page 2

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

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

or stored, processed, copied or distributed by electronic means without the written permission of Danaher Motion Corporation.

Page 3

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

Page 4

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

Page 5

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

Page 6

Safety instructions 03/04 Kollmorgen

Safety Instructions

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.

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

Page 7

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.

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.

SERVOSTAR®601...620 Installation Manual 7

Page 8

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

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.

8 SERVOSTAR®601...620 Installation Manual

Page 9

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 :

see page (cross-ref.) l special emphasis

press once : move up one menu item, increase number by one

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

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

Page 10

03/04 Kollmorgen

This page has been deliberately left blank.

10 SERVOSTAR®601...620 Installation Manual

Page 11

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

Assembly / installation Chapter II

Interfaces Chapter III

Setup the servo amplifier Chapter IV

Accessories Chapter V

Transport, storage, maintenance, disposal of the servo amplifiers Chapter VI

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

Page 12

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 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.

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

Page 13

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

Page 14

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)

three instrument widths : 70 mm for 1.5A up to 10A rated current

100 mm for 14A rated current 120 mm for 20A rated current

wide range of rated voltage (3x208V

shield connection directly at the servo amplifier

two analog setpoint inputs

integrated CANopen (default 500 kBaud), for integration into CAN bus systems and for

–10%

to 3x480V

setting parameters for several amplifiers via the PC-interface of one amplifier

integrated RS232, electrically isolated, integrated pulse-direction interface

Open architecture

open hardware and software architecture

slot for an expansion card

integrated macro language, including compiler

prepared for all conceivable customer-specific extensions

+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

-2CAN- Expansion module, separated connectors for CAN bus and RS232, ð p. 84

Third party expansion cards (ModBus, FireWire, LightBus etc. - contact distributors for further information)

1.4.3 Operation directly from supply

Electrical supply

Directly off grounded 3 phase system,

230V 208V

-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

Fusing (e.g. fusible cutout) provided by the user

single-phase supply (e.g. for setup) is possible

+10%

,50Hz, ,60Hz

Auxiliary supply voltage 24VDC

Electrically isolated, internal fusing (3.15 AT), from an external 24VDC psu, e.g. with insulating transformer

Power input filter

Interference suppression filter for the supply input (to Class A) is integrated

Interference suppression filter for the 24V aux. supply (to Class A) is integrated

14 SERVOSTAR®601...620 Installation Manual

Page 15

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

Direct operation by means of two keys on the servo amplifier and a 3-character LED display

for status display in case there is no PC available

Fully programmable via RS232 interface

Power section

Power supply: B6 rectifier bridge, directly off 3-phase earthed (grounded)

supply system, integral power input filter and inrush circuit

All shielding connections directly on the amplifier

Output stage: IGBT- module with isolated current measurement

Regen circuit: with dynamic distribution of the regen power between several

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

Completely digital control

Digital current controller (space vector pulse-width modulation, 62.5 µs)

digital speed controller adaptable to most different load conditions (65µs or 250 µs)

Integral position controller with adaptation possibilities for customer needs (250 µs)

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

4 programmable digital inputs (normally, two are defined as limit-switch inputs)

2 programmable digital outputs

Freely programmable combinations of all digital signals

Integrated safety

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

Soft-start, overvoltage recognition, short-circuit protection, phase-failure monitoring

Temperature monitoring of servo amplifier and motor (when using our motors with our pre-assembled cables)

SERVOSTAR®601...620 Installation Manual 15

Page 16

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

16 SERVOSTAR®601...620 Installation Manual

Page 17

Kollmorgen 03/04 General

1.6 Components of a servo system

Control / PLC

24V supply

Option -AS-

terminals

SERVOSTAR 600

fuses

drive contactor

motor

SERVOSTAR®601...620 Installation Manual 17

Page 18

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%

Rated installed load for S1 operation kVA 124771014 Rated DC-link voltage V= 260 - 675

Rated output current (rms value, ± 3%)

Peak output current (max. ca. 5s, ± 3%)

1.5 3 6 10 10 14 20

rms

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%

,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

Page 19

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

Page 20

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

Page 21

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 80 200

Bint

) max. kW 0.4 1.2

Bext

) W 80 200

Bint

) max. kW 0.5 1.5

Bext

SERVOSTAR®601...620 Installation Manual 21

Page 22

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

Page 23

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

Page 24

General 03/04 Kollmorgen

This page has been intentionally left blank.

24 SERVOSTAR®601...620 Installation Manual

Page 25

Kollmorgen 03/04 Installation

2 Installation

2.1 Important instructions

Protect the servo amplifier from impermissible stresses. In particular, do not let any

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

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,

–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).

Take care that the servo amplifier and motor are earthed (grounded) properly. Do not use

painted (non-conductive) mounting plates.

Route power and control cables separately. We recommend a separation of at least 200mm.

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

Page 26

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

Page 27

Kollmorgen 03/04 Installation

2.2.1 Dimensions

SERVOSTAR 601/603/606/610

SERVOSTAR 614

SERVOSTAR 620

SERVOSTAR®601...620 Installation Manual 27

Page 28

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

Page 29

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

Page 30

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.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

Page 31

Kollmorgen 03/04 Installation

2.3.2 Example of connections for multi-axis system

Reference Safety Instructions (ð p.6) and Use As Directed (ð p.12) !

SERVOSTAR 600

Power supply

SERVOSTAR 600

SERVOSTAR®601...620 Installation Manual 31

Page 32

Installation 03/04 Kollmorgen

2.3.3 Pin assignments

32 SERVOSTAR®601...620 Installation Manual

Page 33

Kollmorgen 03/04 Installation

2.3.4 Notes on connection techniques

Please consider our application note “Cables and connectors”

2.3.4.1 Shielding connection to the front panel

Remove the outer covering of the cable and the shielding braid from the cores for the required length. Secure the cores with a cable tie.

Remove the outer covering of the cable over a length of about 30mm, without damaging the shielding braid.

Pull a cable tie through the slot in the shielding rail (front panel) of the servo amplifier.

SERVOSTAR 600

Use the cable tie to clamp the shielding braid of the cable firmly to the shielding rail.

SERVOSTAR®601...620 Installation Manual 33

Page 34

Installation 03/04 Kollmorgen

2.3.4.2 Technical data for connecting cables

Further information on the chemical, mechanical and electrical characteristics of the cables can be obtained from our customer service.

Observe the restrictions in the chapter "Conductor cross-sections" on page 19 .

Insulation material

Sheathing - PUR (polyurethane, code 11Y) Core insulation - PETP (polyesteraphtalate, code 12Y)

Capacitance

Motor cable - less than 150 pF/m RES-/Encoder-cable - less than 120 pF/m

Technical data

— The brackets in the cable designation indicate the shielding. — All cables are suitable for use as trailing cables. — The technical data refer to the use as moveable cables.

Operating life : 1 million bending cycles

Operation-

Cores

[mm²]

(4x1.0) number -30 / +80 -22 / 176 10 100 (4x1.5) number -30 / +80 -22 / 176 10,5 105 (4x2.5) number -30 / +80 23 / 158 12,6 125

(4x4) number -30 / +80 23 / 158 14,7 150 (4x1.0+(2x0.75)) color -30 / +80 -22 / 176 10,5 100 (4x1.5+(2x0.75)) number -30 / +80 14 / 176 11,5 120

(4x2.5+(2x1)) color -30 / +80 -22 / 176 14,2 145

(4x2x0,25) color (7x2x0.25) color

Coretype

Temperature

range

[°C]

-30 / +80

Operation-

Temperature

range

[°F]

-22 / 176 7,7 70

-22 / 176 9,9 80

Outside

diameter

[mm]

Bending

radius

[mm]

Remarks

twisted

pairs

34 SERVOSTAR®601...620 Installation Manual

Page 35

Kollmorgen 03/04 Installation

2.4 Setup software

2.4.1 General

This chapter describes the installation of the setup software DRIVE.EXE for the SERVOSTAR 600 digital servo amplifiers.

We offer training and familiarization courses on request.

2.4.1.1 Use as directed

The setup software is intended to be used for setting up and storing the operating parameters for the SERVOSTAR 600 series of servo amplifiers. The attached servo amplifier can be setup with the assistance of the software - during this process the drive can be controlled directly by the service functions.

Only professional personnel who have the relevant expertise described on page 11 are permitted to carry out online parameter setting for a drive which is running. Sets of data which are stored on data media are not safe against unintended alteration by other persons. After loading a set of data you must therefore check all parameters thoroughly before enabling the servo amplifier.

2.4.1.2 Software description

The servo amplifiers must be adapted to the requirements of your installation. Usually you will not have to carry out this parameter setting yourself on the amplifier, but on a PC, with the assistance of the setup software. The PC is connected to the servo amplifier by a null-modem cable. The setup software provides the communication between SERVOSTAR 600 and the PC.

You will find the setup software on the accompanying CD-ROM and at the Danaher Motion web site in the Danaher Motion download area.

With very little effort you can alter parameters and instantly observe the effect on the drive, since there is a continuous (online) connection to the amplifier. Simultaneously, important actual values are read out from the amplifier and displayed on the PC monitor (oscilloscope function).

Any interface modules (expansion cards) which may be built into the amplifier are automatically recognized, and the additional parameters which are required for position control or motion-block definition are made available.

Sets of data can be stored on data media (archived) and loaded again. Sets of data which are sto red on data media can be printed.

We supply you with motor-specific default sets of data for the most common combinations of servo amplifier and motor. In most applications you will be able to use these default values to get your drive running without any problems.

SERVOSTAR®601...620 Installation Manual 35

Page 36

Installation 03/04 Kollmorgen

2.4.1.3 Hardware requirements

The PC interface (X6, RS232) of the servo amplifier is connected to the serial interface of the PC by a null-modem cable (not a null-modem link cable !)(ð p.52).

Connect / disconnect the interface cable only when the supply is switched off for both the PC and the servo amplifier.

The interface in the servo amplifier is electrically isolated by an optocoupler, and is at the same potential as the CANopen interface.

Minimum requirements for the PC:

Processor : 80486 or higher Operating system : WINDOWS 95(c) / 98 / 2000 / ME / XP, WINDOWS NT 4.0 Graphics adapter : Windows compatible, color Drives : hard disk with at least 5 MB free space

CD-ROM drive Main memory : at least 8MB Interface : one free serial interface (COM1:, 2:, 3: or COM4:)

2.4.1.4 Operating systems

WINDOWS 95(c) / 98 / 2000 / ME / NT / XP

DRIVE.EXE is executable under WINDOWS 95(c) / 98 / 2000 / ME / XP and WINDOWS NT 4.0. The HTML help system is not available under WINDOWS 95a and 95b.

WINDOWS FOR WORKGROUPS 3.xx, DOS, OS2 Unix, Linux

DRIVE.EXE is not executable under WINDOWS 3.xx, DOS, OS2, Unix and Linux. In emergency, operation is possible through an ASCII terminal emulation (without user-interface). Interface settings : 9600 bps, no parity, no handshake

2.4.2 Installation under WINDOWS 95 / 98 / 2000 / ME / NT / XP

An installation program called SETUP.EXE can be found on the CD-ROM which makes it easy to install the setup software on your PC.

Connection to the serial interface of the PC:

Connect the interface cable to a serial interface on your PC and the PC interface (X6) of the SERVOSTAR 600 (ð p.52).

Switch-on:

Switch on your PC-AT and the monitor. After the start phase (boot-up) is finished, the Windows user-interface appears on the screen.

Installation: Click on START (Taskbar), then on Run. Enter the program call in the entry window:

x:\setup.exe (with x= the correct drive letter for CD-ROM drive).

Click on OK and follow the instructions.

Setting up the graphics card (font size)

Please note that the screen resolution must at least be 800x600 Pixel. Click on the desktop with the right mouse button. The dialogue window “Properties” will appear. Select the file card “Settings”. Set the Font size to “Small Fonts”. Follow the instructions provided by the system.

36 SERVOSTAR®601...620 Installation Manual

Page 37

Kollmorgen 03/04 Interfaces

3 Interfaces

All important interfaces are shown in this Chapter. The precise location of the connectors and terminals can be seen on page 32. The block diagram below is just an overview.

SERVOSTAR®601...620 Installation Manual 37

Page 38

Interfaces 03/04 Kollmorgen

3.1 Power supply

3.1.1 Mains supply connection (X0)

— Directly to earthed (grounded) 3~ supply, integrated EMI filter

— Fusing (e.g. fusible cut-outs) provided by the user ð p.18

SERVOSTAR 600

3.1.2 24V auxiliary supply (X4)

— Electrically isolated, external 24VDC supply, e.g. with insulating transformer

— Required current rating ð p.18

— Integrated EMI filter for the 24V auxiliary supply

SERVOSTAR 600

3.1.3 DC-link (X7)

Can be connected in parallel. A patented circuit distributes the regen power among all the amplifiers connected to the same DC-link circuit. (Connection example ð p.31).

38 SERVOSTAR®601...620 Installation Manual

Page 39

Kollmorgen 03/04 Interfaces

3.2 Motor connection with brake (X9)

Lead length £ 25m

SERVOSTAR 600

Lead length >25m For lead lengths above 25m the choke box 3YL-20 must be wired into the motor lead, close to the amplifier.

SERVOSTAR 600

3.3 External regen resistor (X8)

Remove the plug-in link between the terminals X8/1 (-RB) and X8/2 (+R

SERVOSTAR 600

bint

SERVOSTAR®601...620 Installation Manual 39

Page 40

Interfaces 03/04 Kollmorgen

3.4 Feedback

3.4.1 Resolver connection (X2)

Our rotatory servomotors have 2-pole hollow-shaft resolvers built in as a standard. It is possible to connect 2...36-pole resolvers to the SERVOSTAR 600. If lead lengths of more than 100m are planned, please contact our customer service. The thermostat contact in the motor is connected via the resolver cable to the SERVOSTAR 600 and evaluated there.

SERVOSTAR 600

SubD9

12pol.round

colors for European cables only

40 SERVOSTAR®601...620 Installation Manual

Page 41

Kollmorgen 03/04 Interfaces

3.4.2 Encoder (X1)

As an option, our servomotors can be fit with a single-turn or multiturn sine-cosine encoder. Prefer red types are ECN1313 and EQN1325.

This encoder is used by the SERVOSTAR 600 as a feedback device for drive tasks which require highly precise positioning or extremely smooth running.

If lead lengths of more than 50m are planned, please consult our customer service.

The thermostat contact in the motor is connected via the encoder cable to the SERVOSTAR 600 and evaluated there.

SERVOSTAR 600

SubD15

17pol.round

colors for European cables only

SERVOSTAR®601...620 Installation Manual 41

Page 42

Interfaces 03/04 Kollmorgen

3.5 Control signals, monitor signals

3.5.1 Analog inputs (X3)

The servo amplifier is equipped with two differential inputs for analog setpoints which are programmable. AGND (X3/1) must always be joined to the CNC-GND of the controls as a ground reference.

Technical characteristics

— Differential-input voltage max. ± 10 V — Resolution 1.25 mV — Ground reference : AGND, terminal X3/1 — Input resistance 20 kW — Common-mode voltage range for both inputs ± 10 V

SERVOSTAR 600

Input analog-in.1 (terminals X3/4-5)

Differential input voltage max. ± 10 V, resolution 14-bit, scalable Standard setting : speed setpoint

Input analog-in.2 (terminals X3/6-7)

Differential input voltage max. ± 10 V, resolution 12-bit, scalable Standard setting : torque setpoint

Application examples for setpoint input analog-in.2: — adjustable external current limit — reduced-sensitivity input for setting-up/jog operation — pre-control / override

Fixing the direction of rotation

Standard setting : clockwise rotation of the motor shaft (looking at the shaft end) — Positive voltage between terminal X3/4 (+ ) and terminal X3/5(-)or — Positive voltage between terminal X3/6 (+ ) and terminal X3/7(-)

To reverse the direction of rotation, swap the connections to terminals X3/4-5 and. X3/6-7 or change the ROT. DIRECTION parameter in the “Speed controller” screen.

42 SERVOSTAR®601...620 Installation Manual

Page 43

Kollmorgen 03/04 Interfaces

3.5.2 Analog outputs (X3)

Technical characteristics

— Reference ground is analog-GND (AGND, terminal X3/1 and X3/10) — Output resistance : 2.2kW — Output voltage ±10V — Resolution : 10 bit.

SERVOSTAR 600

Programmable analog outputs Analog-out 1 / Analog-out 2

The terminals X3/8 (Analog-out 1) or X3/9 (Analog-out 2) can have the following analog signals assigned to them:

Standard setting :

Analog-out 1 : Tachometer voltage VTA (speed) The output delivers ±10V at the preset limit speed.

Analog-out 2 : Current setpoint IDC (torque) The IDC-monitor delivers ± 10V at the preset peak current Ipeak (effective r.m.s. value).

You can use the terminals X3/8 (Analog-out 1) or X3/9 (Analog-out 2) to output converted analog values for digital measurements which are contained in the servo amplifier.

You can find a list of pre-programmed functions on the "analog I/O" screen of our setup software.

SERVOSTAR®601...620 Installation Manual 43

Page 44

Interfaces 03/04 Kollmorgen

3.5.3 Digital control inputs (X3)

All digital inputs are electrically isolated through optocouplers. Technical characteristics

— Reference ground is digital-GND (DGND, terminal X3/18) — The logic is PLC-compatible according to IEC 1131

SERVOSTAR 600

ENABLE input

The output stage of the servo amplifier is activated by the enable signal (terminal X3/15, input 24V, active-high). In the inhibited state (low signal) the motor which is attached does not have any torque.

Programmable digital inputs :

You can use the digital inputs PSTOP / NSTOP / DIGITAL-IN1 and DIGITAL-IN2 to initiate preprogrammed functions that are stored in the servo amplifier. You can find a list of pre-programmed functions on the "digital I/O" screen of our setup software. If an input is freshly assigned to a pre-programmed function, then the data set must be stored in the EEPROM of the servo amplifier, and the 24V auxiliary supply of the servo amplifier must be switched off and on again (to reset the amplifier software).

Limit-switches PSTOP / NSTOP

Terminals X3/13 and X3/14 are normally programmed for the connection of limit switches. If these inputs are not needed for the connection of limit switches, then they are programmable for other input functions.

Limit-switch positive/negative (PSTOP / NSTOP, terminals X3/13 and X3/14), high level in normal operation (fail-safe for a cable break).

A low signal (open) inhibits the corresponding direction of rotation, the ramp function remains

effective.

DIGITAL-IN 1 / DIGITAL-IN 2

The digital inputs on terminal X3/11 (DIGITAL-IN 1) or terminal X3/12 (DIGITAL-IN 2) can be logi cally combined in a pre-programmed function.

44 SERVOSTAR®601...620 Installation Manual

Page 45

Kollmorgen 03/04 Interfaces

3.5.4 Digital control outputs (X3)

Technical characteristics

— Reference ground is digital-GND (DGND, terminal X3/18) — All digital outputs are floating — DIGITAL-OUT1 and 2 : PLC compatible according to IEC 1131

BTB/RTO : Relay output, max. 30VDC or 42VAC, 0.5A

SERVOSTAR 600

Ready-to-operate contact BTB/RTO

Operational readiness (terminals X3/2 and X3/3 ) is signaled by a floating relay contact. The contact is closed when the servo amplifier is ready for operation, the signal is not influenced by the enable signal, the I²t- limit, or the regen threshold.

All faults cause the BTB/RTO contact to open and the switch-off of the output stage.

A list of the error messages can be found on page 60.

Programmable digital outputs DIGITAL-OUT1/2:

You can use the digital outputs DIGITAL-OUT1 (terminal X3/16) and DIGITAL-OUT2 (terminal X3/17) to output messages from pre-programmed functions that are stored in the servo amplifier. You can find a list of pre-programmed functions on the "digital I/O" screen of our setup software.

If an input is freshly assigned to a pre-programmed function, then the data set must be stored in the EEPROM of the servo amplifier, and the 24V auxiliary supply of the servo amplifier must be swit ched off and on again (to reset the amplifier software).

Evaluate the outputs via inverting interface relays (see connection diagram), for example Phönix DEK-REL-24/I/1 (turn-on delay 6 ms, turn-off delay 16ms).

The described logic in the SETUP SOFTWARE manual and the online help refers to the output of the inverting interface relays. Consider the delay of the applied relay !

SERVOSTAR®601...620 Installation Manual 45

Page 46

Interfaces 03/04 Kollmorgen

3.6 Encoder simulations

3.6.1 Incremental encoder simulation - A quad B position output (X5)

The incremental-encoder interface is part of the package supplied. Select the encoder function ROD (screen page “Encoder”). In the servo amplifier, the position of the motor shaft is calculated from the cyclic-absolute signals of the resolver or encoder. Incremental-encoder compatible pulses are generated from this information. Pulses are output on the SubD-connector X5 as two signals, A and B, with 90° phase difference and a zero pulse.

The resolution (lines before quadrature) can be changed with the RESOLUTION parameter:

Encoder function (ENCMODE) Feedback system Resolution Zero position

Resolver 16...1024

ROD (1)

ROD interpolation (3)

EnDat / HIPERFACE

Incremental encoders wit hout absolute data channel

16...4096 and

8192...524288 (2n)

4...128

TTL lines per sine line

You can also adjust and store the position of the zero pulse within one mechanical turn (parameter NI-OFFSET).

one per revolution (only if A=B=1) one per revolution (only if A=B=1) analog pass through from X1 to X5

The drivers are supplied from an internal supply voltage.

PGND must always be connected to the controls.

The max. admissible cable length is 10 m.

Connections and signal description for incremental-encoder interface :

SERVOSTAR 600

46 SERVOSTAR®601...620 Installation Manual

Page 47

Kollmorgen 03/04 Interfaces

3.6.2 SSI encoder simulation - position output (X5)

The SSI interface (synchronous serial absolute-encoder simulation) is part of the delivered package. Select the encoder function SSI (screen page “Encoder”). In the servo amplifier, the posi tion of the motor shaft is calculated from the cyclically absolute signals from the resolver or encoder. This information is used to create a position output in a format that is compatible with the standard SSI-absolute-encoder format. 24 bits are transmitted. SINGLE TURN selected: The upper 12 bits are fixed to ZERO, the lower 12 bits contain the posi tion information. For 2-pole resolvers, the position value refers to the position within one turn of the motor, for 4-pole resolvers it is within half a turn, and for 6-pole resolvers it is within a third of a turn. Exception bits are set to 1 (data invalid!) until a homing run is performed.

: If an encoder with a commutation track is used as the feedback unit, then the upper 12

MULTI TURN selected: The upper 12 bits contain the number of motor turns, the lower 12 bits con tain the position information.

The signal sequence can be output in Gray code (standard) or in binary code (parameter SSI-CODE). The servo amplifier can be adjusted to the clock frequency of your SSI-evaluation with the SSI-TAKT parameter (200 kHz or 1.5MHz and inverted).

Drivers are supplied from internal supply voltage. PGND must always be connected.

Connection and signal description for SSI interface :

The count direction for the SSI interface is upwards when the motor shaft is rotating clockwise (loo king at the shaft end).

SERVOSTAR 600

SERVOSTAR®601...620 Installation Manual 47

Page 48

Interfaces 03/04 Kollmorgen

3.6.3 Interface for master-slave operation, encoder input

This interface can be used to link several SERVOSTAR amplifiers together in master-slave operation. The parameters for the slave amplifiers are set up with the aid of the setup software. The resolution (no. of pulses/turn) can be adjusted. The analog setpoint inputs are out of action.

AGND and DGND (connector X3) must be joined together !

Signal diagram (for encoders with RS422 or 24V output)

3.6.3.1 Connection to a SERVOSTAR master, 5V signal level (X5)

This interface can be used to link several SERVOSTAR amplifiers together in master-slave operation. Up to 16 slave amplifiers can be controlled by the master via the encoder output. The connector X5 must be used.

Edge frequency: 1,5MHz, slew rate tv £ 0,1µs

AGND and DGND (connector X3) must be joined together !

SERVOSTAR 600

48 SERVOSTAR®601...620 Installation Manual

Page 49

Kollmorgen 03/04 Interfaces

3.6.3.2 Connection to encoders with 24V signal level (X3)

This interface can be used to operate the SERVOSTAR as a slave, mastered by an encoder with 24V signal level (master-slave operation). The digital inputs DIGITAL-IN 1 and 2 at connector X3 must be used.

Edge frequency: 250 kHz, slew rate tv £ 0,1µs

AGND and DGND (connector X3) must be joined together !

SERVOSTAR 600

3.6.3.3 Connection to a sine-cosine encoder (X1)

This interface can be used to operate the SERVOSTAR as a slave, mastered by a sine-cosine encoder (master-slave operation). The connector X1 must be used. Edge frequency: 250 kHz

AGND and DGND (connector X3) must be joined together !

The cable colors in the wiring diagram are valid for the European 4x2x0,25mm² cable.

SERVOSTAR 600

SERVOSTAR®601...620 Installation Manual 49

Page 50

Interfaces 03/04 Kollmorgen

3.7 Interface for stepper-motor controls (pulse-direction)

This interface can be used to connect the servo amplifier to a third-party stepper-motor controller. The parameters for the servo amplifier are set up with the aid of the setup software (electrical gea ring). The number of steps can be adjusted, so that the servo amplifier can be adjusted to the pulse-direction signals of any stepper-motor controller. Various monitoring signals can be output. The analog setpoint inputs are out of action.

AGND and DGND (connector X3) must be joined together !

Speed profile and signal diagram

Note: Encoder Input A quad B offers more EMI suppression.

50 SERVOSTAR®601...620 Installation Manual

Page 51

Kollmorgen 03/04 Interfaces

3.7.1 Connection to stepper-motor controller with 5V signal level (X5)

This interface can be used to connect the servo amplifier to a stepper-motor controller with 5V sig nal level. The connector X5 must be used. Edge frequency: 1,5MHz

AGND and DGND (connector X3) must be joined together !

SERVOSTAR 600

3.7.2 Connection to stepper-motor controller with 24V signal level (X3)

This interface can be used to connect the servo amplifier to a stepper-motor controller with 24V signal level. The digital inputs DIGITAL-IN 1 and 2 at connector X3 must be used. Edge frequency: 250 kHz

AGND and DGND (connector X3) must be joined together !

SERVOSTAR 600

SERVOSTAR®601...620 Installation Manual 51

Page 52

Interfaces 03/04 Kollmorgen

3.8 RS232 interface, PC connection (X6)

The setting of the operating, position control, and motion-block parameters can be carried out with an ordinary commercial PC.

Connect the PC interface (X6) of the servo amplifier while the supply to the equipment is swit

ched off via a normal commercial 3-core null-modem cable to a serial interface on the PC.

Do not use a null-modem link cable!

The interface is electrically isolated through an optocoupler, and is at the same potential as the CANopen interface.

The interface is selected and set up in the setup software. Further notes can be found on page 35.

With the optional expansion card -2CAN- the two interfaces for RS232 and CAN, which otherwise use the same connector X6, are separated onto two connectors (ð p.84).

SERVOSTAR 600

Interface cable between the PC and servo amplifiers of the

SERVOSTAR 600 series:

(View : looking at the face of the built-in SubD connectors, this corresponds to the solder side of the SubD sockets on the cable)

52 SERVOSTAR®601...620 Installation Manual

Page 53

Kollmorgen 03/04 Interfaces

3.9 CANopen Interface (X6)

The interface for connection to the CAN bus (default 500 kBaud). The integrated profile is based on the communication profile CANopen DS301 and the drive profile DSP402. The following functions are available in connection with the integrated position controller: Jogging with variable speed, reference traverse (zeroing), start motion task, start direct task, digital setpoint provision, data transmission functions and many others. Detailed information can be found in the CANopen manual. The interface is electrically isolated by optocouplers, and is at the same potential as the RS232 interface. The analog setpoint inputs can still be used. With the optional expansion card -2CAN- the two interfaces for RS232 and CAN, which otherwise use the same connector X6, are separated onto two connectors ð p.84).

If the analog setpoint inputs are not used, then AGND and DGND (connector X3) must be joi ned together !

SERVOSTAR 600

CAN bus cable

To meet ISO 11898 you should use a bus cable with a characteristic impedance of 120 W. The maximum usable cable length for reliable communication decreases with increasing transmission speed. As a guide, you can use the following values which we have measured, but they are not to be taken as assured limits: Cable data: Characteristic impedance 100-120 W

Cable capacitance max. 60 nF/km Lead resistance (loop) 159.8 W/km

Cable length, depending on the transmission rate

Transmission rate (kbaud) max. cable length (m)

1000 20

500 70 250 115

Lower cable capacitance (max. 30 nF/km) and lower lead resistance (loop, 115 W/km) make it possible to achieve greater distances. (Characteristic impedance 150 ± 5WÞterminating resistor 150 ± 5W). For EMC reasons, the SubD connector housing must fulfill the following conditions:

— metal or metallised housing — provision for cable shielding connection in housing, large-area connection

SERVOSTAR®601...620 Installation Manual 53

Page 54

Interfaces 03/04 Kollmorgen

This page has been intentionally left blank.

54 SERVOSTAR®601...620 Installation Manual

Page 55

Kollmorgen 03/04 Setup

4 Setup

4.1 Important notes

Only professional personnel with extensive knowledge in the fields of electrical/ drive technology are allowed to setup the servo amplifier.

The procedure for setup is described as an example. Depending on the application, a different procedure may be sensible or necessary.

In multi-axis systems, setup each servo amplifier individually.

Caution ! Check that all live connecting elements are protected from accidental contact. Deadly voltages can be present, up to 900V. Never disconnect any of the electrical connections to the servo amplifier while it is live. Capacitors can still have residual charges with dangerous levels up to 300 seconds af ter switching off the supply power. Heat sinks and front panels of the amplifier can reach a temperature of up to 80°C(176°F) in operation. Check (measure) the heat sink temperature. Wait until the heat sink has cooled down below 40°C (104°F) before touching it.

Warning ! If the servo amplifier has been stored for longer than 1 year, then the DC-link capacitors will have to be re-formed. To do this, disconnect all the electrical connections. Supply the servo amplifier for about 30 min. from single-phase 230VAC to the termi nals L1 / L2. This will re-form the capacitors.

Further information on setup : The adaptation of parameters and the effects on the control loop behavior are descri bed in the manual for the setup software and in the online help of the setup software. The setup of the expansion card (if present) is described in the corresponding manual on the CD-ROM. We can provide further know-how through training courses (on request).

SERVOSTAR®601...620 Installation Manual 55

Page 56

Setup 03/04 Kollmorgen

The following instructions should help you to carry out the setup in a sensible order, without any hazards to people or machinery.

Check installation

Inhibit

Enable signal

Switch on 24V

auxiliary voltage

Switch on PC,

start setup software

Check displayed

parameters,

and correct

if necessary

Supply voltage : set to the actual mains supply voltage Rated motor voltage : at least as high as the DC-link voltage of the amplifier Motor pole-no. : must match the motor (see motor manual) Feedback : must match the feedback unit in the motor I

RMS

PEAK

Limit speed : maximum is the rated motor speed (on nameplate) Regen power : maximum is the permitted regen resistor dissipation Station address : unique address (see setup software manual)

ð p. 25ff. Disconnect the servo amplifier from the supply.

0V on terminal X3/15 (Enable)

24VDC on terminal X4/1, ground on terminal X4/3 After the initialization procedure (about 0.5 sec.) the status is shown in the LED display (ð p.58)

Select the interface to which the servo amplifier is connected, The parameters which are stored in the SRAM of the servo amplifier are transferred to the PC.

Caution ! It is especially important to check the following parameters. If you do not set them properly, parts of the system can be damaged or destroyed.

: maximum is the motor standstill current I0(on nameplate) : maximum is 4 x motor standstill current I

Check

safety devices

Switch on

supply power

Apply 0V setpoint

Enable

Setpoint

Optimization

Setup

the expansion card

Caution ! Make sure that any unintended movement of the drive cannot cause danger to machinery or personnel.

through the ON/OFF button of the contactor control

0V on terminals X3/4-5 or X3/6-7

(500 ms after switching on the supply power) 24VDC on terminal X3/15, motor stands with standstill torque M

apply a small analog setpoint, about 0.5V is recommended, to terminals X3/4-5 or X3/6-7

If the motor oscillates, the parameter Kp in the menu page “speed controller” must be reduced

- the motor is endangered!

Optimize speed, current and position controllers

see setup instructions in the corresponding manual on the CD-ROM

56 SERVOSTAR®601...620 Installation Manual

Page 57

Kollmorgen 03/04 Setup

4.2 Parameter setting

A default parameter set is loaded into your servo amplifier by the manufacturer. This contains valid and safe parameters for the current and speed controllers. A database for motor parameters is stored in the servo amplifier. During setup you must select the data set for the motor that is connected and store it in the servo amplifier. For most applications these settings will already provide good to very good control loop characteristics. An exact description of all parameters and the possibilities for optimizing the control loop character istics can be found in the manual “Setup Software DRIVE.EXE”.

4.2.1 Multi-axis systems

Using a special multilink cable, you can connect up to six servo amplifiers together and to your PC : Cable type -SR6Y- (for 4 amplifiers) or -SR6Y6- (for 6 amplifiers)

With the PC connected to just one servo amplifier you can now use the setup software to select all four / six amplifiers through the preset station addresses and set up the parameters.

Cable -SR6Y-

COMx

RS232

Add.:

4.2.1.1 Node address for CAN-bus

During setup it makes sense to preset the station addresses for the individual amplifiers and the baud rate for communication by means of the keypad on the front panel (ð p.59).

4.2.1.2 Baud rate for CAN-bus

After changing the station address and baud rate you must turn the 24V auxiliary supply of the servo amplifier off and on again.

PC/CAN

Baud rate identical for all amplifiers,

CAN

Add.:

see table below

CAN

Add.:

CAN

Add.:

Coding of the baud rate in the LED display :

Coding Baud rate in kbit/s Coding Baud rate in kbit/s

0 10 5 250 1 20 6 333 2 50 7 500 3 100 8 666 4 125 9 800

10 1000

SERVOSTAR®601...620 Installation Manual 57

Page 58

Setup 03/04 Kollmorgen

4.2.2 Key operation / LED display

In this chapter the two possible operation menus and the use of the keys in the front panel are shown. Normally, the SERVOSTAR 600 only places the standard menu at your disposal. If you want to attend the amplifier via the detailed menu, you must keep the right key pressed while swit ching on the 24V-supply.

4.2.2.1 Key operation

The two keys can be used to perform the following functions:

Key symbol Functions

press once : go up one menu item, increase number by one

press twice in rapid succession : increase number by ten press once : go down one menu item, decrease number by one press twice in rapid succession : decrease number by ten press and hold right key, then press left key as well : enter a number, return function name

4.2.2.2 Status display

58 SERVOSTAR®601...620 Installation Manual

Page 59

Kollmorgen 03/04 Setup

4.2.2.3 Standard menu structure

ð p.57

4.2.2.4 Extended menu structure

ð p.57

SERVOSTAR®601...620 Installation Manual 59

Page 60

Setup 03/04 Kollmorgen

4.3 Error messages

Errors which occur are shown in coded form by an error number in the LED display on the front panel. All error messages result in the BTB/RTO contact being opened, and the output stage of the amplifier being switched off (motor loses all torque). If a motor-holding brake is installed, it will be activated.

Number Designation Explanation

F01*

F02*

F03*

F04

F05*

F06

F07

F08*

F09 F10 F11 F12

F13*

F14 F15

F16*

F17

F18

F19*

F20 F21

F22

F23 F24 F25 F26 F27 F28 F29 F30 F31 F32

heat sink temperature

overvoltage

following error message from the position controller feedback cable break, short circuit, short to ground

undervoltage

motor temperature

aux. voltage internal aux. voltage not OK overspeed motor running away, speed is too high EEPROM checksum error Flash-EPROM checksum error brake cable break, short circuit, short to ground motor phase motor phase missing (cable break or similar) internal temperature internal temperature too high output stage fault in the output stage I²t max I²t max. value exceeded supply - BTB/RTO 2 or 3 phases missing in the supply feed

A/D converter

regen regen circuit faulty or incorrect setting

supply phase

Slot fault Hardware fault of the expansion card Handling fault Software fault of the expansion card Short circuit to earth (ground) CAN Bus off CAN Bus total communication error Warning Warning displays as error Commutation error Encoder systems only Limit switch Homing error (hardware limit switch reached) AS-option Operating error for AS-option reserved reserved SERCOS SERCOS error Emerg. Stop Timeout Emerg. Stop Timeout reserved reserved system error system software not responding correctly

heat sink temperature too high limit is set by manufacturer to 80°C (176°F) overvoltage in DC-link limit depends on the mains supply voltage

undervoltage in DC-link limit is set by manufacturer to 100V motor temperature too high limit is set by manufacturer to145°C (293°F)

error in the analog-digital conversion, usually caused by excessive EMI

a supply phase is missing (can be switched off for 2-phase operation)

SERVOSTAR 640/670 only: short circuit to earth (ground)

* = These error messages can be cancelled by the ASCII command CLRFAULT, without executing a reset. If only these errors are present, and the RESET button or the I/O-function RESET is used, the CLRFAULT com mand is also all that is carried out.

60 SERVOSTAR®601...620 Installation Manual

Page 61

Kollmorgen 03/04 Setup

4.4 Warning messages

Faults which occur, but which do not cause a switch-off of the amplifier output stage (BTB/RTO con tact remains closed), are indicated in the LED display on the front panel by a coded warning num

ber.

Number Designation Explanation

n01

n02 n03* n04*

n05 n06* n07*

n08

n09 n10* n11*

n12

n13*

n14

n15

n16-n31

n32

I²t I²t threshold exceeded regen power preset regen power reached S_fault exceeded preset contouring error response monitoring response monitoring (fieldbus) is active supply phase supply phase missing Sw limit-switch 1 passed software limit-switch 1 Sw limit-switch 2 passed software limit-switch 2 motion task error a faulty motion task was started no reference point no reference point set at start of motion task PSTOP PSTOP limit-switch activated NSTOP NSTOP limit-switch activated

Only sine encoders with ENDAT or HIPERFACE format.

motor default values loaded

expansion card expansion card not functioning correctly

SinCos feedback

Table error Velocity current table INXMODE 35 error reserved reserved Firmware beta version The firmware is an unreleased beta version Reset RESET is active at DIGITAL IN x

Motor number stored in encoder memory different from number stored in drive memory, default parameters loaded

Sine encoder “wake & shake mode” , ends if drive is enabled and wake & shake is done.

* = These warning messages lead to a controlled shut-down of the drive (braking with the emergency ramp)

SERVOSTAR®601...620 Installation Manual 61

Page 62

Setup 03/04 Kollmorgen

This page has been intentionally left blank.

62 SERVOSTAR®601...620 Installation Manual

Page 63

Kollmorgen 03/04 Extensions / Accessories

5 Extensions / Accessories

5.1 Option -AS-, restart lock for personal safety

5.1.1 Advantages of the -AS- option

A frequently required application task is the protection of personnel against the restarting of drives. This can not be achieved by an electronic inhibit, but must be implemented with mechanical ele ments (positively driven relay contacts).

To get round this problem, up to now either the main contactor in the mains supply line was swit ched off, or another contactor was used to disconnect the motor from the servo amplifier.

The disadvantages of this method are :

— the DC-link has to be charged up again at restart — wear on the contacts of the contactors, caused by switching under load — extensive wiring required, with additional switching components

The -AS- option avoids these disadvantages. A safety relay in the servo amplifier is activated either by the PLC or manually. Positively driven contacts provide a safe disconnection of the servo ampli fier, the setpoint input of the servo amplifier is inhibited, and a signal is sent to the safety circuit.

The suggested circuits (ð p. 66) fulfills safety category 1 (EN 954-1). You can fulfill safety category 3, if you use a mains contactor with suited supervision.

Advantages of the -AS- option :

— the DC-link remains charged up, since the mains supply line remains active — only low voltages are switched, so there is no contact wear — very little wiring is required — the functionality and the personnel safety when using the circuit recommendations

in this documentation have been approved by the Trade Liability Association.

5.1.2 Functional description

An additional connector (X10) is mounted on the front panel of the SERVOSTAR 600. The coil connections and a make (n.o.) contact of a safety relay are made available through 4 terminals on this connector.

The 24VDC safety relay in the servo amplifier (approved) is controlled externally. All the relay con tacts have positive action.

Two contacts switch off the driver supply of the output stage in the servo amplifier, and short the internal setpoint signal to AGND (0 V).

The make (n.o.) contact used for monitoring is looped into the control circuit.

If the safety relay is not energized, then the monitoring contact is open and the servo amplifier is ready for operation.

If the drive is electronically braked, the servo amplifier is disabled and the motor-holding brake is on, then the safety relay is energized (manually or by the controls).

The supply voltage for the driver circuit of the output stage is switched off in a safe manner, the internal setpoint is shorted to 0V, and the monitoring contact bridges the safety logic in the control circuit of the system (monitoring of protective doors etc.)

Even if the output stage or driver is destroyed, it is impossible to start the motor.

If the safety relay itself is faulty, then the monitoring contact cannot bridge the safety logic of the system. Opening the protective devices will then switch off the system.

SERVOSTAR®601...620 Installation Manual 63

Page 64

Extensions / Accessories 03/04 Kollmorgen

5.1.3 Block diagram

5.1.4 Signal diagram (sequence)

64 SERVOSTAR®601...620 Installation Manual

Page 65

Kollmorgen 03/04 Extensions / Accessories

5.1.5 Installation / Setup

5.1.5.1 Safety instructions

Observe "Use as directed" on page 12.

The monitoring contacts (KSO1/2) for each amplifier with an -AS- option must be looped into

the control circuit. This is vital, so that a malfunction of the internal safety relay or a cable bre ak can be recognized.

If the -AS- option is automatically activated by a control system (KSI1/2), then make sure that

the output of the control is monitored for possible malfunction. This can be used to prevent a faulty output from activating the -AS- option while the motor is running.

It is vital to keep to the following functional sequence when the -AS- option is used:

1. Brake the drive in a controlled manner (speed setpoint = 0V)

2. When speed = 0 rpm, disable the servo amplifier (enable = 0V)

3. If there is a suspended load, apply an additional mechanical block to the drive

4. Activate the -AS- option

5.1.5.2 Functional test

The functioning of the restart lock must be tested during setup, after every alteration in the wiring of the system, or after exchanging one or more components of the system.

1. Stop all drives, with setpoint 0V, disable drives, mechanically block any suspended loads

2. Activate the -AS- option.

3. Open protective screens (but do not enter hazardous area)

4. Pull off the X10 connector from an amplifier: the mains contactor must drop out

5. Reconnect X10. Switch on mains contactor again.

6. Repeat steps 4 and 5 for each individual servo amplifier.

5.1.5.3 Connection diagram

SERVOSTAR 600

SERVOSTAR®601...620 Installation Manual 65

Page 66

Extensions / Accessories 03/04 Kollmorgen

5.1.6 Application examples

5.1.6.1 Moving single axes or axis-groups in setting-up operation

In setting-up operation, people will frequently be within the danger zone of the machinery. Axes will normally be moved under the control of permission switches. An additional switch-off of the unused axes, by means of the restart lock, increases the safety margin and avoids the repeated switching of main contactors or motor contactors.

5.1.6.2 Switching off grouped axes with separate working areas

Even when several SERVOSTAR 600 are operating off a common mains supply and DC-link, it is possible to set up groups for separate working areas. These groups can then be switched off sepa rately for personnel safety. For this purpose, we have provided you with a suggested circuit (mains supply circuit and control circuit for 2 separate working groups which have interconnected DC-links and a common mains supply voltage).

5.1.6.2.1 Control circuit

The suggested circuit fulfills safety category 1 (EN 954-1). You can fulfill safety category 3, if you use a mains contactor with suited supervision.

66 SERVOSTAR®601...620 Installation Manual

Page 67

Kollmorgen 03/04 Extensions / Accessories

5.1.6.2.2 Mains supply circuit

SERVOSTAR

SERVOSTAR SERVOSTAR SERVOSTAR SERVOSTAR

SERVOSTAR®601...620 Installation Manual 67

Page 68

Extensions / Accessories 03/04 Kollmorgen

5.2 Expansion card -I/O-14/08-

This chapter describes the I/O-expansion card -I/O-14/08-. It only describes the additional features that the expansion card makes available for the SERVOSTAR 600.

If you ordered the expansion card together with the servo amplifier, then it will be delivered already inserted into the expansion slot of the servo amplifier and screwed fast.

The -I/O-14/08- provides you with 14 additional digital inputs and 8 digital outputs. The functions of the inputs and outputs are fixed. They are used to initiate the motion tasks that are stored in the servo amplifier and to evaluate signals from the integrated position control in the higher-level control.

The functions of the inputs and signal outputs correspond exactly to the functions that can be assig ned to the digital-I/O on connector X3 of the SERVOSTAR 600.

The 24VDC supply for the expansion card is taken from the controller. All inputs and outputs are electrically isolated from the servo amplifier by optocoupler.

5.2.1 Fitting the expansion card

If you want to retrofit the I/O expansion card into a SERVOSTAR 600, proceed as follows:

Use a suitable screwdriver to lever off the cover of the option slot.

Take care that no small items (such as screws) fall into the open option slot.

l Push the expansion card carefully into the guide rails that are provided, without twisting it.

l Press the expansion card firmly into the slot, until the front cover touches the fixing lugs. This

ensures that the connectors make good contact.

l Screw the screws on the front cover into the threads in the fixing lugs.

5.2.2 Technical data

Control inputs 24V / 7mA, PLC-compatible Signal outputs 24V / max. 500mA, PLC-compatible

Supply inputs, to IEC 1131

Fusing (external) 4 AT Connectors MiniCombicon, 12-pole, coded on PIN1 and 12 respectively

Cables

Waiting time between 2 motion tasks depends on the response time of the control system Addressing time (min.) 4ms Starting delay (max.) 2ms Response time of digital outputs max. 10ms

24V (18 ... 36V) / 100mA plus total current of the outputs (de pends on the input wiring of the controls)

Data – up to 50m long : 22 x 0.5mm², unshielded, Supply – 2 x 1mm², check voltage drop

The 24VDC voltage has to be supplied by an electrically isolated power supply, e.g. with insulating transformer.

5.2.3 Light emitting diodes (LEDs)

Two LEDs are mounted next to the terminals on the expansion card. The green LED signals that the 24V auxiliary supply is available for the expansion card. The red LED signals faults in the out puts from the expansion card (overload, short-circuit).

68 SERVOSTAR®601...620 Installation Manual

Page 69

Kollmorgen 03/04 Extensions / Accessories

5.2.4 Position of the connectors

Coding

Plan view of the connectors as built in

SERVOSTAR®601...620 Installation Manual 69

Page 70

Extensions / Accessories 03/04 Kollmorgen

5.2.5 Connector assignments

Connector X11A

Terminal Function Description

1 In A0 Motion task no., LSB 2 In A1 Motion task no., 2 3 In A2 Motion task no., 2 4 In A3 Motion task no., 2 5 In A4 Motion task no., 2 6 In A5 Motion task no., 2 7 In A6 Motion task no., 2 8 In A7 Motion task no., MSB

Polls the reference switch. If a digital input on the basic unit is used as

9 In Reference

10 In FError_clear Clear the warning of a following error or the response monitoring.

11 In Start_MT Next

12 In Start_Jog v=x

a reference input, then the input on the I/O expansion card will not be evaluated.

The following task, that is defined in the motion task by “Start with I/O” is started. The target position of the present motion task must be rea ched before the following task can be started. The next motion block can also be started by an appropriately configu red digital input on the basic unit. Start of the setup mode "Jog Mode" with a defined speed. After selec ting the function, you can enter the speed in the auxiliary variable “x”. The sign of the auxiliary variable defines the direction. A rising edge starts the motion, a falling edge cancels the motion.

Connector X11B

Terminal Function Description

Continues the motion task that was previously interrupted.

1 In MT_Restart

2 In Start_MT I/O

3 Out InPos

4 Out

5 Out FError 6 Out PosReg1 7 Out PosReg2 8 Out PosReg3

9 Out PosReg4 10 Out PosReg5 Can only be adjusted by ASCII commands. 11 Supply 24VDC auxiliary supply voltage 12 Supply I/O-GND Digital-GND for the controls

Next-InPos

PosReg0 Can only be adjusted by ASCII commands.

The motion task can also be continued by an appropriately configured digital input on the basic unit. Start of the motion task that has the number that is presented, bit-coded, at the digital inputs (A0 to A7). The digital function with the same name, in the basic unit, starts the motion task with the address from the digital inputs on the basic unit. When the target position for a motion task has been reached (the InPosition window), this is signaled by the output of a HIGH-signal.

A cable break will not be detected

The start of each motion task in an automatically executed sequence of motion tasks is signaled by an inversion of the output signal. The output produces a Low signal at the start of the first motion task of the motion task sequence. The form of the message can be varied by using ASCII commands.

Contouring-error (low-active).

The preset function of the corresponding position register is indicated by a HIGH-signal.

5.2.6 Select motion task number (Sample)

Motion task no.

(decimal

174 10101110

A7 A6 A5 A4 A3 A2 A1 A0

Motion task no. (binary)

70 SERVOSTAR®601...620 Installation Manual

Page 71

Kollmorgen 03/04 Extensions / Accessories

5.2.7 Connection diagram

SERVOSTAR 600

-I/O-14/08

AGND and DGND (connector X3) must be joined together !

SERVOSTAR®601...620 Installation Manual 71

Page 72

Extensions / Accessories 03/04 Kollmorgen

5.3 Expansion card -PROFIBUS-

This chapter describes the PROFIBUS expansion card for the SERVOSTAR 600. Information on the range of functions and the software protocol can be found in the manual "Communication profile PROFIBUS DP". If you ordered the expansion card together with the servo amplifier, then the expansion card is already fitted and screwed into the slot when the servo amplifier is delivered. The PROFIBUS expansion card has two 9-pin Sub-D sockets wired in parallel. The supply voltage for the expansion card is provided by the servo amplifier.

5.3.1 Position of the connectors

5.3.2 Fitting the expansion card

If you want to retrofit the PROFIBUS expansion card into a SERVOSTAR 600, proceed as follows:

Use a suitable screwdriver to lever off the cover of the option slot.

Take care that no small items (such as screws) fall into the open option slot.

Push the expansion card carefully into the guide rails that are provided, without twisting it.

Press the expansion card firmly into the slot, until the front cover touches the fixing lugs. This ensures that the connectors make good contact.

Screw the screws on the front cover into the threads in the fixing lugs.

72 SERVOSTAR®601...620 Installation Manual

Page 73

Kollmorgen 03/04 Extensions / Accessories

5.3.3 Connection technology

Cable selection, cable routing, shielding, bus connector, bus termination and transmission times are all described in the “Installation guidelines for PROFIBUS-DP/”, Order No. 2.111, from PNO, the PROFIBUS User Organization.

5.3.4 Connection diagram

SERVOSTAR 600

AGND and DGND (connector X3) must be joined together !

SERVOSTAR®601...620 Installation Manual 73

Page 74

Extensions / Accessories 03/04 Kollmorgen

5.4 Expansion card -SERCOS-

This chapter describes the SERCOS expansion card for SERVOSTAR 600. Information on the range of functions and the software protocol can be found in the manual

"IDN Reference Guide SERCOS". If you ordered the expansion card together with the servo amplifier, then the expansion card is already fitted and screwed into the slot when the servo amplifier is delivered.

AGND and DGND (connector X3) must be joined together !

5.4.1 Position of the connectors

5.4.2 Fitting the expansion card

The expansion card can be retrofitted from firmware version 4.30. Proceed as follows:

Use a suitable screwdriver to lever off the cover of the option slot.

Take care that no small items (such as screws) fall into the open option slot.

Push the expansion card carefully into the guide rails that are provided, without twisting it.

Press the expansion card firmly into the slot, until the front cover touches the fixing lugs. This ensures that the connectors make good contact.

Screw the screws on the front cover into the threads in the fixing lugs.

74 SERVOSTAR®601...620 Installation Manual

Page 75

Kollmorgen 03/04 Extensions / Accessories

5.4.3 Light emitting diodes (LEDs)

RT: indicates whether SERCOS telegrams are being correctly received. In the final Communi-

cation Phase 4 this LED should flicker, since cyclical telegrams are being received.

TT: indicates that SERCOS telegrams are being transmitted.

In the final Communication Phase 4 this LED should flicker, since cyclical telegrams are being transmitted. Check the stations addresses for the controls and the servo amplifier if:

- the LED never lights up in SERCOS Phase 1 or

- the axis cannot be operated, although the RT LED is lighting up cyclically.

Err : indicates that SERCOS communication is faulty or suffering from interference.

If this LED is very bright, then communication is suffering strong interference, or is non-existent. Check the SERCOS transmission speed for the controls and the servo amplifier (BAUDRATE) and the fibre-optic connection. If this LED flickers, this indicates a low level of interference for Sercos communication, or the optical transmitting power is not correctly adjusted to suit the length of cable. Check the transmitting power of the (physically) previous SERCOS station. The transmitting power of the servo amplifier can be adjusted in the setup software DRIVE.EXE on the SERCOS screen page, by altering the LWL length parameter for the cable length.

5.4.4 Connection technology

For the optical fibre (LWL) connection, only use SERCOS components to the SERCOS Standard IEC 61491. Receive data: The optical fibre carrying receive data for the drive in the ring structure

is connected to X13 with an FSMA connector.

Transmit data: Connect the optical fibre for the data output to X14 with an FSMA connector.

5.4.5 Connection diagram

Layout of the SERCOS bus system in ring topology, with optical fibre cables (schematic).

SERVOSTAR®601...620 Installation Manual 75

Page 76

Extensions / Accessories 03/04 Kollmorgen

5.5 Expansion card -DeviceNet-

This chapter describes the DeviceNet expansion card for SERVOSTAR 600. Information on the range of functions and the software protocol can be found in the manual

"DeviceNet communication profile". If you ordered the expansion card together with the servo amplifier, then the expansion card is already fitted and screwed into the slot when the servo amplifier is delivered.

5.5.1 Position of the connectors

5.5.2 Fitting the expansion card

If you want to retrofit the DeviceNet expansion card into a SERVOSTAR 600, proceed as follows:

Use a suitable screwdriver to lever off the cover of the option slot.

Take care that no small items (such as screws) fall into the open option slot.

Push the expansion card carefully into the guide rails that are provided, without twisting it.

Press the expansion card firmly into the slot, until the front cover touches the fixing lugs. This ensures that the connectors make good contact.

Screw the screws on the front cover into the threads in the fixing lugs.

76 SERVOSTAR®601...620 Installation Manual

Page 77

Kollmorgen 03/04 Extensions / Accessories

5.5.3 Connection technology

Cable selection, cable routing, shielding, bus connector, bus termination and transmission times are all described in the “DeviceNet specification, volumes I, II, release 2.0", published by ODVA

5.5.4 Connection diagram

SERVOSTAR 600

AGND and DGND (connector X3) must be joined together!

5.5.5 Combined Module/Network Status LED

LED is To indicate:

Device is not online.

off

green

flashing green

flashing red

red

The device has not completed the Dup_MAC_ID test yet.

The device may not be powered. The device is operating in a normal condition and the device is online with connections in the estab lished state.

- The device is allocated to a Master The device is operating in a normal condition and the device is online with no connections in the established state.

The device has passed the Dup_MAC_ID test, is online, but has no established connections to ot her nodes.

This device is not allocated to a master.

Configuration missing, incomplete or incorrect.

Recoverable fault and/or one or more I/O Connections are in the Timed–Out state.

- The device has an unrecoverable fault; may need replacing.

- Failed communication device. The device has detected an Error that has rendered it incapable of communicating on the network (e.g. Duplicate MAC ID, or Bus–off).

SERVOSTAR®601...620 Installation Manual 77

Page 78

Extensions / Accessories 03/04 Kollmorgen

5.6 Expansion card- ETHERNET -

The Ethernet option card enables ASCII communication with SERVOSTAR via a TELNET connec tion. This card can be used with 10BaseT or 100BaseTX Ethernet.

The card is automatically set to the required transmission rate when it is connected to the network.

The IP-address, subnet mask, gateway address and MAC-address can be set through software. If the local network has a DHCP server, then the Ethernet option card can acquire the IP-address, subnet mask and gateway address from the DHCP server. If not, then the settings must be made manually. The MAC address must always be set manually.

5.6.1 Fitting the expansion card

The operation of the Ethernet expansion card requires a special firmware. Please con tact our customer support.

If you want to retrofit the Ethernet expansion card in the SERVOSTAR 600, proceed as follows:

Use a suitable screwdriver to lever off the cover of the option slot.

Take care that no small items (such as screws) fall into the open option slot.

Push the expansion card carefully into the guide rails that are provided, without twisting it.

Press the expansion card firmly into the slot, until the front cover touches the fixing lugs. This

ensures that the connectors make good contact.

l Screw the screws on the front cover into the threads in the fixing lugs.

5.6.2 Connectors

XDATA: RJ-45-Ethernet

The connection of the card to the local network is made via an RJ-45 patch cable.

5.6.3 LEDs

LINK

10:

100

indicates whether an Ethernet connection is established.

indicates whether the card is operating in 10BaseT mode (transmission rate = 10 Mbit/s); blinks if data is being sent or received. indicates whether the card is operating in 100BaseTX mode (transmission rate = 100 Mbit/s); blinks if data is being sent or received.

78 SERVOSTAR®601...620 Installation Manual

Page 79

Kollmorgen 03/04 Extensions / Accessories

5.6.4 Position of the connectors

5.6.5 Connection diagram

SERVOSTAR®601...620 Installation Manual 79

Page 80

Extensions / Accessories 03/04 Kollmorgen

5.7 Expansion card for Single Axis Controller -SAC-

This section describes the Motion Controller expansion card -SAC-. Only those additional features are described which this expansion card makes available for theSERVOSTAR 600. If you ordered the expansion card together with the servo amplifier, then the expansion card is already installed into the slot when the servo amplifier is delivered.

The -SAC- provides you with 10 additional digital inputs and 5 digital outputs (X18), a serial commu nication interface (X17) and an optional DeviceNet interface (X16).

The 24V DC operating voltage for the expansion card is provided by the control system.

All inputs and outputs on X18 are isolated via optocouplers, and thus floating with regard to the servo amplifier.

5.7.1 Fitting the expansion card

If you want to retrofit the SAC expansion card to the SERVOSTAR 600, proceed as follows:

Use a suitable screwdriver to lever off the cover of the option slot.

Take care that no small items (such as screws) fall into the open option slot.

Push the expansion card carefully into the guide rails that are provided, without twisting it.

Press the expansion card firmly into the slot, until the front cover touches the fixing lugs. This

ensures that the connectors make good contact.

l Screw the screws on the front cover into the threads in the fixing lugs.

5.7.2 Technical data

Supply inputs as per IEC 1131

10 control inputs 24V / 7mA , PLC-compatible, IEC 1131 5 signal outputs 24V, PLC-compatible Processor type STPC-Elite Processor speed 100 MHz Onboard RAM type SDRAM Onboard ROM size 16 MB Communication with the amplifier DPRAM Software watchdog Yes

Serial communikation interface

DeviceNet interface 5-pole Phönix clamp connector Fusing for 24V supply (external) 4 AT

24V (18 … 36V) / 100mA plus the summed currents of the outputs (depends on the input circuit of the control system)

RS-232 RS-485 Full Duplex link RS-485 Half Duplex link

The 24V DC supply voltage must be provided by an electrically isolated source (e.g. via an isolating transformer).

80 SERVOSTAR®601...620 Installation Manual

Page 81

Kollmorgen 03/04 Extensions / Accessories

5.7.3 Position of the connectors

5.7.4 Connector assignments

5.7.4.1 RS-232 communication X17 (SubD 9-pin, plug)

SERVOSTAR 600, X17

SERVOSTAR®601...620 Installation Manual 81

Page 82

Extensions / Accessories 03/04 Kollmorgen

5.7.4.2 RS-485 communication X17 (SubD 9-pin, plug)

State as delivered: RS485 full duplex mode

Connection diagram for full-duplex mode:

SERVOSTAR 600, X17

RS485 Half Duplex Modus is adjustable throught the setup software DRIVE.EXE

Connection diagram for half-duplex mode

SERVOSTAR 600, X17

5.7.4.3 DeviceNet communication X16 (Phönix, 5-pin)

Cable selection, cable routing, shielding, bus connector, bus termination and transmission times are all described in the “DeviceNet Specification, Volume I, II, Edition 2.0”, published by the ODVA.

AGND and DGND (connector X3) must be linked together!

SERVOSTAR 600

82 SERVOSTAR®601...620 Installation Manual

Page 83

Kollmorgen 03/04 Extensions / Accessories

5.7.4.4 Digital inputs/outputs, connector X18 (SubD 26-pin, socket)

Connection diagram

SERVOSTAR 600

Pin assignments for connector X18 (SubD 26-pin)

Pin Description Pin Description

1 IN 3 Input 3 14 OUT 4 Output 4 2 OUT 1 Output 1 15 OUT 5 Output 5 3 GND IN 1-4 Ground for inputs 1-4 16 GND OUT 3-5 Ground for outputs 3-5 4 GND IN 5-8 Ground for inputs 5-8 17 GND OUT 3-5 Ground for outputs 3-5 5 IN 6 Input 6 18 IN 7 Input 7 6 GND OUT 3-5 Ground for outputs 3-5 19 IN 2 Input 2 7 IN 5 Input 5 20 IN 1 Input 1 8 GND IN 9-10 Ground for inputs 9-10 21 GND OUT 1-2 Ground for outputs 1-2

9 IN 8 Input 8 22 GND IN 1-4 Ground for inputs 1-4 10 IN 4 Input 4 23 GND IN 5-8 Ground for inputs 5-8 11 OUT 2 Output 2 24 IN 10 Input 10 12 GND OUT 1-2 Ground for outputs 1-2 25 IN 9 Input 9 13 OUT 3 Output 3 26 GND IN 9-10 Ground for inputs 9-10

SERVOSTAR®601...620 Installation Manual 83

Page 84

Extensions / Accessories 03/04 Kollmorgen

5.8 Expansion module -2CAN-

Connector X6 of the SERVOSTAR is assigned to the signals for the RS232 interface and the CAN interface. It is therefore not the standard pin assignment for these interfaces, and a special cable is required to be able to use both interfaces simultaneously. The -2CAN- expansion module provides the interfaces on separate Sub-D connectors. The two CAN connectors are wired in parallel. A termination resistor (120 W) for the CAN bus can be swit ched into circuit if the SERVOSTAR is at the end of the bus.

5.8.1 Position of the connectors

5.8.2 Fitting the expansion module

If you want to retrofit the -2CAN- expansion module into a SERVOSTAR 600, proceed as follows:

Use a suitable screwdriver to lever off the cover of the option slot.

Take care that no small items (such as screws) fall into the open option slot.

Screw the distance pieces into the fixing lugs of the option slot.

Place the expansion module onto the option slot.

Screw the screws into the threads of the distance pieces.

Plug the Sub-D9 socket into connector X6 on the SERVOSTAR

84 SERVOSTAR®601...620 Installation Manual

Page 85

Kollmorgen 03/04 Extensions / Accessories

5.8.3 Connection technology

Standard shielded cables can be used for the RS232 and CAN interfaces.

If the servo amplifier is the last device on the CAN bus, then the switch for the bus ter mination must be set to ON. Otherwise, the switch must be set to OFF (condition as delivered).

5.8.4 Connector assignments

RS232 CAN1=CAN2

X6A Pin Signal X6B=X6C Pin Signal

1 Vcc 1 2 RxD 2 CAN-Low 3 TxD 3 CAN-GND 44 5 GND 5 66 7 7 CAN-High 88 99

5.8.5 Connection diagram

SERVOSTAR®601...620 Installation Manual 85

Page 86

Extensions / Accessories 03/04 Kollmorgen

5.9 Accessories

5.9.1 External 24V DC / 5A supply

Technical data

Input voltage 120 / 230V Input current 0,9 / 0,6A Frequency 50/60Hz Primary fuse 3,15AT Output voltage 24V ± 1% Max. output current 5A Residual ripple <150mVss Switching peaks <240mVss Output fuse short circuit proof Temperature range 0...+60°C (140°F)

Type of mounting

Weight 0,75kg

DIN-rails, vertical mounting

Keep a clear space of 50mm above and below the instrument

86 SERVOSTAR®601...620 Installation Manual

Page 87

Kollmorgen 03/04 Extensions / Accessories

5.9.2 External 24V DC / 20A supply

Technical data

Input voltage 3 x 400VAC ± 10% Input current ca. 1,1A Frequency 50/60Hz Primary fuse none Output voltage 24V ± 1% Max. output current 20A Residual ripple <0,1% Output fuse short circuit proof Test voltage acc. to VDE 0550 Temperature range -20...+60°C (-4...140°F)

Type of mounting

Weight 3,5kg

on the supplied mounting plate

Keep the required space clear

SERVOSTAR®601...620 Installation Manual 87

Page 88

Extensions / Accessories 03/04 Kollmorgen

5.9.3 External regen resistor BARxxx

Caution: Surface temperature may exceed 200°C. Observe the requested free space. Do not mount to combustible surface

88 SERVOSTAR®601...620 Installation Manual

Page 89

Kollmorgen 03/04 Extensions / Accessories

5.9.4 External regen resistor BAR(U)xxx

Caution: Surface temperature may exceed 200°C. Observe the requested free space. Do not mount to combustible surface

SERVOSTAR®601...620 Installation Manual 89

Page 90

Extensions / Accessories 03/04 Kollmorgen

5.9.5 Motor choke box 3YL-20

Technical data:

Nom. data Sym DIM 3 YL-20 Rated current Frequency Inductance

0rms

max

L mH 1.2

A Max.3x20

kHz 8.3

90 SERVOSTAR®601...620 Installation Manual

Page 91

Kollmorgen 03/04 Appendix

6 Appendix

6.1 Transport, storage, maintenance, disposal

Transport : — only by qualified personnel

— only in the manufacturer’s original recyclable packaging — avoid shocks — temperature –25 to +70°C (-13...158°F), max. 20K/hr rate of change — humidity max. 95% relative humidity, no condensation — the servo amplifiers contain electrostatically sensitive components which can

— be damaged by incorrect handling — Discharge yourself before touching the servo amplifier. Avoid contact with — highly insulating materials (artificial fabrics, plastic films etc.). — Place the servo amplifier on a conductive surface.

— if the packaging is damaged, check the unit for visible damage.

— In this case, inform the shipper and the manufacturer.

Packaging : — cardboard box, can be recycled

— Dimensions: SERVOSTAR 601-610 (HxWxD) 125x415x350 mm

SERVOSTAR 614/620 (HxWxD) 170x415x350 mm

— Labeling : nameplate outside at the box

Storage : — only in the manufacturer’s original recyclable packaging

— the servo amplifiers contain electrostatically sensitive components which can

— be damaged by incorrect handling — Discharge yourself before touching the servo amplifier. Avoid contact with — highly insulating materials (artificial fabrics, plastic films etc.), — Place the servo amplifier on a conductive surface.

— max. stacking height 8 cartons — storage temperature –25 to +55oC(-13...131°F),

max.20K/hr. rate of change — humidity relative humidity max. 95%, no condensation — storage duration < 1 year without restriction

> 1 year : capacitors must be re-formed before

setting up the servo amplifier.

To re-form, remove all electrical connections, and

supply the servo amplifier for about 30 min. from

230VAC, single-phase, on terminals L1 / L2.

Maintenance : — the servo amplifiers do not require any maintenance

— opening the enclosure invalidates the warranty

Cleaning : — if the casing is dirty, clean with Isopropanol or similar cleaning agent

Do not immerse or spray. — dirt inside the unit must be cleaned by the manufacturer — dirty protective grill (fan) may be cleaned with a dry brush

Disposal : — the servo amplifier can be reduced to its principal components by removing

the screws (aluminum heat sink and front panel steel housing sections,

electronics boards) — disposal should be carried out by a certified disposal company.

— We can give you suitable addresses.

SERVOSTAR®601...620 Installation Manual 91

Page 92

Appendix 03/04 Kollmorgen

6.2 Removing faults/warnings

The table below should be regarded as a “First-aid” box. Depending on the conditions in your instal lation, there may be a wide variety of reasons for the fault. In multi-axis systems there may be furt her hidden causes of a fault. Our customer service can give you further assistance with problems.

Fault possible causes

HMI message: communication fault

F01 message: heat sink temperature

F02 message: overvoltage

F04 message: feedback unit

F05 message: undervoltage

F06 message: motor temperature

F07 message: aux. voltage F08 message: motor runs away (overspeed)

F11 message: brake

F13 message: internal temperatu re

F14 message: output stage fault

F16 message: mains BTB/RTO

F17 message: A/D converter

— wrong cable used — cable plugged into wrong position

in servo amplifier or PC

— wrong PC interface selected

— permissible heat sink temperature

exceeded

— regen power is insufficient. regen power

limit was reached and the regen resistor was switched off. This causes excessive

voltage in the DC-link circuit. — supply voltage too high — feedback connector not properly inserted — feedback cable is broken, crushed or

otherwise damaged — supply voltage not present or too low

when servo amplifier is enabled

— motor thermostat has been activated

— feedback connector is loose or break in

feedback cable — the aux. voltage produced by the servo

amplifier is incorrect

— motor phases swapped — feedback set up incorrectly

— short-circuit in the supply cable for the

motor-holding brake — motor-holding brake is faulty — fault in brake cable — no brake connected, although the

brake parameter is set to "WITH"

— permissible internal temperature exceeded — improve ventilation

— motor cable has short-circuit/ground short — motor has short-circuit / ground short — output module is overheated — output stage is faulty

— short-circuit / short to ground in the

external regen resistor — enable was applied, although the

supply voltage was not present.

— at least 2 supply phases are missing — error in the analog-digital conversion,

usually caused by excessive EMI

Measures to remove the cause of the fault

— use null-modem cable — plug cable into the correct sockets

on the servo amplifier and PC

— select correct interface

— improve ventilation

— shorten the braking time RAMP or

use an external regen resistor with a higher power rating and

adjust the regen power parameter — use mains transformer — check connector — check cable

— only enable the servo amplifier

when the mains supply voltage

has been switched on

delay > 500 ms — wait until motor has cooled down,

then check why it became so hot — tighten connector or use

new feedback cable — return the servo amplifier to the

manufacturer for repair

— correct motor phase sequence — set up correct offset angle

— remove short-circuit

— replace motor — check shielding of brake cable — brake parameter set to "WITHOUT"

— replace cable — replace motor — improve ventilation — return the servo amplifier to the

manufacturer for repair — remove short-circuit / ground short

— only enable the servo amplifier

when the mains supply voltage

has been switched on — check electrical supply — reduce EMI,

check screening and grounding

92 SERVOSTAR®601...620 Installation Manual

Page 93

Kollmorgen 03/04 Appendix

Fault possible causes

F25 message: Commutation error

F27 message: error AS-option

— wrong cable — wrong phasing

— -AS-24V relay AND hardware enable AND

software enable are active — servo amplifier not enabled — break in setpoint cable — motor phases swapped

motor does not rotate

— brake not released — drive is mechanically blocked — no. of motor poles set incorrectly — feedback set up incorrectly — gain too high (speed controller)

motor oscillates

— shielding in feedback cable has a break — AGND not wired up —I

or I

rms

drive reports following error

motor overheating

— setpoint ramp is too long —I

peak

set too high — reduce I

rms/Ipeak

— Kp (speed controller) too low — Tn (speed controller) too high

drive too soft

— PID-T2 too high — T-Tacho too high — Kp (speed controller) too high

drive runs roughly

— Tn (speed controller) too low

— PID-T2 too low — T-Tacho too low — offset not correctly adjusted for analog

axis drifts at setpoint = 0V

setpoint provision — AGND not joined to the CNC-GND of the

controls

n12 message: Motor default values loaded

n14 message: Wake & shake active

— Motor number stored in sine encoders

EEPROM different than what drive is

configured for

— Wake & shake not executed — Enable the drive

is set to low

measures to remove the cause of the fault

— check wiring — check resolver poles (RESPOLES)

check motor poles (MPOLES) check offset (MPHASE)

— check PLC programming and

wiring — apply enable signal — check setpoint cable — correct motor phase sequence — check brake control — check mechanism — set no. of motor poles — set up feedback correctly — reduce Kp (speed controller) — replace feedback cable — join AGND to CNC-GND — increase I

rms

or I

peak

(keep within motor data !) — shorten setpoint ramp +/-

rms/Ipeak

— increase Kp (speed controller) — use motor default value for

Tn (speed controller) — reduce PID-T2 — reduce T-Tacho — reduce Kp (speed controller) — use motor default value for

Tn (speed controller) — increase PID-T2 — increase T-Tacho — adjust setpoint-offset (analog I/O)

— join AGND and CNC-GND

— If n12 is displayed, default values

for the motor are loaded.

Motor number will be automatically

stored in EEPROM with SAVE.

SERVOSTAR®601...620 Installation Manual 93

Page 94

Appendix 03/04 Kollmorgen

6.3 Glossary

C Clock Clock signal

Common-mode voltage The maximum amplitude of a disturbance (on both

inputs) which a differential input can eliminate

CONNECT- modules Modules built into the servo amplifier, with integrated

position control, which provide special versions of the interface for the connection to the higher-level control

Continuous power of regen circuit Mean power which can be dissipated in the regen circuit

-1

Counts Internal count pulses, 1 pulse = 1/2

Current controller Regulates the difference between the current setpoint

and the actual value to 0 Output: power output voltage

D DC-link Rectified and smoothed power voltage

Disable Removal of the enable signal (0V or open)

E Enable Enable signal for the servo amplifier (+24V)

F Final speed Maximum value for speed normalization at ±10V

Fieldbus interface CANopen, PROFIBUS, SERCOS etc.

G GRAY-code Special method of representing binary numbers

H Holding brake Brake in the motor, which can only be used when the

motor is at a standstill

I I²t threshold Monitoring of the actually required r.m.s. current

Input drift Temperature and age-dependent alteration of an analog

input

Incremental encoder interface Position signaling by 2 signals with 90° phase

difference, not an absolute position output

Ipeak, peak current The effective value of the peak current

Irms, effective current The r.m.s. value of the continuous current

K Kp, P-gain Proportional gain of a control loop

L Limit-switch Switch limiting the traverse path of the machine;

implemented as n.c. (break) contact

M Machine The complete assembly of all connected parts or

devices, of which at least one is movable

Monitor output Output of an analog measurement

Motion-block Data packet with all the position control parameters

which are required for a motion task

Multi-axis system Machine with several independently driven axes

N Natural convection Free movement of air for cooling

O Optocoupler Optical connection between two electrically

independent systems

turn

94 SERVOSTAR®601...620 Installation Manual

Page 95

Kollmorgen 03/04 Appendix

P P-controller Control loop with purely proportional behavior

Phase shift Compensation for the lag between the electromagnetic

and magnetic fields in the motor

PID-controller Control loop with proportional, integral and

differential behavior

PID-T2 Filter time constant for the speed controller output

Position controller Regulates the difference between the position setpoint

and the actual position to 0 Output : speed setpoint

Potential isolation Electrically decoupled

Power contactor System protection device with phase monitoring

Pulse power of the regen circuit Maximum power which can be dissipated in the

regen circuit

R Regen circuit Converts superfluous energy, which is fed back

during braking, into heat in the regen resistor

Reset New start of the microprocessor

Resolver-digital converter Conversion of the analog resolver signals into

digital information

Reversing mode Operation with a periodic change of direction

Ring core Ferrite rings for interference suppression

ROD-Interface Incremental position output

S Servo amplifier Control device for regulating the position of a

servomotor

Setpoint ramps Limits for the rate of change of the speed setpoint

Short to ground Electrically conductive connection between a

phase and PE (protective earth (ground))

Short-circuit here: electrically conductive connection between

two phases

Speed controller Regulates the difference between the speed setpoint

and the actual value to 0 Output : current setpoint

SSI-interface Cyclic-absolute, serial position output

Supply filter Device to divert interference on the power supply

cables to PE

T T-tacho, tachometer time constant Filter time constant in the speed feedback

of the control loop

Tachometer voltage Voltage proportional to the actual speed

Thermostat Temperature-sensitive switch built into the

motor winding

Tn, I-integration time Integral section of a control loop

Z Zero pulse Output once per turn from incremental encoders,

used to zero the machine

SERVOSTAR®601...620 Installation Manual 95

Page 96

Appendix 03/04 Kollmorgen

6.4 Order numbers

In the table below you'll find the order numbers for the servo amplifiers, options and accessories.

Type European order number North America order code SERVOSTAR 601 SERVOSTAR 603 SERVOSTAR 606 SERVOSTAR 610 SERVOSTAR 610-30 SERVOSTAR 614 SERVOSTAR 620

89700 Not available in North America 89701 S60300-NA (S60301-NA with -AS- option) 89702 S60600-NA (S60601-NA with -AS- option) 89703 S61000-NA (S61001-NA with -AS- option)

102192 S610-3000-NA (S610-3001-NA with -AS- option)

90846 S61400-NA (S61401-NA with -AS- option) 89704 S62000-NA (S62001-NA with -AS- option)

Option -AS-

Expansion card PROFIBUS DP Expansion card SERCOS Expansion card -I/0-14/08Expansion card DeviceNet Expansion card Ethernet Expansion card SAC Expansion module -2CAN-

RS232 cable RS232 multilink cable -SR6YRS232 multilink cable -SR6Y6-

Power supply 24V/5A Power supply 24V/20A

Regen resistor BAR250 Regen resistor BAR500 Regen resistor BAR1500

Motor choke box 3YL-20

Product CDROM

90058 see order code in brackets

90056 OPT-PB 90879 OPT-SE

90057 OPT-EI 103571 OPT-DN 104974 Not available in North America

Not available in Europe OPT-MD

101174 Not available in North America

90067 A-97251-004

90060 A-SR6Y

92042 Not available in North America

83034 Not available in North America

81279 Not available in North America

90068 BAR-250-33

90069 BAR-500-33

90070 BAR-1500-33

90074 3YL-20

90079 KOL-1270

96 SERVOSTAR®601...620 Installation Manual

Page 97

Kollmorgen 03/04 Appendix

6.5 Index

! 24Vaux. supply, interface ...........38

A abbreviations ..................9

AGND .....................20

ambient temperature ..............19

AS-Option ...................63

assembly ....................26

Assignment...................96

B Baudrate ....................57

block diagram (overview) ...........37

brake ......................20

BTB/RTO....................45

C CANopen-Interface...............53

CE conformity ..................7

choke 3YL-20 .................90

conductor cross-sections............19

connection diagram ..............30

connection techniques .............33

D DC-link interface ................38

DeviceNet expansion card ...........76

DGND .....................20

disposal ....................91

E Emergency Stop strategies ..........23

EMI.......................25

encoder

emulations .................46

interface ..................41

interface master-slave ...........48

error messages ................60

Ethernet expansion card ............78

external fusing .................18

F forming .....................55

G Glossary ....................94

ground symbol .................28

grounding

connection diagram ............30

installation .................29

H hardware requirements.............36

holding brake..................20

humidity ....................91

I inputs

analog setpoints ..............42

DIGI-IN 1/2.................44

enable ...................44

NSTOP...................44

PSTOP...................44

installation

hardware ..................28

software ..................36

K key operation ..................58

L LC-Display ...................58

LED display ..................19

Limit Switch Inputs ...............44

M mains supply connection, interface ......38

mains supply networks .............16

maintenance ..................91

master-slave ..................48

monitor outputs.................43

motor

interface ..................39

motor choke

connection example ............31

motor holding brake ..............20

mounting position ...............19

multi-axis systems

connection example ............31

N nameplate ...................13

NSTOP .....................44

O options .....................14

other operating systems ............36

outputs

BTB/RTO..................45

DIGI-OUT 1/2 ...............45

Monitor1/2 .................43

P Package supplied ...............13

Packaging ...................91

Parameter setting ...............57

PC cable ....................52

PC connection .................52

PGND .....................20

pin assignments ................32

pollution level..................19

protection....................19

PSTOP .....................44

pulse-direction, interface ............50

R Regen circuit ..................21

resolver

interface ..................40

ROD interface .................46

RS232/PC, interface ..............52

S SAC expansion card ..............80

safety instructions ................6

setpoint inputs .................42

Setup ......................55

SETUP.EXE ..................36

shielding

connection diagram ............30

installation .................29

site .......................29

site altitude ...................19

SSI, interface..................47

stacking height .................91

standards ....................7

storage .....................91

storage duration ................91

storage temperature ..............91

supply voltage .................19

Switch-on and switch-off behavior .......22

system components, overview .........17

T technical data .................18

torque, connectors ...............19

transport ....................91

U use as directed .................12

servo amplifier ...............12

setup software ...............35

V ventilation

Installation .................29

Tech.Data .................19

W Warning messages ...............61

wiring ......................29

X XGND .....................20

SERVOSTAR®601...620 Installation Manual 97

Page 98

www.DanaherMotion.com

Sales and Service

We are committed to quality customer service. In order to serve in the most effective way, please contact your local sales representative for assistance. If you are unaware of your local sales representative, please contact us.

Europe

Visit the European Danaher Motion web site at www.DanaherMotion.net for Setup Software upgrades, application notes, technical publications and the most recent version of our product manuals.

Danaher Motion Customer Support - Europe

Internet www.DanaherMotion.net E-Mail virtapp@danahermotion.net Phone: +49(0)203 - 99 79 - 0 Fax: +49(0)203 - 99 79 - 155

North America

Visit the North American Danaher Motion web site at www.DanaherMotion.com for Setup Software upgrades, application notes, technical publications and the most recent version of our product manuals.

Danaher Motion Customer Support North America

Internet www.DanaherMotion.com E-Mail customer.support@danahermotion.com Phone: (815) 226 - 2222 Fax: (815) 226 - 3148