Kollmorgen SERVOSTAR 640, SERVOSTAR 670 Instruction Manual
SERVOSTAR®640 / 670
Digital Servo Amplifier
Instructions Manual
Edition 12/2010
Translation of the original manual.
Valid for Hardware Revision 02.10
Keep all manuals as a product component
during the life span of the product.
Pass all manuals to future users / owners
of the product.
File sr640_e.***
Previous versions :
Edition Remarks
07/1999 First edition
11/1999 technical data, encoder connection diagram
12/1999 encoder cable length
10/2000
05/2001 some UL/cUL related hints
01/2002
06/2002
02/2006
09/2006
04/2007
07/2007 Timing diagramm motor brake, example cat.3 EN954-1
06/2008 Repair, deinstallation, syntax: "regen" => "brake", EMC standards, Hiperface, CE declaration
08/2008 SCCR->42kA
07/2010 Logo, notes holding brake, HWR 2.10, GOST-R, repair, disposal
12/2010 Company name and address, name plat, CE certificate, fax form
Dimensions mains filter, setup software on CD-ROM only, wiring diagrams electr. gearing, warning and er
ror messages, recommended torque, various corrections
-Options -I/O-14/08- and -2CAN - incorporated, hardware-description incorporated for PROFIBUS and
SERCOS, nameplate, motor list and connector assignment corrected, LED-display corrected, error mes
sages expanded, Regen resistor BAR replaced by BAS type
Front page 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
Chapter 1 updated, motor choke added, DeviceNet, SynqNet and EtherCAT expansion cards added,
chapter 6 restructured, order codes restructured, feedback section updated, cross section (awg)
Hardware Revision, disposal acc. to WEEE-2002/96/EG, new structure, new cover pages, Quickstart inte
grated, warnings updated
Part number scheme new, shock-hazard protection new, servo system graphics / different mains supply
networks expanded&removed, feedback expanded, enc. emulation, switch-on and switch-off behavior ex
panded, AS expanded, accessories removed, DC Bus link expanded
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-
-
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Hardware Revision (HR)
Hardware Rev. Firmware Rev. DRIVE.EXE Rev. Remarks
02.06 >= 5.99 >= 5.53_284 Standard
>=6.68 >= 5.53_284 with BiSS support
02.10 >=7.76 >= 5.53_285 CAN Controller neu, Standard
>=6.86 >= 5.53_285 CAN Controller new, BiSS/EtherCAT Support
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
EtherCAT is a registered trademark of EtherCAT Technology Group
SERVOSTAR is a registered trademark of Danaher Motion.
Technical changes which improve the performance of the equipment may be made without prior notice !
Printed in the Federal Republic of Germany
All rights reserved. No part of this work may be reproduced in any form (by photocopying, microfilm or any other method)
or stored, processed, copied or distributed by electronic means without the written permission of Kollmorgen Europe
GmbH.
Kollmorgen
12/2010 Contents
1 General
1.1 About this manual ....................................................................... 7
1.2 Target group ........................................................................... 7
1.3 Hints for the online edition (PDF format) ...................................................... 7
1.4 Symbols used........................................................................... 7
1.5 Abbreviations used....................................................................... 8
2 Safety
2.1 Safety Instructions ....................................................................... 9
2.2 Use as directed ........................................................................ 10
2.3 Prohibited use ......................................................................... 10
3Approvals
3.1 UL and cUL- Conformance................................................................ 11
3.2 EC - conformance ...................................................................... 11
3.2.1 EC Declaration of Conformity......................................................... 12
3.2.2 European directives and standards for the machine builder .................................13
3.3 GOST-R Conformance................................................................... 14
4 Handling
4.1 Transport ............................................................................. 15
4.2 Packaging ............................................................................ 15
4.3 Storage .............................................................................. 15
4.4 Maintenance........................................................................... 15
4.5 Disassembling ......................................................................... 16
4.6 Repair ............................................................................... 16
4.7 Disposal .............................................................................. 16
5 Package
5.1 Package supplied....................................................................... 17
5.2 Nameplate ............................................................................ 17
5.3 Part number scheme .................................................................... 18
6 Technical description
6.1 The digital servo amplifiers of the series SERVOSTAR 640/670 ................................... 19
6.2 Technical data ......................................................................... 21
6.2.1 Recommended torques ............................................................. 22
6.2.2 Fusing .......................................................................... 22
6.2.3 Ambient conditions, ventilation, mounting position......................................... 22
6.2.4 Conductor cross-sections............................................................ 23
6.3 LED display ........................................................................... 23
6.4 Grounding system ...................................................................... 23
6.5 Control for motor holding brake ............................................................ 24
6.6 Electrical brake circuit ................................................................... 25
6.7 Switch-on and switch-off behavior .......................................................... 26
6.7.1 Behavior in standard operation ....................................................... 27
6.7.2 Behavior in the event of an error (with standard setting) .................................... 28
6.8 Stop/Emergency Stop Function to EN 60204.................................................. 29
6.8.1 Stop: Standards ................................................................... 29
6.8.2 Emergency Stop: Standards ......................................................... 30
6.9 Shock-hazard protection ................................................................. 31
6.9.1 Leakage current ................................................................... 31
6.9.2 Residual-current circuit breakers (FI)................................................... 31
6.9.3 Isolating transformers .............................................................. 31
7 Mechanical Installation
7.1 Safety Instructions ...................................................................... 33
7.2 Guide to mechanical installation............................................................ 33
7.3 Assembly ............................................................................. 34
7.4 Dimensions ........................................................................... 35
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SERVOSTAR®640/670 Instructions Manual 3
Contents
12/2010 Kollmorgen
8 Electrical Installation
8.1 Safety Instructions ...................................................................... 37
8.2 Guide to electrical installation.............................................................. 38
8.3 Wiring................................................................................ 39
8.3.1 Safety Instructions ................................................................. 39
8.3.2 Shielding connection to the front panel ................................................. 40
8.3.3 Technical data for cables ............................................................ 41
8.4 Components of a servo system ............................................................ 42
8.5 Block diagram ......................................................................... 43
8.6 Pin assignments........................................................................ 44
8.7 Connection diagram (overview) ............................................................ 45
8.8 Power supply .......................................................................... 46
8.8.1 Connection to various mains supply networks ............................................ 46
8.8.2 Mains supply connection (X0) ........................................................ 47
8.8.3 24V auxiliary supply (X4) ............................................................ 47
8.8.4 DC bus link (X0)................................................................... 47
8.9 Motor connection with brake (X0, X4) ....................................................... 48
8.10 External brake resistor (X0) ............................................................... 48
8.11 Feedback ............................................................................. 49
8.11.1 Resolver (X2) ..................................................................... 50
8.11.2 Sine encoder with BISS (X1) ......................................................... 51
8.11.3 Sine Encoder with EnDat 2.1 or HIPERFACE (X1) ........................................ 52
8.11.4 Sine Encoder without data channel (X1) ................................................ 53
8.11.5 Incremental or sine encoder with hall sensors (X1) ........................................ 54
8.11.6 ComCoder (X1) ................................................................... 55
8.11.7 Incremental Encoder (X5) ........................................................... 56
8.12 Electronic Gearing, Master-slave operation ................................................... 57
8.12.1 Connection to a SERVOSTAR master, 5 V signal level (X5) ................................. 58
8.12.2 Connection to incremental encoder master with 24 V signal level (X3) .........................58
8.12.3 Connection to a sine-cosine encoder master (X1) ......................................... 59
8.12.4 Connection to a SSI encoder (X5) ..................................................... 60
8.12.5 Connection to stepper-motor controllers (step and direction)................................. 60
8.12.5.1 Step/Direction with 5 V signal level (X5) ............................................. 61
8.12.5.2 Step/Direction with 24 V signal level (X3) ............................................ 61
8.13 Encoder emulations ..................................................................... 62
8.13.1 Incremental encoder output - A quad B (X5) ............................................. 62
8.13.2 SSI output (X5) ................................................................... 63
8.14 Digital and analog inputs and outputs ....................................................... 64
8.14.1 Analog inputs (X3) ................................................................. 64
8.14.2 Analog outputs (X3) ................................................................ 65
8.14.3 Digital inputs (X3).................................................................. 66
8.14.4 Digital outputs (X3) ................................................................ 67
8.15 RS232 interface, PC connection (X6) ....................................................... 68
8.16 CANopen interface (X6) .................................................................. 69
8.17 Restart lock -AS- ....................................................................... 70
8.17.1 Safety instructions ................................................................. 70
8.17.2 Use as directed ................................................................... 71
8.17.3 Block diagram .................................................................... 71
8.17.4 Functional description .............................................................. 72
8.17.5 Signal diagram (sequence) .......................................................... 72
8.17.6 Functional test .................................................................... 73
8.17.7 Connection diagram (principle) ....................................................... 73
8.17.8 Application example category 1 according to EN 954-1..................................... 74
8.17.8.1 Control circuit ................................................................. 74
8.17.8.2 Mains supply circuit............................................................. 74
8.17.9 Application example category 3 according to EN 954-1..................................... 75
8.17.9.1 Control circuit ................................................................. 75
8.17.9.2 Mains supply circuit............................................................. 75
8.17.9.3 Flow chart .................................................................... 76
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4 SERVOSTAR®640/670 Instructions Manual
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12/2010 Contents
9Setup
9.1 Safety instructions ...................................................................... 77
9.2 Setup software ......................................................................... 78
9.2.1 General ......................................................................... 78
9.2.1.1 Use as directed ................................................................ 78
9.2.1.2 Software description ............................................................ 78
9.2.1.3 Hardware requirements.......................................................... 79
9.2.1.4 Operating systems ............................................................. 79
9.2.2 Installation under WINDOWS 95 / 98 / 2000 / ME / NT / XP ................................. 79
9.3 Quickstart Guide ....................................................................... 80
9.3.1 Preparation ...................................................................... 80
9.3.1.1 Unpacking, Mounting and Wiring the Servo Amplifier ...................................80
9.3.1.2 Documents ................................................................... 80
9.3.1.3 Minimum Wiring for Drive Test .................................................... 81
9.3.2 Connect ......................................................................... 82
9.3.3 Important Screen Elements .......................................................... 83
9.3.4 Basic Setup ...................................................................... 84
9.3.5 Motor (synchronous) ............................................................... 85
9.3.6 Feedback ........................................................................ 86
9.3.7 Save Parameters and Restart ........................................................ 87
9.3.8 Jogging the Motor (Speed Control) .................................................... 88
9.3.9 Status........................................................................... 89
9.3.10 Monitor.......................................................................... 89
9.3.11 Additional Setup Parameters ......................................................... 89
9.4 Multi-axis system ....................................................................... 90
9.4.1 Node address for CAN-bus .......................................................... 90
9.4.2 Baud rate for CAN-bus.............................................................. 90
9.4.3 Example of connections for a multi-axis system........................................... 91
9.5 Key operation / LED display............................................................... 92
9.5.1 Key operation..................................................................... 92
9.5.2 Status display..................................................................... 92
9.5.3 Standard menu structure ............................................................ 93
9.5.4 Extended menu structure ............................................................ 93
9.6 Error messages ........................................................................ 94
9.7 Warning messages ..................................................................... 95
9.8 Removing faults / warnings ............................................................... 96
10 Expansion Cards
10.1 Guide to installation of expansion cards...................................................... 97
10.2 Expansion card -I/O-14/08- ............................................................... 98
10.2.1 Front view ....................................................................... 98
10.2.2 Technical data .................................................................... 98
10.2.3 Light emitting diodes (LEDs) ......................................................... 98
10.2.4 Select motion task number (sample) ................................................... 98
10.2.5 Connector assignments ............................................................. 99
10.2.6 Connection diagram............................................................... 100
10.3 Expansion cards -PROFIBUS-............................................................ 101
10.3.1 Front view ...................................................................... 101
10.3.2 Connection technology............................................................. 101
10.3.3 Connection diagram............................................................... 101
10.4 Expansion card -SERCOS- .............................................................. 102
10.4.1 Front view ...................................................................... 102
10.4.2 Light emitting diodes (LEDs) ........................................................ 102
10.4.3 Connection technology............................................................. 102
10.4.4 Connection diagram............................................................... 103
10.4.5 Modifying the station address ....................................................... 103
10.4.6 Modifying the baud rate and optical power.............................................. 103
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SERVOSTAR®640/670 Instructions Manual 5
Contents
10.5 Expansion card -DEVICENET-............................................................ 104
10.5.1 Front view ...................................................................... 104
10.5.2 Connection technology............................................................. 104
10.5.3 Connection diagram............................................................... 104
10.5.4 Combined module/network status-LED ................................................ 105
10.5.5 Setting the station address (device address) ............................................ 105
10.5.6 Setting the transmission speed ...................................................... 105
10.5.7 Bus cable ....................................................................... 106
10.6 Expansion card -ETHERCAT- ............................................................ 107
10.6.1 Front view ...................................................................... 107
10.6.2 LEDs .......................................................................... 107
10.6.3 Connection diagram............................................................... 107
10.7 Expansion card -SYNQNET- ............................................................. 108
10.7.1 Front view ...................................................................... 108
10.7.2 NODE ID Switch ................................................................. 108
10.7.3 Node LED table .................................................................. 108
10.7.4 SynqNet Connection, Connector X21B/C (RJ-45) ........................................ 108
10.7.5 Digital inputs/outputs, connector X21A (SubD 15-pin, socket)............................... 109
10.7.6 Connection diagram digital inputs/outputs, connector X21A ................................ 109
10.8 Expansion module -2CAN-............................................................... 110
10.8.1 Installation ...................................................................... 110
10.8.2 Front View ...................................................................... 110
10.8.3 Connection technology............................................................. 110
10.8.4 Connector assignments ............................................................ 111
10.8.5 Connection diagram............................................................... 111
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11 Appendix
11.1 Glossary............................................................................. 113
11.2 Order codes .......................................................................... 115
11.2.1 Servo amplifiers .................................................................. 115
11.2.2 Expansion cards ................................................................. 115
11.2.3 Connectors...................................................................... 115
11.3 Repair-/Disposal request Telefax form...................................................... 116
11.4 Index ............................................................................... 117
Page
6 SERVOSTAR®640/670 Instructions Manual
Kollmorgen
1 General
1.1 About this manual
This manual describes the digital servo amplifiers of the SERVOSTAR®640/670 series
(standard version).
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 with Internet browser, Acrobat Reader) in several
language versions.
Technical data and dimensional drawings of accessories such as cables, brake resistors, mains
supplies, etc., can be found in the accessories manual.
You can print this documentation on any standard printer. A printed copy of the documentation is
available from us at extra cost.
More background information can be found in the "Product WIKI", please check
www.wiki-kollmorgen.eu.
1.2 Target group
12/2010 General
This manual addresses personnel with the following qualifications:
Transport : only by personnel with knowledge of handling electrostatically sensitive
components.
Unpacking: only by electrically qualified personnel.
Installation : only by electrically qualified personnel.
Setup : only by qualified personnel with extensive knowledge of electrical
engineering and drive technology
The qualified personnel must know and observe the following standards:
IEC 60364 and IEC 60664
national accident prevention regulations
During operation there are deadly hazards, with the possibility of death, severe
injury or material damage. The operator must ensure that the safety instructions in
this manual are followed. The operator must ensure that all personnel responsible
for working with the servo amplifier have read and understood the product manual.
1.3 Hints for the online edition (PDF format)
Bookmark:
Table of contents and index are active bookmarks.
Table of contents and index in the text:
The lines are active cross references. Click on the desired line and the appropriate page is indica
ted.
Page/chapter numbers in the text:
Page/chapter numbers with cross references are active. Click at the page/chapter number to reach
the indicated target.
-
1.4 Symbols used
ð p.
Danger to personnel
from electricity and its
effects effects
see page l special emphasis
Danger to maschinery,
general warning
Important no
tes
SERVOSTAR®640/670 Instructions Manual 7
-
General
1.5 Abbreviations used
The abbreviations used in this manual are explained in the table below.
Abbreviation 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
F-SMA Fiber Optic Cable connector according to IEC 60874-2
IEC International Electrotechnical Commission
IGBT Insulated Gate Bipolar Transistor
INC Incremental Interface
ISO International Standardization Organization
LED Light-emitting diode
MB Megabyte
NI Zero pulse
NSTOP Limit-switch input for CCW rotation (left)
PELV Protected low voltage
PGND Ground for the interface
PSTOP Limit-switch input for CW rotation (right)
PWM Pulse-width modulation
RAM Volatile memory
R
B
R
Bext
R
Bint
RES Resolver
ROD 426 (EEO) 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
Brake resistor
External brake resistor
Internal brake resistor
12/2010 Kollmorgen
8 SERVOSTAR®640/670 Instructions Manual
Kollmorgen
2 Safety
2.1 Safety Instructions
Only properly qualified personnel are permitted to perform activities such as trans
l
port, installation, setup and maintenance. Properly qualified persons are those who
are familiar with the transport, assembly, installation, setup and operation of the pro
duct, and who have the appropriate qualifications for their job. The qualified person
nel must know and observe:
— IEC 60364 and IEC 60664
— national accident prevention regulations
12/2010 Safety
-
-
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Check the Hardware Revision Number of the product (see product label). This revi
l
sion number must match the Hardware Revision Number on the cover page of the
manual.
Read this documentation before carrying out installation and setup. Incorrect hand
l
ling 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 servo amplifiers contain electrostatically sensitive components which may be
l
damaged by incorrect handling. Ground yourself before touching the servo amplifier
by touching any unpainted metal surface. Avoid contact with highly insulating mater
ials (artificial fabrics, plastic film etc.). Place the servo amplifier on a conductive sur
face.
The manufacturer of the machine must produce a hazard analysis for the machine
l
and take appropriate measures to ensure that unforeseen movements do not result in
personal injury or material damage.
l
Do not open or touch the equipment during operation. Keep all covers and cabinet
doors closed during operation. Touching the equipment is allowed during installation
and commissioning for properly qualified persons only. Otherwise, there are deadly
hazards, with the possibility of death, severe injury or material damage.
— During operation, servo amplifiers may have uncovered live
components, depending on their level of enclosure protection.
— Control and power connections may be live, even though the
motor is not rotating.
— Servo amplifiers may have hot surfaces during operation.
Surface can reach temperatures above 80°C.
-
-
-
-
l
Never undo any electrical connections to the servo amplifier while it is live. There is a
danger of electrical arcing with damage to contacts and personal injury.
Wait at least five minutes after disconnecting the servo amplifier from the main
supply power before touching potentially live sections of the equipment (e.g. con
tacts) or undoing any connections. Capacitors can still have dangerous voltages pre
sent up to five minutes after switching off the supply power. To be sure, measure the
voltage in the DC Bus link and wait until it has fallen below 40V.
Safety instructions
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SERVOSTAR®640/670 Instructions Manual 9
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Safety
2.2 Use as directed
The servo amplifiers are components which are built into electrical equipment or machines,
l
and can only be used as integral components of such equipment.
The manufacturer of the machine must generate a hazard analysis for the machine, and
l
take appropriate measures to ensure that unforeseen movements cannot cause injury or
damage to any person or property.
The SERVOSTAR 640/670 family of servo amplifiers (overvoltage category III acc. to EN
l
61800-5-1) can be connected directly to symmetrically earthed(grounded) three-phase indu
strial mains supply networks [TN-system, TT-system with earthed(grounded) neutral point,
not more than 42,000rms symmetrical amperes, 480VAC maximum] when protected by
fuses type Fusetron FRS-R-50 for SERVOSTAR 640 or FRS-R-80 class RK5 for
SERVOSTAR 670, manufactured by Bussman, or equivalent, 480VAC min. Connection to
other mains supply networks ð p. 46.
The use of external mains chokes and mains filters is required.
12/2010 Kollmorgen
-
Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo ampli
l
fier 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.
The brake resistors have to be protected by fuses type Limitron KLM, rated for 500VAC/DC
l
The SERVOSTAR 640/670 family of servo amplifiers is only intended to drive specific
l
brushless synchronous servomotors with closed-loop control of torque, speed and/or position. The rated voltage of the motors must be at least as high as the DC bus link voltage of
the servo amplifier. The motor must have integral thermal protection.
l The servo amplifiers may only be operated in a closed switchgear cabinet, taking into
account the ambient conditions defined on page 22 and the dimensions shown on page 34.
Ventilation or cooling may be necessary to prevent enclosure ambient from exceeding 45°C
(113°F).
l
Use copper wire only. Wire size may be determined from EN 60204 (or table 310-16 of the
NEC 60°C or 75°C column for AWG size).
l
Consider the specifications on page 71 when you use the personnel safe restart lock -AS-.
2.3 Prohibited use
l
Other use than described in chapter II.52.2 is not intended and can lead to damage of per
sons, equipment or things.
l
The use of the servo amplifier in the following environments is prohibited:
- potentially explosive areas
- environments with corrosive and/or electrically conductive acids, alkaline solutions,
oils, vapours, dusts
- directly on non-grounded supply networks or on asymmetrically grounded supplies
with a voltage >230V.
- on ships or off-shore applications
l
Commissioning the servo amplifier is prohibited if the machine in which it was installed,
- does not meet the requirements of the EC Machinery Directive
- does not comply with the EMC Directive or with the Low Voltage Directive
- does not comply with any national directives
l
The control of holding brakes by the SERVOSTAR 640/670 alone may not be used in appli
cations, where personnel security is to be ensured with the brake.
-
-
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10 SERVOSTAR®640/670 Instructions Manual
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12/2010 Approvals
3 Approvals
3.1 UL and cUL- Conformance
This servo amplifier is listed under UL file number E217428.
UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfill the relevant U.S. and
Canadian standard (in this case UL 840 and UL 508C).
This standard describes the fulfillment by design of minimum requirements for electrically operated
power conversion equipment, such as frequency converters and servo amplifiers, which is intended
to eliminate the risk of fire, 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 fulfillment by design of minimum requirements for electrically operated
power conversion equipment, such as frequency converters and servo amplifiers, which is intended
to eliminate the risk of fire being caused by such equipment.
UL 840
UL 840 describes the fulfillment by design of air and insulation creepage spacings for electrical
equipment and printed circuit boards.
3.2 EC - conformance
Conformance with the EC EMC Directive (2004/108/EC) and the Low Voltage Directive
(2006/95/EC) is mandatory for the supply of servo amplifiers within the European Community. Product standard EN 61800-3 is applied to ensure conformance with the EMC Directive.
Concerning noise immunity the servo amplifier meets the requirements to the 2nd environmental
category (industrial environment). For noise emission the amplifier meets the requirement to a product of the category C2 (motor cable £ 25m).
This product can cause high-frequency interferences in non industrial
environments which can require measures for interference suppression.
With a motor cable length from 25m onwards, the servo amplifier meets the requirement to the
category C3.
The servo amplifiers have been tested in a defined configuration, using the system components that
are described in this documentation. Any divergence from the configuration and installation descri
bed in this documentation means that you will be responsible for carrying out new measurements to
ensure conformance with regulatory requirements. The standard EN 61800-5-1 is applied to ensure
conformance with the Low Voltage Directive.
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SERVOSTAR®640/670 Instructions Manual 11
Approvals
12/2010 Kollmorgen
3.2.1 EC Declaration of Conformity
12 SERVOSTAR®640/670 Instructions Manual
Kollmorgen
12/2010 Approvals
3.2.2 European directives and standards for the machine builder
Servo amplifiers are components that are intended to be incorporated into electrical plant and
machines for industrial use. When the servo amplifiers are built into machines or plant, the amplifier
must not be used until it has been established that the machine or equipment fulfills the require
ments of the
EC Machinery Directive (2006/42/EG)
l
EC EMC Directive (2004/108/EC)
l
EC Low Voltage Directive (2006/95/EC)
l
Standards to be applied for conformance with the EC Machinery Directive (2006/42/EG)
EN 60204-1 (Safety and Electrical Equipment in Machines)
EN 12100 (Safety of Machines)
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.
Standards to be applied for conformance with the EC Low Voltage Directive(2006/95/EC)
EN 60204-1 (Safety and Electrical Equipment in Machines)
EN 60439-1 (Low Voltage Switchgear Combinations)
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Standards to be applied for conformance with the EC EMC Directive (2004/108/EC)
EN 61000-6-1 / 2 (Interference Immunity in Residential & Industrial Areas)
EN 61000-6-3 / 4 (Interference Generation in Residential & Industrial Areas)
The manufacturer of the machine/plant is responsible for ensuring that it meets the limits required
by the EMC regulations. Advice on the correct installation for EMC (such as shielding, grounding,
treatment of connectors and cable layout) can be found in this documentation.
The machine/plant manufacturer must check whether other standards or EC
Directives must be applied to the machine/plant.
We only guarantee the conformance of the servo system with the standards cited in this chapter if
the components (motor, cables, chokes etc.) are those supplied by us.
SERVOSTAR®640/670 Instructions Manual 13
Approvals
3.3 GOST-R Conformance
Certificate for servo amplifiers and accessories (cover page).
12/2010 Kollmorgen
14 SERVOSTAR®640/670 Instructions Manual
Kollmorgen
4 Handling
4.1 Transport
Only by qualified personnel in the manufacturer’s original recyclable packaging
l
Avoid shocks
l
Temperature –25 to +70°C (-13...158°F), max. 20K/hr rate of change
l
Humidity max. 95% relative humidity, no condensation
l
The servo amplifiers contain electrostatically sensitive components which can be
l
damaged by incorrect handling. Discharge yourself before touching the servo ampli
fier. 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 ship
l
per and the manufacturer.
4.2 Packaging
Cardboard box, can be recycled
l
Dimensions: (HxWxD) 410x470x490 mm
l
12/2010 Handling
-
-
Weight incl. accessories approx. ca. 25 Kg
l
Labeling : nameplate outside at the box
l
4.3 Storage
l
Storage only in the manufacturer’s original recyclable packaging
l
Max. stacking height 3 cartons
l
Storage temperature -25 to +55°C, max. rate of change 20°C / hour
l
Storage humidity 5 ... 95% relative humidity, no condensation
l
Storage duration Less than 1 year without restriction.
More than 1 year: capacitors must be re-formed before setting up and operating the servo
amplifier. To do this, remove all electrical connections and apply single-phase 230V AC for
about 30 minutes to the terminals L1 / L2.
4.4 Maintenance
The instruments do not require any maintenance, opening the instruments invalidates the warranty.
Cleaning : — if the casing is dirty: clean with Isopropanol or similar
— if there is dirt inside the unit it must be cleaned by the manufacturer
— dirty protective grill on fan must be cleaned with a dry brush
do not immerse or spray
SERVOSTAR®640/670 Instructions Manual 15
Handling
4.5 Disassembling
Observe the sequence below, if a servo amplifier has to be disassembled (e.g. for replacement).
1. Electrical disconnection
Switch off the main switch of the switchgear cabinet and the fuses that supply the
system.
Wait at least eight minutes after disconnecting the servo amplifier from the main
supply power before touching potentially live sections of the equipment (e.g.
contacts) or undoing any connections. To be sure, measure the voltage in the DC
Bus link and wait until it has fallen below 40V.
Remove the connectors. Disconnect the earth (ground) connection at last.
2. Check temperature
During operation the heat sink of the servo amplifier may reach temperatures
above 80°C (176°F). Before touching the device, check the temperature and wait
until it has cooled down below 40°C (104°F).
12/2010 Kollmorgen
3. Disassembling
Remove the fan housing and disassemble the servo amplifier (reverse of the procedure described
in chapter "Mechanical installation).
4.6 Repair
Repair of the servo amplifier must be done by the manufacturer. Opening the devices means loss of
the guarantee. Use the telefax form on page 116 for repair request. You'll receive the current dispatch information.
Disassemble the equipment as described in chapter 4.5 and send it in the original packaging to the
address given in the dispatch information.
4.7 Disposal
In accordance to the WEEE-2002/96/EC-Guidelines we take old devices and accessories back for
professional disposal. Transport costs are the responsibility of the sender. Use the telefax form on
page 116 for disposal request. You'll receive the current dispatch information.
Disassemble the equipment as described in chapter 4.5 and send it in the original packaging to the
address given in the dispatch information.
16 SERVOSTAR®640/670 Instructions Manual
Kollmorgen
5 Package
5.1 Package supplied
When you order a SERVOSTAR 640/670 series amplifier (order codes ð p.115), you will receive:
— SERVOSTAR 640/670
— mating connectors X3, X4
The mating SubD connectors are not part of the package!
— Assembly and Installation Instructions (product manual)
— Online documentation on CD-ROM
— Setup software DRIVE.EXE on CD-ROM
12/2010 Package
Accessories:
— Mains filter 3EF required
— Mains choke 3L required
— AC Servomotor (linear or rotary)
— motor cable as a cut-off length
— brake cable as a cut-off length
— feedback cable (pre-assembled) or
both feedback connectors separately, with feedback cable as length
— external brake resistor BAS, usually required
— communications cable to the PC (ð p.68) or Y-adapter (ð p.90) for parameter setting of up
to 6 servo amplifiers from one PC
— power cable, control cables, fieldbus cables (as lengths)
5.2 Nameplate
The nameplate depicted below is attached to the side of the servo amplifier.
The information described0 below is printed in the individual fields.
Servo amplifier type
(must be ordered separately; description see accessories manual)
CommentsSerial number
IND. CONT. EQ.
Enclosure Rating
U
CUS
L
®
LISTED
1VD4
max. ambient
temperature
Electrical supply
Installed load
Output current
in S1 operation
Hardware Revision
SERVOSTAR®640/670 Instructions Manual 17
Package
5.3 Part number scheme
12/2010 Kollmorgen
S64001-SE*
Family
S6 S600
Current rating
40 40A rms
70 70A rms
Voltage rating
0 230...480V
* additional coding defines customer specific specials.
Comparison (without expansion) device name -> part number
Device Name Part Number
SERVOSTAR 640 S64001-NA
SERVOSTAR 670 S67001-NA
Expansions
NA no expansion
DN DeviceNet
PB PROFIBUS
SE SERCOS
SN SynqNet
EC ETHERCAT
IO I/O-Expansion
electr. option
1AS
18 SERVOSTAR®640/670 Instructions Manual
Kollmorgen
12/2010 Technical description
6 Technical description
6.1 The digital servo amplifiers of the series SERVOSTAR 640/670
Standard version
2 current ratings (40 A, 70 A)
l
Wide range of rated voltage (3x208V
l
Overvoltage category III acc. to EN 61800-5-1
l
Shield connection directly at the servo amplifier
l
Integrated CANopen (default 500 kBaud), for integration into CANbus systems and for
l
–10%
to 3x480V
setting parameters for several amplifiers via the PC-interface of one amplifier
Integrated RS232, electrically isolated, integrated pulse-direction interface
l
-AS- built-in safety relay (personnel-safety starting lock-out), (ð p.70)
l
Slot for an expansion card
l
Synchronous servomotors, linear motors and asynchronous motors can be used
l
Power supply
With external mains filter and mains choke directly off grounded 3~ system,
l
-10%
-10%
... 480V
... 480V
230V
208V
+10%
+10%
,50Hz,
,60Hz,
+10%
)
TN-system, TT-system with earthed (grounded) neutral point, not more than 42,000 rms
symmetrical amperes, 480VAC maximum; when protected by fuses type Fusetron FRS-R-80
(Class RK5), manufactured by Bussman, or equivalent 480VAC min
Connection to other mains supply networks only with insulating transformer ð p. 46
l
BB6 rectifier bridge, off 3-phase earthed (grounded) supply, integral inrush circuit
l
Fusing (e.g. fusible cutout) provided by the user
l
All shielding connections directly on the amplifier
l
Output stage: IGBT- module with isolated current measurement
l
Brake circuit: with dynamic distribution of the brake power between several
amplifiers on the same DC bus link circuit, external brake resistor
l
DC bus link voltage 260 ... 900 VDC, can be switched in parallel
l
Interference suppression filter for the 24V aux. supply (to category C2) is integrated
External interference suppression filter for the supply input (to category C2)
required. External mains choke required.
Integrated safety
l
Safe electrical separation between the power input / motor connections and the signal elec
tronics, provided by appropriate insulation/creepage distances and complete electrical isola
tion
l
Soft-start, overvoltage recognition, short-circuit protection, phase-failure monitoring
l
Temperature monitoring of servo amplifier and motor
(when using our motors with our pre-assembled cables)
-
-
Auxiliary supply voltage 24VDC
l
Electrically isolated, internal fusing, from an external 24VDC psu, e.g. with isolating transfor
mer
SERVOSTAR®640/670 Instructions Manual 19
-
Technical description
Operation and parameter setting
With our user-friendly software for setup through the serial interface of a PC
l
Direct operation by means of two keys on the servo amplifier and a 3-character LED display
l
for status display in case of no PC available
Fully programmable via RS232 interface
l
Completely digital control
Digital current controller (space vector pulse-width modulation, 62.5 µs)
l
Freely programmable digital speed controller (62.5 µs or 250 µs)
l
Integral position controller with adaptation possibilities for customer needs (250 µs)
l
Pulse direction interface integrated for connection of a servomotor to a stepping motor
l
control
Evaluation of the resolver signals and sine-cosine signals of a high-resolution encoder
l
Encoder simulation (incremental or SSI)
l
Comfort functions
2 analog monitor outputs
l
4 programmable digital inputs (normally, two are defined as limit-switch inputs)
l
2 programmable digital outputs
l
Freely programmable combinations of all digital signals
l
12/2010 Kollmorgen
Expansions
-I/O-14/08- expansion card, ð p. 98
l
l
PROFIBUS DP expansion card, ð p. 101
l
SERCOS expansion card, ð p. 102
l
DeviceNet expansion card, ð S. 104
l
EtherCAT expansion card, ð S. 107
l
SynqNet expansion card, ð S. 108
l
-2CAN- Expansion module, separated connectors for CAN bus and RS232, ð p. 110
l
Third party expansion cards (ModBus, FireWire, LightBus etc. - contact distributors for furt
her information)
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20 SERVOSTAR®640/670 Instructions Manual
Kollmorgen
6.2 Technical data
Rated data DIM SERVOSTAR 640 SERVOSTAR 670
Rated-supply voltage (grounded system)
Rated installed load for S1 operation kVA 30 50
Rated DC bus link voltage V= 290...675
Rated output current (rms value, ± 3%)
at 230V Arms 40 85
at 400V Arms 40 80
at 480V Arms 40 70
Peak output current (max. ca. 5s, ± 3%)
at 230V 80 160
at 400V 80 160
at 480V 80 140
Clock frequency of the output stage kHz 8
Technical data of the brake circuit — ð p.25
Overvoltage protection threshold V 450...900
Form factor of the output current
(at rated data and min. load inductance)
Bandwidth of subordinate current controller kHz > 1.2
Residual voltage drop at rated current V 5
Quiescent dissipation, output stage disabled W 40
Dissipation at rated current (incl. power
supply losses, without brake dissipation)
Inputs/Outputs
Setpoint 1/2, resolution 14bit/12bit V
Common-mode voltage max. V
Input resistance to AGND
Digital inputs
Digital outputs, open collector
BTB/RTO output, relay contacts
Aux. power supply, electrically isolated V 24 (-0% +15%)
without brake A 2 (max. 16)
Aux. power supply, electrically isolated V 24 (-0% +15%)
with brake (consider voltage loss!) A 5 (max. 16)
Min/max. output current, brake A 0.75 / 3
Connections
Control signals — Combicon 5,08 / 18 pole , 2,5mm²
Power signals — Terminals 10mm² — 50mm²
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)
Thermal control, Motor — min. 15VDC, 5mA
Mechanical
Weight kg 19.5 21
Height without shield sheet, w/o eyes (w. eyes) mm 345 (375)
Height with shield sheet, w/o eyes (w. eyes) mm 484 (495)
Width mm 250
Depth without connectors mm 300
Depth with connectors mm 325
12/2010 Technical description
V~ 3 x 230V-10% ... 480V+10%, 50 Hz
V~ 3 x 208V-10% ... 480V+10%, 60 Hz
— 1.01
W 400 700
±10
±10
kW
V low 0...7 / high 12...36
mA 7
V max. 30
mA 10
V DC max. 30, AC max. 42
mA 500
20
SERVOSTAR®640/670 Instructions Manual 21
Technical description
6.2.1 Recommended torques
Connector Recommended torque
X3, X4 0.3 Nm (2.25 in lb)
X10 0,3 Nm (2.25 in lb)
X0 6...8 Nm (45... 60 in lb)
6.2.2 Fusing
Internal fusing
Circuit Internal fuse
Auxiliary supply 24V 4 AT
Brake resistor electronic
External fusing
Fusible cutouts or similar
(Fuse UL time delay)
AC supply F
Type of branch circuit fuses:
Class RK5, 480V min
Brake resistor F
* (x=SorS-Rfor480V applications x=NorN-Rfor230V applications ð p. 10)
Note: The SERVOSTAR 640/670 drives are suitable for use on a circuit capable of delivering not more
than 42000rms symmetrical amperes, 480VAC max.
N1/2/3
B1/2
12/2010 Kollmorgen
SERVOSTAR 640 SERVOSTAR 670
50 AT (FRx-50) * 80 AT (FRx-80) *
KLM 20 KLM 30
6.2.3 Ambient conditions, ventilation, mounting position
Storage, hints
Transport, hints
Supply voltage tolerances
Input power (ð p.46)
Aux. power supply
Ambient temperature in operation
Humidity in operation
Site altitude
Pollution level
Vibrations
Noise emission
Enclosure protection
Mounting position
Ventilation
Make sure that there is sufficient forced ventilation within the switchgear cabinet.
ð p.15
ð p.15
min 3x230V
min 3x208V
AC / max 3x 480V
-10%
AC / max 3x 480V
-10%
24 VDC (-0% +15%), check voltage drop
0to+45
o
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
Pollution level 2 to EN60204
Class 3M1 according to IEC 721-3-3
max. 45 dB(A)
IP 20 according to EN 60529
generally vertical. ð p.34
forced convection by built-in fans
+10%
,50Hz
+10%
,60Hz
2.5% / K
22 SERVOSTAR®640/670 Instructions Manual
Kollmorgen
6.2.4 Conductor cross-sections
Observe the technical data for connection cables ð p. 41.
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 bus link 25 mm² (2 awg), shielded for lengths > 20 cm, 600V, 80°C (176°F)
Motor cables
Resolver, thermal control
Encoder, thermal control
Setpoints, monitors, AGND 0.25 mm² (22awg) twisted pairs, shielded
Control signals, BTB, DGND 0.5 mm² (20 awg)
Holding brake (motor)
+24 V / XGND
Brake resistor ð p.41, min. 10 mm² (6 awg), shielded, 1000V, 80°C (176°F)
For multi-axis systems, please note the special operating conditions in your installation
To reach the max. permitted cable length, observe cable requirements ð p. 41.
* Kollmorgen North America delivers cables up to 39m length.
* Kollmorgen Europe delivers cables up to the maximum length.
25 mm² (2 awg), shielded between filter and amplifier, 600V, 80°C
(176°F)
ð p.41, cross section see manual of the used motor series,
capacitance <250pF/m, 600V, 80°C (176°F)
4x2x0.25 mm² (22awg) twisted pairs, shielded, max.100m,
capacitance <120pF/m
7x2x0,25 mm² (22awg) twisted pairs, shielded, max.50m,
capacitance <120pF/m
min. 1.5 mm² (14 awg), 600V, 80°C (176°F), shielded,
check voltage drop
max. 2.5 mm² (12 awg), check voltage drop
12/2010 Technical description
6.3 LED display
A 3-character LED display shows the amplifier status after switching on the 24V supply
(ð p.93). During operation and parameter setting of the amplifier via the keys on the front panel, the
parameter and function numbers (ð p.93) are displayed, as well as the numbers of any errors
which occur (ð p.94).
6.4 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 emulation, RS232, CAN, PROFIBUS, optically isolated
The potential isolation is shown in the block diagram (ð p. 43).
SERVOSTAR®640/670 Instructions Manual 23
Technical description
12/2010 Kollmorgen
6.5 Control for motor holding brake
A 24 V / max. 3 A holding brake in the motor can be controlled directly by the servo amplifier.
Check voltage drop, measure the voltage at brake input and check brake function
(brake and no brake). This function does not ensure personnel safety! Hanging
load (vertical axes) require an additional mechanical brake which must be safely
operated.
The brake function must be enabled through the BRAKE parameter (setting: WITH BRAKE). In the
diagram below you can see the time and functional relationships between the ENABLE signal,
speed setpoint, speed and braking force.
During the internal ENABLE delay time of 100 ms (DECDIS) the speed setpoint of the servo ampli
fier is internally driven down a 10 ms ramp to 0. The brake output is switched on when a speed of
5rpm is reached or after 5s (EMRGTO) the latest.
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 48.
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24 SERVOSTAR®640/670 Instructions Manual
Kollmorgen
6.6 Electrical brake 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 brake resistor (ð p. 112). The brake resistor is switched into circuit by the
brake circuit. The brake 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 brake power which is required. A
simple method is described in the "Product Wiki" which is accessible at www.wiki-kollmorgen.eu.A
description of the interface can be found on page 48.
Functional description:
1.- Individual amplifiers, not coupled through the DC bus link (DC+, DC-)
The circuit starts to respond at a DC bus 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 brake power, then the servo amplifier will output the status
“brake power exceeded” and the brake circuit will be switched off. At the next internal check of the
DC bus 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. 94).
The BTB/RTO contact (terminal X3/2,3) will be opened at the same time (ð p. 67).
2.- Several servo amplifiers coupled through the DC bus link circuit (DC+, DC-)
Thanks to the built-in brake circuit with its patented power distribution, several amplifiers (even with
different current ratings) can be operated off a common DC bus link. This is achieved by an auto
matic adjustment of the brake thresholds (which vary, because of tolerances).
The brake 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. 67).
12/2010 Technical description
-
Brake circuit: technical data SERVOSTAR
Supply voltage Rated data DIM 640 670
External regen resistor Ohm 15 10
Upper switch-on level of regen circuit V 400 - 430
3 x 230 V
Switch-off level of regen circuit V 380 - 410
Overvoltage F02 V 450
Continuous power of regen circuit (R
Pulse power, external (R
max. 1s) kW 10 16
Bext
) max. kW 6
Bext
External regen resistor Ohm 15 10
Upper switch-on level of regen circuit V 720 - 750
3 x 400 V
Switch-off level of regen circuit V 680 - 710
Overvoltage F02 V 800
Continuous power of regen circuit (R
Pulse power, external (R
max. 1s) kW 35 50
Bext
) max. kW 6
Bext
External regen resistor Ohm 15 10
Upper switch-on level of regen circuit V 840 - 870
3 x 480 V
Switch-off level of regen circuit V 800 - 830
Overvoltage F02 V 900
Continuous power of regen circuit (R
Pulse power, external (R
max. 1s) kW 45 70
Bext
) max. kW 6
Bext
Suitable external regen resistors can be found in our accessories manual.
SERVOSTAR®640/670 Instructions Manual 25
Technical description
12/2010 Kollmorgen
6.7 Switch-on and switch-off behavior
This chapter describes the switch-on and switch-off behavior of the SERVOSTAR 6xx and the steps
required to achieve operational stopping or emergency stop behavior that complies with standards.
The servo amplifier’s 24 V supply must remain constant. The ASCII commands
ACTFAULT (error response) and STOPMODE (ENABLE signal response) dictate
how the drive will behave.
STOPMODE ACTFAULT
0 (default) 0
1 1 (default)
Behavior during a power failure
The servo amplifiers use an integrated circuit to detect if one or more input phases (power supply
feed) fail. The behavior of the servo amplifier is set using the setup software: Under “Response to
Loss of Input Phase” (PMODE) on the Basic Setup screen, select:
Warning if the higher-level control system is to bring the drive to a standstill: Warning n05 is
l
output if an input phase is missing, and the motor current is limited to 4 A. The servo ampli
fier is not disabled. The higher-level control system can now selectively end the current cycle
or start bringing the drive to a standstill. Therefore, the error message “MAINS BTB, F16" is
output on a digital output of the servo amplifier and evaluated by the control system, for ins
tance.
Error message if the servo amplifier is to bring the drive to a standstill: Error message F19
l
is output if an input phase is missing. The servo amplifier is disabled and the BTB contact
opens. Where the factory setting is unchanged (ACTFAULT=1), the motor is braked using
the set “EMERGENCY STOP RAMP”.
Behavior when undervoltage threshold is reached
If the undervoltage threshold is undershot in the DC bus link (the threshold value depends on the
type of servo amplifier), the error message “UNDERVOLTAGE, F05" is displayed. The drive
response depends on the ACTFAULT/STOPMODE setting.
Behavior (see also ASCII reference in the
tup software)
Motor coasts to a standstill in an uncontrolled manner
Motor is braked in a controlled manner
online help of the se
-
-
-
Behavior with enabled “holding brake” function
Servo amplifiers with an enabled holding brake function have a special procedure for switching off
the output stage ( ð p. 24). Removing the ENABLE signal triggers electrical braking. As with all
electronic circuits, the general rule applies that there is a possibility of the internal “holding brake”
module failing. Bringing a motor to a standstill using a holding brake in a way that is personnel safe
also requires an electromechanical “make” contact for the holding equipment and a suppressor
device for the brake.
Behavior of the restart lock -AS-
With the personnel safe restart lock –AS-, the drive can be secured on standstill using its internal
electronics so that even when power is being supplied, the drive shaft is protected against uninten
tional restart. The chapter “Personnel safe restart lock -AS-” describes how to use the restart lock
–AS-. See page 70 onwards.
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26 SERVOSTAR®640/670 Instructions Manual
Kollmorgen
12/2010 Technical description
6.7.1 Behavior in standard operation
The behavior of the servo amplifier always depends on the current setting of a number of different
parameters (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see
below illustrates the correct functional sequence for switching the servo amplifier on and off.
DC bus link
online help). The diagram
Motor speed
Power stage
Enable (internal)
Devices which are equipped with a selected “Brake” function use a special sequence for switching
off the output stage (ð p. 24).
The built-in restart lock -AS- can be used to switch off the drive via a positive-action (approved by
Trade Liability Association) safety relay, so that personnel safety is ensured at the drive shaft
(ð p. 70).
SERVOSTAR®640/670 Instructions Manual 27
Technical description
12/2010 Kollmorgen
6.7.2 Behavior in the event of an error (with standard setting)
The behavior of the servo amplifier always depends on the current setting of a number of different
parameters (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see
gram shows the startup procedure and the procedure that the internal control system follows in the
event of one or more electrical supply phases failing, assuming that the standard parameter settings
apply.
online help ). The dia
-
(F16/F19 = error messages Mains BTB /input phase, F05 = error message Undervoltage)
Even if there is no intervention from an external control system (in the example, the ENABLE signal
remains active), the motor is immediately braked using the emergency stop ramp if an input phase
error is detected and assuming that no changes have been made to the factory setting (ACT
FAULT=1).
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28 SERVOSTAR®640/670 Instructions Manual
Kollmorgen
12/2010 Technical description
6.8 Stop/Emergency Stop Function to EN 60204
With the personnel safe restart lock –AS- (see page 70 onwards) the drive can be
secured on standstill (torque-free) using its internal electronics so that even when
power is being supplied, the drive shaft is protected against unintentional restart.
The parameters “STOPMODE” and “ACTFAULT” must be set to 1 in order to
implement the stop categories. If necessary, change the parameters via the
terminal screen of the setup software and store the data in the EEPROM.
Examples for implementation can be found in the Product WIKI on page "Stop and Emergency Stop
Function".
6.8.1 Stop: Standards
The Stop function is used to shut down the machine in normal operation. The Stop functions are
defined by EN 60204.
Category 0: Shut-down by immediate switching-off of the energy supply to the
drive machinery (i.e. an uncontrolled shut-down);
Category 1: A controlled shut-down , whereby the energy supply to the drive
machinery is maintained to perform the shut-down, and the energy
supply is only interrupted when the shut-down has been completed;
Category 2: A controlled shut-down, whereby the energy supply to the drive
machinery is maintained.
The Stop Category must be determined by a risk evaluation of the machine. In addition, suitable
means must be provided to guarantee a reliable shut-down.
Category 0 and Category 1 Stops must be operable independently of the operating mode, whereby
a Category 0 Stop must have priority. Stop functions must be implemented by disconnection of the
appropriate circuitry, and have priority over assigned start functions.
If necessary, provision must be made for the connection of protective devices and lock-outs. If
applicable, the Stop function must signal its status to the control logic. A reset of the Stop function
must not create a hazardous situation.
Examples for implementation can be found in the Product WIKI on page "Stop and Emergency Stop
Function".
SERVOSTAR®640/670 Instructions Manual 29
Technical description
12/2010 Kollmorgen
6.8.2 Emergency Stop: Standards
The emergency Stop function is used for the fastest possible shut-down of the machine in a dan
gerous situation. The Emergency Stop function can be triggered by the actions of a single person. It
must be fully functional and available at all times. The user must not have to work out how to ope
rate this mechanism.
The Emergency Stop function is defined by EN 60204.
In addition to the requirements for Stop, the emergency Stop must fulfil the following requirements:
emergency stop must have priority over all other functions and controls in all operating situa
l
tions;
the energy supply to any drive machinery that could cause dangerous situations must be
l
switched off as fast as possible, without causing any further hazards (e.g. by using mechani
cal latching devices that do not require an external supply of energy, by counter-current bra
king in Stop Category 1);
the reset must not initiate a restart.
l
If necessary, provision must be made for the additional connection of emergency stop devices (see
EN 60204, "Requirements for emergency stop devices").
The Emergency Stop must be effective as a stop of either Category 0 or Category 1.
The Emergency Stop Category must be determined by a risk evaluation of the machine.
Category 0
Only hard-wired, electromechanical components may be used for the Category 0 Emergency Stop
function. It must not be triggered using switching logic (hardware or software), by transferring commands via a communication network, or via a data link.
The drive must be shut down using an electromechanical circuit. If the connected servo motor has
an integrated brake, this must always be controlled by an electromechanical circuit as well.
-
-
-
-
-
Category 1
With the Category 1 Emergency Stop function, there must be absolute certainty in terms of the
power supply for the machine drives being switched off (i.e., secured) using electromechanical components. Additional Emergency Stop equipment may be connected. Bringing the motor to a standstill by interrupting the mains supply and using controlled electronic braking. The 24 V supply for the
servo amplifier must remain constant. The issue of which circuit should be used is highly dependent
on the requirements of the application at hand.
Usually a brake in a servo motor only has the function of a holding brake. To ensure an emergency
stop function, the braking torque that is required must be checked. If the holding brake fulfills the
dynamic requirements, it must be taken into acount that this application will cause increased wear.
Examples for implementation can be found in the Product WIKI on page "Stop and Emergency Stop
Function".
30 SERVOSTAR®640/670 Instructions Manual
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