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
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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.
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-
-
-
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
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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
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Output stage: IGBT- module with isolated current measurement
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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
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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)
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Freely programmable digital speed controller (62.5 µs or 250 µs)
l
Integral position controller with adaptation possibilities for customer needs (250 µs)
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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
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Encoder simulation (incremental or SSI)
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Comfort functions
2 analog monitor outputs
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4 programmable digital inputs (normally, two are defined as limit-switch inputs)
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2 programmable digital outputs
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Freely programmable combinations of all digital signals
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12/2010 Kollmorgen
Expansions
-I/O-14/08- expansion card, ð p. 98
l
l
PROFIBUS DP expansion card, ð p. 101
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SERCOS expansion card, ð p. 102
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DeviceNet expansion card, ð S. 104
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EtherCAT expansion card, ð S. 107
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SynqNet expansion card, ð S. 108
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-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
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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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6.9 Shock-hazard protection
6.9.1 Leakage current
Leakage current via the PE conductor results from the combination of equipment and cable leakage
currents. The leakage current frequency pattern comprises a number of frequencies, whereby the
residual-current circuit breakers definitively evaluate the 50Hz current. For this reason, the leakage
current cannot be measured using a conventional multimeter.
As a rule of thumb, the following assumption can be made for leakage current on our low-capacity
cables at a mains voltage of 400 V, depending on the clock frequency of the output stage:
Ileak=nx20mA+Lx1mA/m at 8kHz clock frequency at the output stage
Ileak=nx20mA+Lx2mA/m at a 16kHz clock frequency at the output stage
(where Ileak=leakage current, n=number of amplifiers, L=length of motor cable)
At other mains voltage ratings, the leakage current varies in proportion to the voltage.
Example: 2 x servo amplifiers + a 25m motor cable at a clock frequency of 8kHz:
2 x 20mA + 25m x 1mA/m = 65mA leakage current.
Since the leakage current to PE is more than 3.5 mA, in compliance with EN
61800-5-1 the PE connection must either be doubled or a connecting cable with a
cross-section >10mm² must be used.
The following measures can be used to minimise leakage currents.
— Reduce the length of the engine cable
— Use low-capacity cables (see p.41)
12/2010 Technical description
6.9.2 Residual-current circuit breakers (FI)
In conformity with DIN IEC 60364-4-41 – Regulations for installation and EN 60204 – Electrical
equipment of machinery, residual-current circuit-breakers (called FI below) can be used provided
the requisite regulations are complied with.
The SERVOSTAR 640/670 is a 3-phase system with a B6 bridge. Therefore, FIs which are sensi-
tive to all currents must be used in order to detect any d.c. fault current. Refer to chapter 6.9.1 for
the rule of thumb for determining the leakage current.
Rated residual currents in the FI
10 -30 mA
50 -300 mA
Protection against "indirect contact" (personal fire protection) for stationary and mo
bile equipment, as well as for "direct contact".
Protection against "indirect contact" (personal fire protection) for stationary equip
ment
Recommendation: In order to protect against direct contact (with motor cables
<5m) we recommend that each servo amplifier be protected individually using a
30mA residual-current circuit-breaker which is sensitive to all currents.
If you use a selective FI circuit-breaker, the more intelligent evaluation process will prevent spurious
tripping of the circuit-breakers.
6.9.3 Isolating transformers
If protection against indirect contact is absolutely essential despite a higher leakage current, or if an
alternative form of shock-hazard protection is sought, the SERVOSTAR 640/670 can also be opera
ted via an isolating transformer.
-
-
-
A ground-leakage monitor can be used to monitor for short circuits.
We would advise you to keep the length of wiring between the transformer and the
servo amplifier as short as possible.
SERVOSTAR®640/670 Instructions Manual 31
Technical description
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32 SERVOSTAR®640/670 Instructions Manual
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12/2010 Mechanical Installation
7 Mechanical Installation
7.1 Safety Instructions
There is a danger of electrical shock by high EMC level which could result in injury,
if the servo amplifier (or the motor) isn't properly EMC-grounded. Do not use
painted (i.e. non-conductive) mounting plates.
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.
The servo amplifier will switch-off itself in case of overheating. Ensure that there is
an adequate flow of cool, filtered air into the bottom of the control cabinet, or use a
heat exchanger. Please refer to page 22.
Don't mount devices, which produce magnetic fields, directly beside the servo
amplifier. Strong magnetic fields could directly affect internal components. Install
devices which produce magnetic field with distance to the servo amplifiers and/or
shield the magnetic fields.
7.2 Guide to mechanical installation
The following notes should assist you to carry out the mechanical installation in a sensible
sequence, without overlooking anything important.
In a closed switchgear cabinet. Observe page 22 .
Site
Ventilation
Assembly
Grounding
Shielding
The site must be free from conductive or corrosive materials.
For the mounting position in the cabinet ð p. 34
Check that the ventilation of the servo amplifier is unimpeded
and keep within the permitted ambient temperature ð p. 22 .
Keep the required space clear above and below the servo amplifier ð p34.
Assemble the servo amplifier and power supply, filter and choke close
together on the conductive, grounded mounting plate in the cabinet.
EMC-compliant (EMI) shielding and grounding (ð p. 45)
Earth (ground) the mounting plate, motor housing and CNC-GND of the controls.
Notes on connection techniques are on page 40
SERVOSTAR®640/670 Instructions Manual 33
Mechanical Installation
7.3 Assembly
Ask our customer service for information for pass through mounting
Material : 4 hexagon socket screws to EN 4762, M6
Tool required : 5 mm Allen key
12/2010 Kollmorgen
- A.4.038.4/12
SERVOSTAR 640/670
34 SERVOSTAR®640/670 Instructions Manual
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7.4 Dimensions
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SERVOSTAR®640/670 Instructions Manual 35
Mechanical Installation
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36 SERVOSTAR®640/670 Instructions Manual
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8 Electrical Installation
8.1 Safety Instructions
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 serious personal
injury. Wait at least five minutes after disconnecting the servo amplifier from the
main supply power before touching potentially live sections of the equipment (e.g.
contacts) or undoing any connections.
Capacitors can still have dangerous voltages present up to five minutes after
switching off the supply power. To be sure, measure the voltage in the DC Bus link
and wait until it has fallen below 40V.
Control and power connections can still be live, even if the motor is not rotating.
Wrong mains voltage, unsuitable motor or wrong wiring will damage the amplifier.
Check the combination of servo amplifier and motor. Compare the rated voltage
and current of the units. Implement the wiring according to the connection diagram
on page 39.
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
circumstances (see EN 60204-1).
12/2010 Electrical Installation
The use of external mains chokes and mains filters is required. Excessively high
external fusing will endanger cables and devices. The fusing of the AC supply
input and 24V supply must be installed by the user, best values are given on p.22.
Hints for use of Residual-current circuit breakers (FI) ð p.31.
Correct wiring is the basis for reliable functioning of the servo system.
Route power and control cables separately. We recommend a distance of at least
200mm. This improves the interference immunity. If a motor power cable is used
that includes cores for brake control, the brake control cores must be separately
shielded. Ground the shielding at both ends. Ground all shielding with large areas
(low impedance), with metalized connector housings or shield connection clamps
wherever possible. Notes on connection techniques can be found on page 40.
Feedback lines may not be extended, since thereby the shielding would be
interrupted and the signal processing could be disturbed. Lines between amplifiers
and external brake resistor must be shielded. Install all power cables with an
adequate cross-section, as per EN 60204 (ð p.23) and use the requested cable
material (ð p. 41) to reach max. cable length.
The servo amplifier's status must be monitored by the PLC to acknowledge critical
situations. Wire the BTB/RTO contact in series into the emergency stop circuit of
the installation. The emergency stop circuit must operate the supply contactor.
It is permissible to use the setup software to alter the settings of the servo
amplifier. Any other alterations will invalidate the warranty.
SERVOSTAR®640/670 Instructions Manual 37
Electrical Installation
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8.2 Guide to electrical installation
The following notes should assist you to carry out the electrical installation in a sensible sequence,
without overlooking anything important.
Cable selec
tion
Grounding
Shielding
Wiring
-
Select cables according to EN 60204 (ð p. 23)
EMC-compliant (EMI) shielding and grounding (ð p. 45)
Earth (ground) the mounting plate, motor housing and CNC-GND of the controls.
Notes on connection techniques are on page 40
Route power leads and control cables separately
Wire the BTB/RTO contact in series into the emergency stop
circuit of the system.
— Connect the digital control inputs to the servo amplifier
— 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 emulation, if required
— Connect the expansion card (see corresponding manual on the CD-ROM)
— Connect the motor cables, connect shielding to EMI connectors at both ends
— Connect motor-holding brake, connect shielding to EMI connectors at
both ends
— Connect the external regen resistor (with fusing)
— Connect aux. supply (for max. permissible voltage values ð p. 22)
— Connect mains choke and mains filter (shielded lines between filter and
servo amplifier)
— Connect main power supply (for max. permissible voltage values ð p. 22)
— Connect PC (ð p. 68).
Final check
— Final check of the implementation of the wiring,
— according to the wiring diagrams which have been used.
38 SERVOSTAR®640/670 Instructions Manual
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8.3 Wiring
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).
8.3.1 Safety Instructions
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.
Only professional staff who are qualified in electrical engineering are allowed to
install the servo amplifier.
12/2010 Electrical Installation
The ground symbol
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:
Overview : page 45
Mains power : page 47
Motor : page 48
Feedback : page 49ff
Electronic Gearing / Master Slave
Master-Slave : page 57
Pulse-Direction : page 60
Encoder Emulation
ROD (A quad B) : page 62
SSI : page 63
Analog/Digital Inputs/Outputs : page 64ff
RS232 / PC : page 68
CAN Interface : page 69
Restart lock -AS- : page 73
Multi-axis systems, example : page 91
Expansion cards
I/O-14/08 : page 100
PROFIBUS : page 101
SERCOS : page 103
DeviceNet : page 104
EtherCAT : page 107
SynqNet : page 108
-2CAN- : page 111
X, which you will find in all the wiring diagrams, indicates
SERVOSTAR®640/670 Instructions Manual 39
Electrical Installation
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8.3.2 Shielding connection to the front panel
SERVOSTAR 640/670
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.
Use the cable tie to clamp the
shielding braid of the cable firmly
to the shielding rail.
SERVOSTAR 640/670
40 SERVOSTAR®640/670 Instructions Manual
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8.3.3 Technical data for cables
Further information on the chemical, mechanical and electrical characteristics of the cables can be
obtained from out customer service .
Observe the restrictions in the chapter "Conductor cross-sections" on page 23.
To operate the amplifier with the max. permitted cable length, you must use cable
material which meets the requirements on the capacity given below.
Insulation material
Sheathing PUR (polyurethane, code 11Y)
Core insulation PETP (polyesteraphtalate, code 12Y)
Capacitance
Motor cable £ 4mm² : less than 150 pF /m
>4mm² : less than 250 pF/m
Feedback cable less than 120 pF/m
Technical data
For a detailed description of cable types and how to assemble them, please refer to the accessories
manual.
12/2010 Electrical Installation
SERVOSTAR®640/670 Instructions Manual 41
Electrical Installation
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8.4 Components of a servo system
PC
Control / PLC
SERVOSTAR 640/670
restart lock -AS-
24V-power
supply
Mains filter
Mains choke
Drive contactor
Fuses
Fuses
Brake resistor
Motor
Terminals
Cables drawn bold are shielded. Electrical ground is
drawn with dash-dotted lines. The required accesso
ries are described in our accessories manual.
-
42 SERVOSTAR®640/670 Instructions Manual
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8.5 Block diagram
The block diagram below is just an overview.
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SERVOSTAR®640/670 Instructions Manual 43
Electrical Installation
8.6 Pin assignments
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44 SERVOSTAR®640/670 Instructions Manual
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8.7 Connection diagram (overview)
Reference Safety Instructions (ð p.9) and
Use As Directed (ð p.10) !
SERVOSTAR 640/670
ð p.51ff
ð p.50
ð p.48
ð p.47
ð p.64
ð p.65
ð p.66
ð p.67
ð p.48
ð p.47
ð p.70
ð p.62
ð p.63
ð p.57
ð p.60
ð p.69
ð p.68
ð p.98
ð p.101
ð p.102
ð p.104
ð p.107
ð p.108
SERVOSTAR®640/670 Instructions Manual 45
Electrical Installation
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8.8 Power supply
8.8.1 Connection to various mains supply networks
This page illustrates all the possible connection variations for different electrical supply networks.
An isolating transformer is always required for 400...480V mains networks without
earth (ground) and for networks with asymmetrical earth (ground).
SERVOSTAR
208V with 60Hz only
230...480V with 50Hz or 60Hz
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
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12/2010 Electrical Installation
8.8.2 Mains supply connection (X0)
— EMI filter and mains choke (required) provided by the user
— Fusing (e.g. fusible cut-outs) provided by the user ð p. 22
SERVOSTAR 640/670
8.8.3 24V auxiliary supply (X4)
— Electrically isolated, external 24VDC supply, e.g. with insulating transformer
— Required current rating ð p. 21
— Integrated EMI filter for the 24V auxiliary supply
SERVOSTAR 640/670
8.8.4 DC bus link (X0)
Can be connected in parallel, thanks to patented circuit to distribute the brake power among all the
amplifiers connected to the same DC bus link circuit. (Connection example ð p. 91).
Only servo amplifiers with mains supply from the same mains (identical mains
supply voltage) may be connected by the DC bus link.
The sum of the rated currents for all of the servo amplifiers connected in parallel
to an SERVOSTAR 640/670 must not exceed 300A.
Use unshielded single cores (>=10mm²) with a max. length of 500 mm. Use
shielded cables for longer lengths.
SERVOSTAR®640/670 Instructions Manual 47
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8.9 Motor connection with brake (X0, X4)
Cable cross section see motor documentation.
SERVOSTAR 640/670
8.10 External brake resistor (X0)
Fusing and brake resistor provided by the user
SERVOSTAR 640/670
48 SERVOSTAR®640/670 Instructions Manual
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8.11 Feedback
Every closed servo system will normally require at least one feedback device for sending actual
values from the motor to the servo drive. Depending on the type of feedback device used, informa
tion will be fed back to the servo amplifier using digital or analog means.
SERVOSTAR 640/670 supports the most common types of feedback device whose functions must
be assigned with the parameters
FBTYPE (screen page FEEDBACK), primary Feedback
EXTPOS (screen page POSITION), secondary Feedback
GEARMODE (screen page GEARING), secondary Feedback
in the setup software. Scaling and other settings must always be made here.
12/2010 Electrical Installation
-
Configuration Location ASCII Parameter
One Feedback
Two Feedbacks
For a detailed description of the ASCII parameters, please refer to the online help of the setup soft
ware.
The table below provides an overview of the supported feedback types, their corresponding para
meters and a reference to the relevant connection diagram in each case. On each of these, the pin
assignment shown on the encoder side relates to the Kollmorgen motors.
Primary feedback type Connector
Resolver X2
SinCos Encoder BISS X1
SinCos Encoder ENDAT X1
SinCos Encoder HIPERFACE X1
SinCos Encoder w/o data channel X1
SinCos Encoder + Hall X1
RS422 5V + Hall X1
ComCoder X1
RS422 5V X5
Sensorless (w/o feedback) - - 10*
* Can only be set on the terminal screen of the setup software
** RS422 means “incremental encoder AquadB”.
motor FBTYPE
motor FBTYPE
externally
EXTPOS
GEARMODE
Commu-
tation
XXX
XX
Wiring
diagram
ð p.50
ð p.51
ð p.52
ð p.52
ð p.53
ð p.54
ð p.54
ð p.55
ð p.56
Speed
control
FBTYPE
6, 7 (16*)
8*, 9*
0, 3
20*
3, 4
2, 3
11*
12*
12*
Position-
control
X
electr.
gearing
X
-
-
Hints for combining primary with secondary feedback systems for position
control/electr. gearing can be found from page 57.
SERVOSTAR®640/670 Instructions Manual 49
Electrical Installation
8.11.1 Resolver (X2)
Connection of a Resolver (2 to 36-poles) as a feedback system. The thermal control in the motor is
connected via the resolver cable to the SERVOSTAR and evaluated there.
If cable lengths of more than 100 m are planned, please contact our customer service .
FBTYPE 0, 3
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SERVOSTAR 640/670
The pin assignment shown on the encoder side relates to the Kollmorgen motors.
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8.11.2 Sine encoder with BISS (X1)
Wiring of a single-turn or multi-turn sine-cosine encoder with BISS interface as a feedback system
(firmware revision from 6.68). During start-up of the servo amplifier the parameters stored in the
encoder eeprom are uploaded, after that phase only the sine/cosine signals are used.
The thermal control in the motor is connected via the encoder cable to X1 and evaluated there. All
signals are connected using our pre-assembled encoder connection cable.
If cable lengths of more than 50m are planned, please consult our customer service.
Frequency limit (sin, cos): 250 kHz
FBTYPE 20
SERVOSTAR 640/670
The pin assignment shown on the encoder side relates to the Kollmorgen motors.
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8.11.3 Sine Encoder with EnDat 2.1 or HIPERFACE (X1)
Connection of a single-turn or multiturn sine-cosine encoder. Preferred types are ECN1313 and
EQN1325.
The thermal control in the motor is connected via the resolver cable to the SERVOSTAR and eva
luated there. All signals are connected using our pre-assembled encoder connection cable.
If cable lengths of more than 50 m are planned, please consult our customer service.
Frequency limit (sin, cos): 250 kHz
Encoder with EnDat: FBTYPE 3, 4
Encoder with HIPERFACE: FBTYPE 2, 3
SERVOSTAR 640/670
SubD15
17pol.round
-
The pin assignment shown on the encoder side relates to the Kollmorgen motors.
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8.11.4 Sine Encoder without data channel (X1)
Connection of a sine-cosine encoder without data channel as feedback unit. Every time the 24V
auxiliary voltage is switched on, the amplifier needs start-up information for the position controller
(parameter value MPHASE). Depending on the feedback type either wake&shake is executed or
the value for MPHASE is read out of the amplifier's EEPROM.
The thermal control in the motor is connected via the encoder cable to X1 and evaluated there.
If lead lengths of more than 50 m are planned, please consult our customer service.
Frequency limit (sin, cos): 250 kHz
Encoder type FBTYPE Remarks
SinCos 5V 6 MPHASE from EEPROM
SinCos 5V 7 MPHASE with wake & shake
Resolver+SinCos5V 16 Commutation with Resolver, speed&position with Encoder
With vertical load the load could fall during wake&shake, because the brake is not
active and torque is not sufficient to hold the load. Don't use this feedback type
with vertical load (hanging load).
SERVOSTAR 640/670
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8.11.5 Incremental or sine encoder with hall sensors (X1)
Feedback devices (incremental or sine-cosine), which don't deliver an absolute information for com
mutation, can be used as complete feedback system combined with an additional Hall encoder. All
signals are connected to X1.
If cable lengths of more than 25 m are planned, please consult our customer service.
Frequency limit (A, B): 250 kHz
RS422 with Hall: FBTYPE 12
Encoder with Hall: FBTYPE 11
SERVOSTAR 640/670
SubD15
-
54 SERVOSTAR®640/670 Instructions Manual
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8.11.6 ComCoder (X1)
Connection of a ComCoder as feedback unit. For the commutation hall sensors are used and for
the resolution an incremental encoder.
The thermal control in the motor is connected via the ComCoder cable to X1 and evaluated there.
If cable lengths of more than 25 m are planned, please consult our customer service.
Frequency limit (A, B): 250 kHz
RS422 with Hall: FBTYPE 12
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SERVOSTAR 640/670
SubD15
round, 17 pin
The pin assignment shown on the encoder side relates to the Kollmorgen motors.
SERVOSTAR®640/670 Instructions Manual 55
Electrical Installation
8.11.7 Incremental Encoder (X5)
An incremental encoder can be used as standard motor feedback.
Every time the 24V auxiliary voltage is switched on, the amplifier needs start-up information for the
position controller (parameter value MPHASE). Depending on the feedback type either wake&shake
is executed or the value for MPHASE is read out of the amplifier's EEPROM.
The thermal control in the motor is connected to X1 (see p.52) or X2 (see p.50).
If lead lengths of more than 50 m are planned and for questions concerning the power supply of the
encoder, please consult our customer service.
AGND and DGND (connector X3) must be joined together !
Frequency limit: 1.5 MHz
Encoder type FBTYPE Remarks
RS422 5V 9 MPHASE from EEPROM
RS422 5V 8 MPHASE with wake & shake
With vertical load the load could fall during wake&shake, because the brake is not
active and torque is not sufficient to hold the load. Don't use this feedback type
with vertical load (hanging load).
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SERVOSTAR 640/670
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8.12 Electronic Gearing, Master-slave operation
In the case of the “electronic gearing” functionality (see setup software and description of GEAR
MODE parameter), the servo amplifier is controlled by a secondary feedback device as a slave.
It is possible to set up master/slave systems, use an external encoder as a setpoint encoder or con
nect the amplifier to a stepper motor control.
The amplifier is parameterized using the setup software (electronic gearing).
Primary Feedback: adjust on screen page "Feedback" (FBTYPE)
Secondary Feedback: adjust on screen pages "Position" and "Gearing" (EXTPOS, GEARMODE)
Master-/Slave adjustment
Master: adjust encoder emulation on screen page "ROD/SSI/Encoder" (ENCMODE)
Slave: adjust on screen pages "Position" and "Gearing" (EXTPOS, GEARMODE)
The following types of external encoder can be used:
Secondary Feedback type Connector
Incremental Encoder 5V X5
Incremental Encoder 24V X3
Sine/Cosine Encoder X1
SSI Encoder X5
Pulse and Direction 5V X5
Pulse and Direction 24V X3
* adjustable via terminal screen of the setup software
The follwing table shows the allowed feedback combinations:
diagram
Wiring
ð p.58
ð p.58
ð p.59
ð p.60
ð p.61
ð p.61
GEARMODE
3, 5*, 13*, 15*
0, 2*, 10*, 12*
6, 8*, 9*, 16*
7*, 17*
4, 14*
1, 11*
-
-
Secondary Feedback for Position control/Following
Primary Feedback
Resolver (X2)
FBTYPE = 0
Sine Encoder (X1)
FBTYPE = 2,4,6,7,20
Encoder & Hall (X1)
FBTYPE = 11,12
RS422 Encoder (X5)
FBTYPE = 8,9
Sensorless
FBTYPE = 10 -
Sine Encoder
(X1)
EXTPOS = 1,2,3
GEARMODE =
6,8,9,16
FPGA = 0
ENCMODE = 0
Increment. Encoder5V/24V (X5/X3)
EXTPOS = 1,2,3
GEARMODE =
0,2,3,5,10,12,13,15
FPGA = 0
ENCMODE = 0
EXTPOS = 1,2,3
GEARMODE =
-
-
--- -
0,2,3,5,10,12,13,15
FPGA = 1
ENCMODE = 0
EXTPOS = 1,2,3
GEARMODE =
0,2,3,5,10,12,13,15
FPGA = 1
ENCMODE = 0
EXTPOS = 1,2,3
GEARMODE =
0,2,3,5,10,12,13,15
FPGA = 0
ENCMODE = 0
Pulse&Direct.
5V/24V (X5/X3)
EXTPOS = 1,2,3
GEARMODE =
1,4,11,14
FPGA = 0
ENCMODE = 0
EXTPOS = 1,2,3
GEARMODE =
1,4,11,14
FPGA = 1
ENCMODE = 0
EXTPOS = 1,2,3
GEARMODE =
1,4,11,14
FPGA = 1
ENCMODE = 0
EXTPOS = 1,2,3
GEARMODE =
1,4,11,14
FPGA = 0
ENCMODE = 0
SSI Encoder
(X5)
EXTPOS = 1,2,3
GEARMODE =
7,17
FPGA = 1
ENCMODE = 2
EXTPOS = 1,2,3
GEARMODE =
7,17
FPGA = 1
ENCMODE = 2
-
EXTPOS = 1,2,3
GEARMODE =
7,17
FPGA = 1
ENCMODE = 2
SERVOSTAR®640/670 Instructions Manual 57
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8.12.1 Connection to a SERVOSTAR master, 5 V signal level (X5)
You can 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.
Frequency limit: 1.5 MHz, slew rate tv £ 0,1 µs
SERVOSTAR 640/670
SERVOSTAR
AGND and DGND (connector X3) must be joined together !
8.12.2 Connection to incremental encoder master with 24 V signal level (X3)
This interface can be used to operate the SERVOSTAR 640/670 as a slave, mastered by an encoder with 24 V signal level (master-slave operation). The digital inputs DIGITAL-IN 1 and 2 at connector X3 must be used.
Frequency limit: 250 kHz, slew rate tv £ 0.1 µs
SERVOSTAR 640/670
AGND and DGND (connector X3) must be joined together !
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8.12.3 Connection to a sine-cosine encoder master (X1)
You can operate the SERVOSTAR 640/670 as a slave, mastered by a sine-cosine encoder
(master-slave operation). The connector X1 must be used.
If cable lengths of more than 25 m are planned, please consult our customer service.
Frequency limit: 250 kHz
SERVOSTAR 640/670
AGND and DGND (connector X3) must be joined together!
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8.12.4 Connection to a SSI encoder (X5)
You can set up the SERVOSTAR 640/670 as a slave following a synchronous serial absolute-enco
der (master-slave operation). This application uses the SubD connector X5.
If lead lengths of more than 50 m are planned and for questions concerning the power supply of the
encoder, please consult our customer service.
Frequency limit: 1.5MHz
SERVOSTAR 640/670
AGND and DGND (connector X3) must be joined together!
8.12.5 Connection to stepper-motor controllers (step and 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 gearing). 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.
Observe the frequency limit!
Using an A quad B encoder provides better EMC noise immunity.
Speed profile and signal diagram
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8.12.5.1 Step/Direction with 5 V signal level (X5)
This interface can be used to connect the servo amplifier to a stepper-motor controller with 5 V
signal level. The connector X5 must be used.
Frequency limit: 1.5 MHz
AGND and DGND (connector X3) must be joined together !
SERVOSTAR 640/670
8.12.5.2 Step/Direction with 24 V signal level (X3)
This interface can be used to connect the servo amplifier to a stepper-motor controller with 24 V
signal level. The digital inputs DIGITAL-IN 1 and 2 at connector X3 must be used.
Frequency limit: 250 kHz
AGND and DGND (connector X3) must be joined together!
SERVOSTAR 640/670
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8.13 Encoder emulations
8.13.1 Incremental encoder output - A quad B (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)
ROD (1)
ROD interpolation (3) Encoder
You can also adjust and store the position of the zero pulse within one mechanical turn
(parameter NI-OFFSET).
Feedback system Resolution Zero position
Resolver 256...4096
Encoder
256...524288
8
... 219)
(2
2
7
2
...2
TTL lines per sine line
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 :
The count direction is upwards when the motor shaft is rotating clockwise (looking at the shaft end).
SERVOSTAR 640/670
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8.13.2 SSI 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
12/2010 Electrical Installation
-
-
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-CLOCK parameter (cycle time 200 kHz or 1.5 MHz and inverted).
The drivers are supplied from internal supply voltage. PGND must always be
connected.
Connection and signal description for SSI interface :
The count direction is upwards when the motor shaft is rotating clockwise (looking at the shaft end).
SERVOSTAR 640/670
-
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8.14 Digital and analog inputs and outputs
8.14.1 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
— Update rate 62.5 µs
SERVOSTAR 640/670
Input Analog-In1 (terminals X3/4-5)
Differential input voltage max. ± 10 V, resolution 14-bit, scalable
Standard setting : speed setpoint
Input Analog-In2 (terminals X3/6-7)
Differential input voltage max. ± 10 V, resolution 12-bit, scalable
Standard setting : torque setpoint
Application examples for setpoint input Analog-In2:
— 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.
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8.14.2 Analog outputs (X3)
Technical characteristics
— Reference ground is analog-GND (AGND, terminal X3/1 and X3/10)
— Output resistance : 2.2 kW
— Output voltage ±10 V
— Resolution : 10 bit.
— Update rate 62.5 µs
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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 n
The output delivers ±10 V at the preset limit speed.
Analog-Out 2 : Current actual value I
The output delivers ± 10 V at the preset peak current (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.
act
act
(speed)
(torque)
SERVOSTAR®640/670 Instructions Manual 65
Electrical Installation
8.14.3 Digital inputs (X3)
All digital inputs are electrically isolated through optocouplers.
Technical characteristics
— Reference ground is Digital-GND (DGND, terminal X3/18)
— Inputs at X3 meet PLC standards (IEC 61131-2 Typ 1)
— High: 11...30 V / 2...11 mA, Low -3...+5V/<1mA
— Update rate: 250 µs
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ENABLE input
The output stage of the servo amplifier is activated by the enable signal
(terminal X3/15, input 24 V, 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 24 V auxiliary supply of the servo amplifier must be swit
ched 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 terminals X3/11 (DIGITAL-IN 1) or terminal X3/12 (DIGITAL-IN 2) can be logi
cally combined in a pre-programmable function.
-
-
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8.14.4 Digital outputs (X3)
Technical characteristics
— Reference ground is digital-GND (DGND, terminal X3/18)
— All digital outputs are floating
— DIGITAL-OUT1 and 2: Open-collector, max. 30 VDC, 10 mA
BTB/RTO: Relay output, max. 30 VDC or 42 VAC, 0.5 A
— Update rate: 250 µs
SERVOSTAR 640/670
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Ready-to-operate contact BTB/RTO
Operational readiness (terminals X3/2 and X3/3 ) is signalled 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 brake threshold.
All faults cause the BTB/RTO contact to open and the switch-off of the output
stage (if the BTB contact is open, the output stage is disabled -> no power). A list
of the error messages can be found on page 94.
Programmable digital outputs DIGITAL-OUT1/2:
You can use the digital outputs DIGITAL-OUT1 (terminal X3/16) and DIGITAL-OUT2 (terminal
X3/17) to outputs 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 24 V 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 online help of the setup software refers to the output of
the inverting interface relays. Consider the delay of the applied relay !
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8.15 RS232 interface, PC connection (X6)
The setting of the operating, position control, and motion-block parameters, can be carried out on
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 78.
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. 110).
SERVOSTAR 640/670
-
Interface cable between the PC and servo amplifiers of the
(View : looking at the face of the built-in SubD connectors, this corresponds to the solder side of the
SubD sockets on the cable)
SERVOSTAR 640/670 series:
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8.16 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. 110).
AGND and DGND (connector X3) must be joined together !
SERVOSTAR 640/670
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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 capacity 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 capacity (max. 30 nF/km) and lower lead resistance
(loop, 115 W/km) make it possible to achieve greater distances.
(Characteristic impedance 150 ± 5 WÞterminating resistor 150 ± 5 W).
For EMC reasons, the SubD connector housing must fulfil the following conditions:
— metal or metallized housing
— provision for cable shielding connection in housing, large-area connection
SERVOSTAR®640/670 Instructions Manual 69
Electrical Installation
8.17 Restart lock -AS-
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 bus 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 restart lock -AS- 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 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. 74) fulfills safety category 1 (EN 954-1) or category 3 with additional
safety relay (e.g. PNOZ of PILZ company).
Advantages of the restart lock -AS- :
— the DC bus 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.
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-
-
-
Moving single 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.
Switching off grouped axes with separate working areas
Even when several SERVOSTAR 640/670 are operating off a common mains supply and DC bus
link, it is possible to set up groups for separate working areas. These groups can then be switched
off separately for personnel safety.
8.17.1 Safety instructions
l
Observe the chapter "use as directed" for the restart lock -AS- (ð p. 71)
l
The monitoring contacts (KSO1/2) for each amplifier must be looped into the control
circuit. This is vital, so that a malfunction of the internal safety relay or a cable break
can be recognized.
l
If the restart lock -AS- 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 restart lock -AS- while the
motor is running.
l
Keep to the following functional sequence when the restart lock -AS- 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, block the drive mechanically
4. Activate the restart lock -AS-
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8.17.2 Use as directed
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The restart lock -AS- 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, EN12100 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) for all servo amplifiers are wired into
the control signal loop.
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).
8.17.3 Block diagram
-
SERVOSTAR®640/670 Instructions Manual 71
Electrical Installation
8.17.4 Functional description
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The connector (X10) is mounted on the front panel of the SERVOSTAR 640/670.The coil connec
tions and a make (n.o.) contact of a safety relay are made available through 4 terminals on this con
nector.
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.
8.17.5 Signal diagram (sequence)
-
-
-
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8.17.6 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 restart lock -AS-.
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.
8.17.7 Connection diagram (principle)
SERVOSTAR 640/670
Application examples for category 1 see chapters 8.17.8.
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8.17.8 Application example category 1 according to EN 954-1
Flowchart for stop and emergency stop category 0.
8.17.8.1 Control circuit
8.17.8.2 Mains supply circuit
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8.17.9 Application example category 3 according to EN 954-1
Flowchart for stop and emergency stop category 1.
8.17.9.1 Control circuit
8.17.9.2 Mains supply circuit
SERVOSTAR®640/670 Instructions Manual 75
Electrical Installation
8.17.9.3 Flow chart
24V
AS Relais
ON
OFF
K1
K10t / K20t
K30t / Enable
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t(K30t) t(K10t) / t(K20t)
Speed
t(K30t) ³ 500ms
t(K10t) and t(K20t) ensure that the drive remains active until the axis has come to a standstill. This
time depends on the application and must exceed the deceleration ramp.
The drive must have been brought to a safe standstill by the time t(K10t) and
t(K20t) have elapsed. After this point, active braking with the servo amplifier is no
longer possible.
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9 Setup
The setup procedure 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.
9.1 Safety instructions
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.
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 sec
after switching off the supply power.
Heat sinks 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.
12/2010 Setup
Only professional personnel with extensive knowledge in the fields of electrical/
drive technology are allowed to setup the servo amplifier.
If the servo amplifier has been stored for longer than 1 year, then the DC bus link
capacitors will have to be re-formed.
To do this, disconnect all the electrical connections.
Supply the servo amplifier for about 30 min. from single-phase 230VAC to the
terminals L1 / L2. This will re-form the capacitors.
Further setup information:
The adaptation of parameters and the effects on the control loop behavior are
described in the
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).
online help.
SERVOSTAR®640/670 Instructions Manual 77
Setup
9.2 Setup software
9.2.1 General
This chapter describes the installation of the setup software for the SERVOSTAR 640/670 digital
servo amplifiers.
We offer training and familiarisation courses on request.
9.2.1.1 Use as directed
The setup software is intended to be used for setting up and storing the operating parameters for
the SERVOSTAR 640/670 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 7
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.
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9.2.1.2 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 (ð p. 68).
The setup software provides the communication between SERVOSTAR 640/670 and the PC.
You will find the setup software on the accompanying CD-ROM and at our web site in the 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
stored 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.
An extensive
each situation.
online help with integrated description of all variables and functions supports you in
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9.2.1.3 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. 68).
Connect / disconnect the interface cable only when the supply is switched off for
both the PC and the servo amplifier.
The interface in the servo amplifier is electrically isolated by an optocoupler, and is at the same
potential as the CANopen interface.
Minimum requirements for the PC:
Processor : Pentium I or higher
Operating system : WINDOWS 95(c) / 98 / 2000 / ME / NT4.0 / XP
Graphics adapter : Windows compatible, color
Drives : hard disk with at least 10 MB free space
Main memory : at least 8MB
Interface : one free serial interface (COM1...COM10)
9.2.1.4 Operating systems
WINDOWS 95(c) / 98 / 2000 / ME / NT / XP
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CD-ROM drive
DRIVE.EXE is executable under WINDOWS 95(c) / 98 / 2000 / ME / NT 4.0 / XP.
The HTML help system is not available under WINDOWS 95a and 95b.
WINDOWS FOR WORKGROUPS 3.xx, DOS, OS2
DRIVE.EXE is not executable under WINDOWS 3.xx, DOS and OS2.
In emergency, operation is possible through an ASCII terminal emulation (without user-interface).
Interface settings : 9600 bps, no parity, no handshake
Unix, Linux
The software function has not been tested running within Unix or Linux.
WINDOWS VISTA, WINDOWS 7
DRIVE.EXE is not tested with WINDOWS VISTA and WINDOWS 7.
9.2.2 Installation under WINDOWS 95 / 98 / 2000 / ME / NT / XP
The CD-ROM includes an installation program for the setup software.
Installation
Autostart function activated:
Insert the CD-ROM into a free drive. A window with the start screen opens. There you find a link to
the setup software DRIVE.EXE. Click it and follow the instructions.
Autostart function deactivated:
Insert the CD-ROM into a free drive. Click on START (task bar), then on Run. Enter the program
call: x:\index.htm (x = correct CD drive letter).
Click OK and proceed as described above.
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 640/670 (ð p. 68).
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Setup
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9.3 Quickstart Guide
9.3.1 Preparation
9.3.1.1 Unpacking, Mounting and Wiring the Servo Amplifier
1. Unpack servo amplifier and accessories
2. Observe safety instructions in the manuals
3. Mount the servo amplifier as described in chapter 7.3
4. Wire the servo amplifier as described in chapter 8.3 or apply the minimum wiring for drive testing
as described in chapter 9.3.1.3
5. Install the software as described in chapter 9.2
9.3.1.2 Documents
You need access to these documents (located on the product CD-ROM, you can download the
latest editions from our website):
Instructions Manual (this manual)
l
CANopen Communication Profile Manual
l
Accessories Manual
l
Depending on the installed expansion card you need one of these documents:
PROFIBUS DP Communication Profile Manual
l
l
DeviceNet Communication Profile Manual
l
SERCOS Communication Profile Manual
l
EtherCAT Communication Profile Manual
You need Acrobat Reader to read the PDFs, an installation link is on every screen of the product
CD-ROM.
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9.3.1.3 Minimum Wiring for Drive Test
This wiring does not fulfill any requirements to safety or functionality of your
application, it just shows the required wiring for drive testing without load.
PC
2
X3
RES
CAN
Motor-Feedback
ENC
3
Power ON
24V DC
Enable
15
18
24V ON
X4
+
-
Power
3
5
Choke Filter
4
Motor-Power
Motor
Brake Res.
SERVOSTAR®640/670 Instructions Manual 81
Setup
9.3.2 Connect
Connect the interface cable to a serial interface on your PC and to the serial interface X6 of
l
the servo amplifier. USB to serial converter can be used optionally.
Switch on the 24 V power supply for the servo amplifier.
l
Wait about 30 seconds, until the front display of the servo amplifier displays the current
l
classe (e.g. for 40 amps). If the power supply voltage is switched on, too, a leading
P is displayed (e.g. for Power, 40 amps).
If a fault code ( ) or a warning ( ) or a status message (./_ / E/S) appears
in the display, you will find the description on page 94ff. If there is fault, fix the
problem.
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Double-Click the DRIVE.EXE icon on your Windows desktop to start the software.
You can work offline or online with .
Work ONLINE now. Select the interface where the servo am
plifier is connected to.
-
The software tries to communicate with the
drive and to upload the parameters. If it's
not successful, you receive this error mes
sage.
- wrong interface chosen
- wrong connector chosen at the servo amplifier
Frequent causes:
Click OK to remove the error message. Detect and remove the error source. Restart the software.
- interface is used by another software
- 24 V auxiliary voltage for the servo amplifier not working
- interface cable broken or wrong wiring
-
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If communication works, parameters are transmitted from the servoamplifier to the computer.
Then you see the start screen.
9.3.3 Important Screen Elements
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Make sure, that the amplifier is
disabled (Input HW-Enable con
nector X3 pin 15 must be
0 V or open)!
-
Help Function
The
online help gives detailed information to all parameters the servo amplifier can work with.
Starts
Key F1
Menu Bar ? or
Online HTML Help
Tool Bar
Save to EEPROM,
required if you changed parameters.
Reset (coldstart),
required if you changed important configuration parameters.
online help for the actual screen page.
online help with table of contents.
Starts
Operation Mode, use Digital Velocity mode for drive testing.
Disable and Enable of the amplifier's output stage via software.
Status Bar
SERVOSTAR®640/670 Instructions Manual 83
Setup
9.3.4 Basic Setup
On the start screen click "Basic Setup" button.
Regen Resistor: Select "external" brake resistor
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max.Regen Power: Fill in the power of the connected brake resistor.
max. Mains Voltage: Select the nominal mains AC voltage
Mains Phase Missing: You can select either warning "n05" or error "F19" in case of phase loss.
The setting "F19" disables the output stage, "n05" is just a message.
Units: Acceleration, Velocity, Position
Select usable units for your application referring to the moved load.
Leave all other fields unchanged.
Click OK. On the start screen click "Motor" button.
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9.3.5 Motor (synchronous)
Press function key F12 (SW disable) before changing motor parameters.
Motor Type: Select Synchronous Motor. If you use a linear motor or an induction motor, please
contact our support department.
Number-Name: Click the list to start uploading the motor parameter table, which is stored in the
servo amplifier. Search and select the connected motor. If your motor is not listed, please contact
our support department.
12/2010 Setup
Leave all other fields unchanged.
Click OK.
If your motor has a built-in brake, click Yes,
otherwise "No".
If Software Enable is active, a warning appe
ars. You can proceed, but after the amplifier is
restarted, you must check whether the holding
brake configuration is correct.
Click OK.
Parameters are uploaded to the amplifier's
RAM now (takes some seconds). When this is
done, you have to accept the changed confi
guration with "Yes" or to discard the changes
in the appearing screen.
If you click "Yes", the parameters are saved in
the EEPROM and the amplifier makes a cold
start (reset). This takes some seconds.
-
-
-
On the start screen, click "Feedback" button.
SERVOSTAR®640/670 Instructions Manual 85
Setup
9.3.6 Feedback
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Press function key F12 (disable) before chan
ging feedback parameters.
Feedback Type:
Select the feedback type used.
Leave all other fields unchanged.
If Software Enable is active, a warning appears.
The configuration change cannot be performed.
Click OK on the warnings, press F12 (SW disab
le) and start the Feedback procedure again.
If everything was ok, the same procedure (para
meter upload) that has been described for the
motor selection starts.
If you click "Yes", the parameters are saved in
the EEPROM and the amplifier makes a coldstart (reset). This takes some seconds.
-
-
-
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12/2010 Setup
9.3.7 Save Parameters and Restart
You are going to finish setup and you have changed several basic parameters. Depending on the
parameters you changed, two possible reactions can occur:
Configuration parameters changed
A warning appears, that you have to restart the amplifier. This is called "coldstart". Click "YES". The
parameters are saved to the amplifier's EEPROM automatically and a reset command restarts the
amplifier (takes a few seconds). For example, this happens after motor or feedback selection.
Other parameters changed
No warning appears. Parameters are saved in the volatile RAM only. Save the parameters to the
EEPROM of the servo amplifier manually by clicking the symbol in the tool bar. A coldstart
of the amplifier is not necessary.
Reset the amplifier
You can reset the amplifier manually (e.g. in case of an error). Click the icon .
SERVOSTAR®640/670 Instructions Manual 87
Setup
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9.3.8 Jogging the Motor (Speed Control)
Be aware that the actual position of the load permits the subsequent moving
operations. The axis could move to the hardware limit-switch or the mechanical
stop. Make sure that a jerk or a fast acceleration of the load cannot cause any
damage.
Switch on the power supply for the drive.
l
Hardware-Enable: +24 VDC to Enable [connector X3 pin 15].
l
Software-Enable: Click the "Enable" button on the start screen or use key
l
combination Shift+F12. Now, the front display shows an E and the current rating (e.g.
for Enable, 40 amps)
Click the icon "Oscilloscope"
l
l
Select Service-Mode "Speed F6", then click "Parameter" button
l
Enter a safe speed. The sign defines the direction of movement.
Observe the "safe reduced speed" requirements for your application!
l
Click OK.
l
Start the service function ("Start" button or press F6).
Click OK on the warning notice.
Opmode is switched to "0" and the output stage is enabled automatically. The symbol's color
changes to green as long as the function is active.
l
The function is active until you click the "Stop" button or press F9.
l
The output stage can be disabled by pressing function key F12.
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9.3.9 Status
Actual warnings and errors are listed on the Status screen, which can be accessed on the start
screen by clicking the "Status" button. This button monitors the current status of the amplifier and
can appear with different text.
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The Reset button can be used to clear some actual error messages. A description of errors/warnings can be found on page 94.
Now you have setup and tested the basic functions of the drive successfully.
9.3.10 Monitor
9.3.11 Additional Setup Parameters
Detailed information on all setup functions can be found in the Online Help systemand and the inte
grated command reference.
Click the icon "Monitor"
The Monitor screen shows all
important electrical and me
chanical actual values
-
-
SERVOSTAR®640/670 Instructions Manual 89
Setup
9.4 Multi-axis system
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).
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X6
PC/CAN
PC
COMx
RS232
Baud rates are the same for all amplifiers,
see table below
With the PC connected to just one servo amplifier you can now use the setup software to select all
amplifiers through the preset station addresses and set up the parameters.
Add.:01
Cable -SR6Y-
9.4.1 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. 93).
Add.:02
Add.:03
Add.:04
9.4.2 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.
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
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9.4.3 Example of connections for a multi-axis system
Reference Safety Instructions (ð p.9) and
Use As Directed (ð p.10) !
SERVOSTAR 640/670
SERVOSTAR 640/670
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Setup
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9.5 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 640/670 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.
9.5.1 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 :
enters a number, return function
-
9.5.2 Status display
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9.5.3 Standard menu structure
9.5.4 Extended menu structure
Keep the right key pressed while switching on the 24V-supply.
12/2010 Setup
see p.90
the entry will be stored automatically,
when you exit the input field.
see p.90
see p.90
SERVOSTAR®640/670 Instructions Manual 93
Setup
9.6 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
E/S/A/P
...
-
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
* = 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.
Status Messages Status messages, no error, see p. 92
Status Message Updating the startup configuration
Status Message Programming mode
Heat sink temperature
Overvoltage
Following error Message from the position controller
Feedback Cable break, short-circuit, short to ground
Undervoltage
Motor temperature
Internal voltage supply Internal amplifier supply voltages are out of tolerance
Overspeed Motor runs away, speed is too high
EEPROM Checksum error
Flash-EPROM Checksum error
Brake (motor) 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 power output stage
I²t max. I²t maximum value exceeded
Supply BTB/RTO 2 or 3 phases missing in the mains supply feed
A/D converter
Brake Brake circuit faulty or incorrect setting
Supply phase
Slot fault Slot error (hardware fault on expansion card)
Handling error Software error on the expansion card
Earth short circuit Short-circuit between motor phase and ground
CAN-bus off Severe CAN bus communication error
Warning Warning is displayed as fault
Commutation error Commutation error
Limit switch Homing error (machine has driven onto hardware limit switch)
AS
External Trajectory
Slot Fault depends on expansion card, see online help
Emergency timeout Timeout emergency stop
Macro Macro program error
System Error system software not responding correctly
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Heat sink temperature too high
limit is set by manufacturer to 80°
Overvoltage in DC bus link
limit depends on the electrical supply voltage
Undervoltage in DC bus link
limit is set by manufacturer to 100V
Motor temperature too high or temp. sensor defect
limit is set by manufacturer to 145°C
Error in the analog-digital conversion, normally caused by extreme electromagnetic interferences.
A phase is missing in the mains supply power feed
(can be switched off for 2-phase operation)
Operational error with -AS- , input for AS-Enable and ENAB
LE have been set at the same time
External position profile generator created a step, that excee
ded the maximum value
-
-
-
More information to the messages can be found in the ASCII Object Reference
(
Online Hilfe), see parameter ERRCODE. Hints for removal can be found in section
"Trouble-Shooting" of the online help.
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9.7 Warning messages
12/2010 Setup
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
number.
Number Designation Explanation
E/S/A/P
...
n01
n02
n03*
n04*
n05
n06*
n07*
n08
n09
n10*
n11*
n12
n13*
n14
n15
n16
n17
n18
n19
n20
n21
n22
n23...n31
n32
* = These warning messages lead to a controlled shut-down of the drive (braking with the emergency ramp)
Status Messages Status messages, no error, see p. 92
Status Message Updating the startup configuration
Status Message Programming mode
I²t I²t threshold exceeded
Brake power Reached preset electrical brake power limit
S_fault Exceeded preset following error limit
Response monitoring Response monitoring (fieldbus) has been activated
Supply phase Mains supply phase missing
SW limit switch 1 Underrun software limit switch 1
SW limit switch 2 Overrun software limit switch 2
Motion task error A faulty motion task was started
No reference point No reference point (Home) set at start of motion task
PSTOP PSTOP limit-switch activated
NSTOP NSTOP limit-switch activated
Motor default values
loaded
Slot warning 24V supply of the I/O expansion board is missing
SinCos feedback
Table error Fault according to speed/current table INXMODE 35
Summarized warning Summarized warning for n17 to n31
Fielbus Synchronization
Multiturn overrun
Motion task ramps are limited Range overflow on motion task data
Wrong GMT data Wrong "Graphical Motion Task" data
PLC program error For details see plc code
max. motor temperatur rea
ched
reserved reserved
firmware beta version Firmware is an unreleased beta version
Only for ENDAT or HIPERFACE
discrepancy between motor number saved in the en
coder and the amplifier, motor default values loaded
SinCos commutation (wake & shake) not completed,
will be canceled when amplifier is enabled and
wake&shake carried out
The mode synchronization SYNCSRC is selected but
the drive isn’t in synchronies cycle
Using Multiturn encoder feedback, an overrun over
the maximum number of resolutions was detected
-
The user can shut down the process before the tem
perature eror will interrupt the process immediately
®
:
-
-
-
More information to the messages can be found in the ASCII Object Reference
(
Online Hilfe), see parameter STATCODE. Hints for removal can be found in section
"Trouble-Shooting" of the online help.
SERVOSTAR®640/670 Instructions Manual 95
Setup
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9.8 Removing faults / warnings
Depending on the conditions in your installation, there may be a wide variety of reasons for the
fault. In multi-axis systems there may be further hidden causes of a fault.
Detailled hints for removal of faults can be found in the Online Hilfe chapter
"Trouble-Shooting".
Our customer service can give you further assistance with problems.
Fault possible causes
HMI message:
communicati
on fault
— wrong cable used
— cable plugged into wrong position
-
in servo amplifier or PC
— wrong PC interface selected
— servo amplifier not enabled
— break in setpoint cable
motor does
not rotate
— motor phases swapped
— brake not released
— drive is mechanically blocked
— no. of motor poles set incorrectly
— feedback set up incorrectly
motor
oscillates
drive reports
following error
motor overheating
— gain too high (speed controller)
— shielding in feedback cable broken
— AGND not wired up
or I
—I
rms
is set to low
peak
— setpoint ramp is too long
—I
rms/Ipeak
set too high — reduce I
— 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
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
— 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
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12/2010 Expansion Cards
10 Expansion Cards
Information about availability and order numbers can be found on p. 115
10.1 Guide to installation of expansion cards
l
l
Use a suitable screwdriver to unscrew
the cover of the option slot.
Take care that no small items (such
as screws) fall into the open option
slot.
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.
Push the expansion card carefully
l
into the provided guide rails of the
main slot, without twisting it.
SERVOSTAR®640/670 Instructions Manual 97
Expansion Cards
12/2010 Kollmorgen
10.2 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 640/670.
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 640/670.
All inputs and outputs are electrically isolated from the servo amplifier by optocoupler.
10.2.1 Front view
10.2.2 Technical data
Control inputs
Signal outputs
Supply inputs, EN 61131
Fusing (external)
Connectors
Cables
Waiting time between 2 motion
tasks
Addressing time (min.)
Starting delay (max.)
Response time of digital outputs
-
24V / 7mA, PLC-compatible, EN 61131
24V / max. 500mA, PLC-compatible, EN 61131
24V (18 ... 36V) / 100mA plus total current of the outputs
(depends on the input wiring of the controls)
The 24VDC voltage has to be supplied by an electrically
isolated power supply, e.g. with insulating transformer.
4AT
MiniCombicon, 12-pole, coded on PIN1 and 12 respectively
Data – up to 50m long : 22 x 0.5mm², unshielded,
Supply – 2 x 1mm², check voltage drop
depends on the response time of the control system
4ms
2ms
max. 10ms
10.2.3 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).
-
10.2.4 Select motion task number (sample)
Motion task no. A7 A6 A5 A4 A3 A2 A1 A0
binary 1010 1110 10101110
decimal 174 128 - 32 - 8 4 2 -
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10.2.5 Connector assignments
Connector X11A
Terminal Dir 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
9 In Reference
10 In FError_clear
11 In Start_MT Next
12 In Start_Jog v=x
12/2010 Expansion Cards
1
2
3
4
5
6
Polls the reference switch. If a digital input on the basic unit
is used as a reference input, then the input on the I/O expan
-
sion card will not be evaluated.
Clear the warning of a following error or the response moni
toring.
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 reached before the following task can be start
ed. The next motion block can also be started by an appro
-
priately configured digital input on the basic unit.
Start of the setup mode "Jog Mode" with a defined speed. Af
ter selecting the function, you can enter the speed in the au
xiliary 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
Continues the motion task that was previously interrupted.
1 In MT_Restart
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).
2 In Start_MT I/O
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
3 Out InPos
(the InPosition window), this is signalled 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 signalled 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.
4 Out
Next-InPos
The form of the message can be varied by using ASCII com
mands.
PosReg0 Can only be adjusted by ASCII commands.
5 Out FError
Following-error (low-active).
6 Out PosReg1
7 Out PosReg2
8 Out PosReg3
The preset function of the corresponding position register is
indicated by a HIGH-signal.
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
-
SERVOSTAR®640/670 Instructions Manual 99
Expansion Cards
10.2.6 Connection diagram
SERVOSTAR 640/670
-I/O-14/08
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AGND and DGND (connector X3) must be joined together !
100 SERVOSTAR®640/670 Instructions Manual
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