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601
User Manual
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SSI America 601, 620 User Manual

®
SERVOSTAR
601...620
Digital Servo Amplifier
Product Manual
Edition 07/2007 Valid for Hardware Revision 05.10
File sr601_e.***
Previous versions :
Edition Remarks
05/98 First edition 08/98 a few corrections
09/98
01/99 614 added, various minor corrections 02/99 Interface relay for digital outputs (pages 26, 43) 06/99 various corrections, cables and connectors removed, choke box added 08/99 24V tolerance, encoder wiring, ventilation 11/99 Packaging, regen resistor 12/99 Option -AS- integrated, ground-bolt, master-slave 04/00 various corrections, setup software on CDROM only, motors 6SM27LL and 6SM37VL added 06/00 Wiring diagrams electr. gearing, warning and error messages, recommended torque 08/00 Wiring diagram in chapter III.9.2 corrected
07/01
02/02 Dimensions BAR corrected
06/02
07/03 several corrections, DeviceNet expansion card added, directives and standards page revised, cover design 09/03 Ethernet expansion card and Single axis controller expansion card added 03/04 new regen resistors BAR(U), several corrections
02/06
09/06 Hardware Revision, disposal acc. to WEEE-2002/96/EG, new structure+cover pages, Quickstart integrated
04/07
07/07 Timing diagramm motor brake, motor connector, example cat.3 to EN954-1
various minor corrections, parameter description removed, parameter setting for multi-axis systems and on/off switching behavior added, Installation/setup divided into two chapters
S610-30 and options -I/O-14/08- and -2CAN - incorporated, hardware-description incorporated for PROFIBUS and SERCOS, nameplate, motor list and connector assignment corrected, LED-display cor rected, error messages expanded
Frontpage new design, corrections to US English, motor table removed, order numbers added, last page new design and contents, new; connection to diff. mains supply networks, block diagram to ch.III
Company name updated, expansion cards updated, new sections on EtherCat and SynqNet, chapter l re­structured, new sections on motor chokes, Encoder power supply and encoder termination, various error corrections, new ordering codes, Feedback section revised, BAR removed, cross section (awg)
Part number scheme, servo system graphics expanded, shock-hazard protection new, BISS feedback, feedback expanded, enc. emulation, switch-on/off behavior and AS updated, accessories removed, DC-Bus link expanded, fuses regen resistor
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Hardware Revision (HR)
Hardware Rev. Firmware Rev. DRIVE.EXE Rev. Remarks
05.10 >= 5.76 <= 5.53_284 Firmware >=6.68 required with BISS
WINDOWS is a registered trademark of Microsoft Corp.
HIPERFACE is a registered trademark of Max Stegmann GmbH
EnDat is a registered trademark of Dr. Johannes Heidenhain GmbH
SERVOSTAR is a registered trademark of 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 printing, photocopying, microfilm or any other method) or stored, processed, copied or distributed by electronic means without the written permission of Danaher Motion.
Danaher Motion

07/2007 Contents

1 General
1.1 About this manual ....................................................................... 7
1.2 Hints for the online edition (PDF format) ...................................................... 7
1.3 Symbols used........................................................................... 7
1.4 Abbreviations used....................................................................... 8
2 Safety
2.1 Safety Instructions ....................................................................... 9
2.2 Use as directed ........................................................................ 10
3 Standards
3.1 European Directives and Standards......................................................... 11
3.2 American Directives and Standards......................................................... 11
3.3 Asian Directives and Standards ............................................................ 11
3.4 Approvals ............................................................................. 12
3.4.1 CE conformance .................................................................. 12
3.4.2 Conformance with UL and cUL ....................................................... 12
4 Handling
4.1 Transport ............................................................................. 13
4.2 Packaging ............................................................................ 13
4.3 Storage .............................................................................. 13
4.4 Maintenance........................................................................... 13
4.5 Disposal .............................................................................. 13
5 Package
5.1 Package supplied....................................................................... 14
5.2 Nameplate ............................................................................ 14
5.3 Part number scheme .................................................................... 15
6 Technical description
6.1 The SERVOSTAR 600 family of digital servo amplifiers ......................................... 16
6.2 Technical data ......................................................................... 18
6.2.1 Recommended torque .............................................................. 19
6.2.2 Fusing .......................................................................... 19
6.2.3 Ambient conditions, ventilation, mounting position......................................... 19
6.2.4 Conductor cross-sections............................................................ 20
6.3 LED display ........................................................................... 20
6.4 Control for motor holding brake ............................................................ 21
6.5 Grounding system ...................................................................... 22
6.6 Regen circuit .......................................................................... 22
6.7 Switch-on and switch-off behavior .......................................................... 24
6.7.1 Behavior in standard operation ....................................................... 25
6.7.2 Behavior in the event of an error (with standard setting) .................................... 26
6.8 Stop/Emergency Stop Function to EN 60204.................................................. 27
6.8.1 Stop: Standards ................................................................... 27
6.8.2 Emergency Stop: Standards ......................................................... 28
6.8.3 Implementation of the Stop Category 0 ................................................. 29
6.8.4 Implementation of the Stop Category 1 ................................................. 30
6.8.5 Implementation of the Stop Category 2 ................................................. 31
6.9 Shock-hazard protection ................................................................. 32
6.9.1 Leakage current................................................................... 32
6.9.2 Residual-current circuit breakers (FI)................................................... 32
6.9.3 Isolating transformers .............................................................. 33
Page
SERVOSTAR®601...620 Product Manual 3
Contents
07/2007 Danaher Motion
7 Mechanical Installation
7.1 Important notes ........................................................................ 35
7.2 Guide to mechanical installation............................................................ 35
7.3 Assembly ............................................................................. 36
7.4 Dimensions ........................................................................... 37
8 Electrical Installation
8.1 Important notes ........................................................................ 39
8.2 Guide to electrical installation.............................................................. 40
8.3 Wiring................................................................................ 41
8.3.1 Important notes ................................................................... 41
8.3.2 Technical data for connecting cables................................................... 42
8.3.3 Shielding connection to the front panel ................................................. 42
8.3.4 Motor connector with shieldplate ...................................................... 43
8.4 Components of a servo system ............................................................ 44
8.5 Block diagram ......................................................................... 45
8.6 Pin assignments........................................................................ 46
8.7 Connection diagram (overview) ............................................................ 47
8.8 Power supply .......................................................................... 48
8.8.1 Connection to various mains supply networks ............................................ 48
8.8.2 Mains supply connection (X0) ........................................................ 49
8.8.3 24V auxiliary supply (X4) ............................................................ 49
8.8.4 DC bus link (X7)................................................................... 49
8.9 Motor connection with brake (X9)........................................................... 50
8.10 External regen resistor (X8) ............................................................... 50
8.11 Feedback ............................................................................. 51
8.11.1 Resolver (X2) ..................................................................... 52
8.11.2 Sine Encoder 5V with BISS (X1) ...................................................... 53
8.11.3 Sine Encoder with EnDat 2.1 or HIPERFACE (X1) ........................................ 54
8.11.4 Sine Encoder without data channel (X1) ................................................ 55
8.11.5 Incremental encoder / sine encoder with Hall (X1)......................................... 56
8.11.6 Incremental Encoder (X5) ........................................................... 57
8.12 Electronic Gearing, Master-slave operation ................................................... 58
8.12.1 Connection to a SERVOSTAR master, 5 V signal level (X5) ................................. 59
8.12.2 Connection to encoders with 24 V signal level (X3) ........................................ 59
8.12.3 Connection to a sine-cosine encoder (X1) ............................................... 60
8.12.4 Connection to a SSI encoder (X5) ..................................................... 61
8.12.5 Connection to stepper motor controllers (step and direction)................................. 61
8.12.5.1 Step/Direction with 5 V signal level (X5) ............................................. 62
8.12.5.2 Step/Direction with 24 V signal level (X3) ............................................ 62
8.13 Encoder emulations ..................................................................... 63
8.13.1 Incremental encoder output - A quad B (X5) ............................................. 63
8.13.2 SSI output (X5) ................................................................... 64
8.14 Digital and analog inputs and outputs ....................................................... 65
8.14.1 Analog inputs (X3) ................................................................. 65
8.14.2 Analog outputs (X3) ................................................................ 66
8.14.3 Digital inputs (X3).................................................................. 67
8.14.4 Digital outputs (X3) ................................................................ 68
8.15 RS232 interface, PC connection (X6) ....................................................... 69
8.16 CANopen Interface (X6).................................................................. 70
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4 SERVOSTAR®601...620 Product Manual
Danaher Motion
07/2007 Contents
9Setup
9.1 Important notes ........................................................................ 71
9.2 Setup software ......................................................................... 72
9.2.1 General ......................................................................... 72
9.2.1.1 Use as directed ................................................................ 72
9.2.1.2 Software description ............................................................ 72
9.2.1.3 Hardware requirements.......................................................... 73
9.2.1.4 Operating systems ............................................................. 73
9.2.2 Installation under WINDOWS 95 / 98 / 2000 / ME / NT / XP .................................73
9.3 Quickstart Guide ....................................................................... 74
9.3.1 Preparation ...................................................................... 74
9.3.1.1 Unpacking, Mounting and Wiring the Servo Amplifier ...................................74
9.3.1.2 Documents ................................................................... 74
9.3.1.3 Minimum Wiring for Drive Test .................................................... 75
9.3.2 Connect ......................................................................... 76
9.3.3 Important Screen Elements .......................................................... 77
9.3.4 Basic Setup ...................................................................... 78
9.3.5 Motor (synchronous) ............................................................... 79
9.3.6 Feedback ........................................................................ 80
9.3.7 Save Parameters and Restart ........................................................ 81
9.3.8 Jogging the Motor (Speed Control) .................................................... 82
9.3.9 Status........................................................................... 83
9.3.10 Monitor.......................................................................... 83
9.3.11 Additional Setup Parameters ......................................................... 83
9.4 Multi-axis systems ...................................................................... 84
9.4.1 Node address for CAN-bus .......................................................... 84
9.4.2 Baud rate for CAN-bus.............................................................. 84
9.4.3 Example of connections for multi-axis system............................................ 85
9.5 Key operation / LED display............................................................... 86
9.5.1 Key operation..................................................................... 86
9.5.2 Status display..................................................................... 86
9.5.3 Standard menu structure ............................................................ 87
9.5.4 Extended menu structure............................................................ 87
9.6 Error messages ........................................................................ 88
9.7 Warning messages ..................................................................... 89
9.8 Removing faults/warnings ................................................................ 90
10 Expansions / Accessories
10.1 Option -AS-, restart lock for personal safety................................................... 91
10.1.1 Safety instructions ................................................................. 91
10.1.2 Use as directed ................................................................... 92
10.1.3 Block diagram .................................................................... 92
10.1.4 Functional description .............................................................. 93
10.1.5 Signal diagram (sequence) .......................................................... 93
10.1.6 Functional test .................................................................... 94
10.1.7 Connection diagram (principle) ....................................................... 94
10.1.8 Application example category 1 according to EN954-1 ..................................... 95
10.1.8.1 Control circuit ................................................................. 95
10.1.8.2 Mains supply circuit............................................................. 95
10.1.9 Application example category 3 according to EN954-1 ..................................... 96
10.1.9.1 Control circuit ................................................................. 96
10.1.9.2 Mains supply circuit............................................................. 96
10.1.9.3 Flow chart .................................................................... 97
Page
SERVOSTAR®601...620 Product Manual 5
Contents
10.2 Expansion Cards ....................................................................... 98
10.2.1 Guide to installation of expansion cards................................................. 98
10.2.2 Expansion card -I/O-14/08- .......................................................... 99
10.2.2.1 Front view .................................................................... 99
10.2.2.2 Technical data................................................................. 99
10.2.2.3 Light emitting diodes (LEDs) ...................................................... 99
10.2.2.4 Select motion task number (Sample) ............................................... 99
10.2.2.5 Connector assignments......................................................... 100
10.2.2.6 Connection diagram ........................................................... 101
10.2.3 Expansion cards -PROFIBUS-....................................................... 102
10.2.3.1 Front view ................................................................... 102
10.2.3.2 Connection technology ......................................................... 102
10.2.3.3 Connection diagram ........................................................... 102
10.2.4 Expansion card -SERCOS- ......................................................... 103
10.2.4.1 Front view ................................................................... 103
10.2.4.2 Light emitting diodes (LEDs) ..................................................... 103
10.2.4.3 Connection technology ......................................................... 103
10.2.4.4 Connection diagram ........................................................... 104
10.2.4.5 Modifying the station address .................................................... 104
10.2.4.6 Modifying the baud rate and optical power .......................................... 104
10.2.5 Expansion card -DEVICENET- ...................................................... 105
10.2.5.1 Front view ................................................................... 105
10.2.5.2 Connection technology ......................................................... 105
10.2.5.3 Connection diagram ........................................................... 105
10.2.5.4 Combined module/network status-LED............................................. 106
10.2.5.5 Setting the station address (device address)......................................... 106
10.2.5.6 Setting the transmission speed ................................................... 106
10.2.5.7 Bus cable ................................................................... 107
10.2.6 Expansion card -ETHERCAT- ....................................................... 108
10.2.6.1 Front view ................................................................... 108
10.2.6.2 LEDs ....................................................................... 108
10.2.6.3 Connection diagram ........................................................... 108
10.2.7 Expansion card -SYNQNET- ........................................................ 109
10.2.7.1 Front view ................................................................... 109
10.2.7.2 NODE ID Switch .............................................................. 109
10.2.7.3 Node LED table .............................................................. 109
10.2.7.4 SynqNet Connection, Connector X21B/C (RJ-45)..................................... 109
10.2.7.5 Digital inputs/outputs, connector X21A (SubD 15-pin, socket) ........................... 110
10.2.7.6 Connection diagram digital inputs/outputs, connector X21A ............................. 110
10.2.8 Expansion module -2CAN-.......................................................... 111
10.2.8.1 Installation ................................................................... 111
10.2.8.2 Front View ................................................................... 111
10.2.8.3 Connection technology ......................................................... 111
10.2.8.4 Connector assignments......................................................... 112
10.2.8.5 Connection diagram ........................................................... 112
10.3 Special Accessories .................................................................... 113
10.3.1 Power Supply SINCOS ............................................................ 113
10.3.2 Terminating adapter for encoder cables................................................ 113
10.3.3 Hall Dongle ..................................................................... 114
07/2007 Danaher Motion
11 Appendix
11.1 Glossary............................................................................. 115
11.2 Order numbers........................................................................ 117
11.2.1 Servo amplifiers .................................................................. 117
11.2.2 Expansion cards ................................................................. 117
11.2.3 Connectors...................................................................... 117
11.2.4 Special accessories ............................................................... 117
11.3 Index ............................................................................... 118
Page
6 SERVOSTAR®601...620 Product Manual
Danaher Motion

1 General

1.1 About this manual

This manual describes the digital servo amplifiers of the SERVOSTAR®600 series (standard version, 1.5 to 20 Amps nominal current). Servoamplifiers of the SERVOSTAR 640/670 series are described in additional manuals.
SERVOSTAR 601 is sold in Europe only
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 lan guage versions.
Technical data and dimensional drawings of accessories such as cables, regen 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.
This manual makes the following demands on qualified personnel : Transport : only by personnel with knowledge in handling electrostatically
sensitive components. Unpacking: only by electrically qualified personnel. Installation : only by electrically qualified personnel Setup : only by personnel with extensive knowledge of electrical
engineering / drive technology
07/2007 General
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1.2 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 indi cated.
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.

1.3 Symbols used

ð p.
Danger to personnel from electricity and its effects
see page l special emphasis
Danger to maschinery, general warning
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Important notes
SERVOSTAR®601...620 Product Manual 7
General

1.4 Abbreviations used

The abbreviations used in this manual are explained in the table below.
Abbrev. Meaning
AGND Analog ground AS Restart Lock, option BTB/RTO Ready to operate CAN Fieldbus (CANopen) CE Communité Européenne (EC) CLK Clock signal COM Serial interface for a PC-AT DGND Digital ground DIN German Institute for industrial Standards Disk Magnetic storage (diskette, hard disk) EEPROM Electrically erasable programmable memory EMC Electromagnetic compatibility EMI Electromagnetic interference EN European standard ESD Electrostatic discharge 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
regen(RB
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
) Regen resistor
External regen resistor Internal regen resistor
07/2007 Danaher Motion
8 SERVOSTAR®601...620 Product Manual
Danaher Motion

2 Safety

2.1 Safety Instructions

Only properly qualified personnel are permitted to perform activities such as transport,
l
installation, setup and maintenance. Properly qualified persons are those who are fami liar with the transport, assembly, installation, setup and operation of the product, and who have the appropriate qualifications for their job. The qualified personnel must know and observe: — IEC 60364 or DIN VDE 0100 — IEC 60664 or DIN VDE 0110 — national accident prevention regulations or BGV A3
Check the Hardware Revision Number of the product (see product label). This revision
l
number must match the Hardware Revision Number on the cover page of the manual.
Read this documentation before carrying out installation and setup. Incorrect handling
l
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 name plate and in the documentation).
The servo amplifiers contain electrostatically sensitive components which may be da
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maged by incorrect handling. Ground yourself before touching the servo amplifier by touching any unpainted metal surface. Avoid contact with highly insulating materials (artificial fabrics, plastic film etc.). Place the servo amplifier on a conductive surface.
07/2007 Safety
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The manufacturer of the machine must produce a hazard analysis for the machine and
l
take appropriate measures to ensure that unforeseen movements do not result in per­sonal injury or material damage.
l
Do not open or touch the equipment during operation. Keep all covers and cabinet doors closed during operation. Touching the equipment is allowed during installation and commissioning for properly qualified persons only. Otherwise, there are deadly ha­zards, with the possibility of death, severe injury or material damage. — During operation, servo amplifiers may have uncovered live
components, depending on their level of enclosure protection.
— Control and power connections may be live, even though the
motor is not rotating.
— Servo amplifiers may have hot surfaces during operation.
Surface can reach temperatures above 80°C.
l
Never undo any electrical connections to the servo amplifier while it is live. There is a danger of electrical arcing with damage to contacts and personal injury. Wait at least five minutes after disconnecting the servo amplifier from the main supply power before touching potentially live sections of the equipment (e.g. contacts) or un doing 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.
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SERVOSTAR®601...620 Product Manual 9
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 take
l
appropriate measures to ensure that unforeseen movements cannot cause injury or damage to any person or property.
The SERVOSTAR 600 family of servo amplifiers can be connected directly to symmetrically
l
earthed (grounded) three-phase industrial mains supply networks [TN-system, TT-system with earthed (grounded) neutral point, not more than 5000 rms symmetrical amperes, 480VAC ma ximum]. The servo amplifiers must not be operated directly on power supply networks >230V without an earth (ground) or with an asymmetrical earth (ground). Connection to different mains supply networks (with additional isolating transformer) ð p.48.
Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo amplifier
l
may not exceed 1000V (peak value). Transient overvoltages (< 50µs) between the outer conductors may not exceed 1000V. Transient overvoltages (< 50µs) between outer conductors and housing may not exceed 2000V.
If the servo amplifiers are used in residential areas, or in business or commercial premises,
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then additional filter measures must be implemented by the user.
The SERVOSTAR 600 family of servo amplifiers is only intended to drive specific brushless
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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 servo amplifiers may only be operated in a closed switchgear cabinet, taking into account
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the ambient conditions defined on page 19 and the dimensions shown on page 36. Ventilation or cooling may be necessary to prevent enclosure ambient from exceeding 45°C (113°F).
l
Use only copper wire. Wire size may be determined from EN 60204 (or table 310-16 of the NEC 60°C or 75°C column for AWG size).
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We only guarantee the conformance of the servo amplifiers with the standards for industrial areas (page 11), if the components (motors, cables, amplifiers etc) are delivered by Danaher Motion.
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Consider the specifications on page 92 when you use the optional personnel safe restart lock
-AS-.
07/2007 Danaher Motion
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Safety instructions
10 SERVOSTAR®601...620 Product Manual
Danaher Motion

07/2007 Standards

3 Standards

3.1 European Directives and Standards

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 (98/37/EC), the EC EMC Directive (89/336/EEC) and the EC Low Voltage Directive 73/23/EEC.
Standards to be applied for conformance with the EC Machinery Directive (98/37/EC): 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 must implement 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 (73/23/EEC): EN 60204-1 (Safety and Electrical Equipment in Machines) EN 50178 (Electronic Equipment in Power Installations) EN 60439-1 (Low Voltage Switchgear Combinations)
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Standards to be applied for conformance with the EC EMC Directive (89/336/EEC):
EN 61000-6-1 / EN 61000-6-2 (Interference Immunity in Residential & Industrial Areas) EN 61000-6-3 / EN 61000-6-4 (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.

3.2 American Directives and Standards

Chapter in process

3.3 Asian Directives and Standards

Chapter in process
SERVOSTAR®601...620 Product Manual 11
Standards

3.4 Approvals

3.4.1 CE conformance
Conformance with the EC EMC Directive 89/336/EEC and the Low Voltage Directive 73/23/EEC 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. The Declaration of Conformity form can be found on our website (download area).
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 prod uct of the category C3.
Warning! This product can cause high-frequency interferences in non industrial environments which can require measures for interference suppression.
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 described in this documentation means that you will be responsible for carrying out new measure ments to ensure conformance with regulatory requirements. The standard EN 50178 is applied to ensure conformance with the Low Voltage Directive.
07/2007 Danaher Motion
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3.4.2 Conformance with UL and cUL
This servo amplifier is listed under UL file number E217428.
UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S. and Cana­dian standard (in this case UL 840 and UL 508C). This standard describes the fulfilment by design of minimum requirements for electrically operated power conversion equipment, such as frequency converters and servo amplifiers, which is intended to eliminate the risk of fire, electric shock, or injury to persons, being caused by such equipment. The technical conformance with the U.S. and Canadian standard is determined by an independent UL (cUL) inspector through the type testing and regular check-ups. Apart from the notes on installation and safety in the documentation, the customer does not have to observe any other points in direct connection with the UL (cUL)-certification of the equipment.
UL 508C
UL 508C describes the fulfilment by design of minimum requirements for electrically operated power conversion equipment, such as frequency converters and servo amplifiers, which is intended to eliminate the risk of fire being caused by such equipment.
UL 840
UL 840 describes the fulfilment by design of air and insulation creepage spacings for electrical equipment and printed circuit boards.
12 SERVOSTAR®601...620 Product Manual
Danaher Motion

4 Handling

4.1 Transport

Only by qualified personnel in the manufacturer’s original recyclable packaging
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Avoid shocks
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Temperature –25 to +70°C (-13...158°F), max. 20K/hr rate of change
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Humidity max. 95% relative humidity, no condensation
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The servo amplifiers contain electrostatically sensitive components which can be da
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maged by incorrect handling. Discharge yourself before touching the servo amplifier. Avoid contact with highly insulating materials (artificial fabrics, plastic films etc.). Place the servo amplifier on a conductive surface.
If the packaging is damaged, check the unit for visible damage. In this case, inform the shipper
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and the manufacturer.

4.2 Packaging

Cardboard box, can be recycled
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Dimensions: SERVOSTAR 601...610 (HxWxD) 125x415x350 mm
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Labeling : nameplate outside at the box
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07/2007 Handling
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SERVOSTAR 614 / 620 (HxWxD) 170x415x350 mm

4.3 Storage

Storage only in the manufacturer’s original recyclable packaging
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Max. stacking height 8 cartons
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Storage temperature -25 to +55°C, max. rate of change 20°C / hour
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Storage humidity 5 ... 95% relative humidity, no condensation
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Storage duration Less than 1 year without restriction. More than 1 year: capacitors must be re-formed before setting up and operating the servo am plifier. 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

4.5 Disposal

In accordance to the WEEE-2002/96/EG-Guidelines we take old devices and accessories back for professional disposal, if the transport costs are taken over by the sender. Send the devices to:
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do not immerse or spray
Danaher Motion GmbH
Wacholderstr. 40-42
D-40489 Düsseldorf
SERVOSTAR®601...620 Product Manual 13
Package

5 Package

5.1 Package supplied

When you order a SERVOSTAR 600 series amplifier (order numbers ð p.117), you will receive:
— SERVOSTAR 6xx — mating connectors X3, X4, X0A, X0B, X7, X8
The mating SubD connectors and motor connector X9 are not part of the package!
— Assembly, Installation and Setup Instructions (product manual) — Online documentation on CD-ROM — Setup software DRIVE.EXE on CD-ROM
07/2007 Danaher Motion
Accessories:
— AC synchronous servomotor (linear or rotary) — motor cable (pre-assembled), or both motor connectors separately, with motor cable as a
cut-off length
— feedback cable (pre-assembled or both feedback connectors separately,
with feedback cable as length
— Power supply for encoders with a power consumption of more than 150mA (ð p. 113) — Terminating adapter for encoders with no terminating resistors (ð p. 113) — motor choke 3YL for cable length above 25m — external regen resistor BAR(U) — communications cable to the PC(ð p.69) or Y-adapter (ð p.84) for setting parameters 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 described below is printed in the individual fields.
Servo amplifier type
(must be ordered separately; description see accessories manual)
CommentsSerial number
Enclosure Rating
Danaher Motion GmbH Wacholderstr. 40-42 D-40489 Düsseldorf www.DanaherMotion.com
Typenbezeichnung
Spannungsversorgung
Umgebungstemp. Ambient temp.
example
max. ambient
temperature
Customer Support Europe Tel. +49 (0)203 / 99790 Italy 3 36 594260Tel. + 9 (0) 2 / North America Tel. +1 540 633 3400
Model Number
Power Supply
Electrical supply
Installed load
Ser.Nr
Nennstrom
Output current
in S1 operation
Ser.No.
Nom. Current
E217428
Bemerkung
Schutzart
example
U
CUS
L
®
LISTED
IND. CONT. EQ.
1VD4
Hardware Revision
Comment
Encl.Rating
Hardware Revision
14 SERVOSTAR®601...620 Product Manual
Danaher Motion

5.3 Part number scheme

07/2007 Package
S60600-SE*
Family
S6 S600
Current rating
01 1A rms 03 3A rms 06 6A rms 10 10A rms 1P 10/30A rms 14 14A rms 20 20A rms
Voltage rating
0 230...480V
* additional coding defines customer specific specials.
Comparison (without expansion) device name -> part number
Device Name Part Number
SERVOSTAR 601 S60100-NA SERVOSTAR 603 S60300-NA SERVOSTAR 606 S60600-NA SERVOSTAR 610 S61000-NA SERVOSTAR 610-30 S61P00-NA SERVOSTAR 614 S61400-NA SERVOSTAR 620 S62000-NA
Expansions
NA no expansion DN DeviceNet PB PROFIBUS SE SERCOS SN SynqNet EC ETHERCAT IO I/O-Expansion
electr. option
0 no option 1 AS option
SERVOSTAR®601...620 Product Manual 15
Technical description
07/2007 Danaher Motion

6 Technical description

6.1 The SERVOSTAR 600 family of digital servo amplifiers

Standard version
6 current ratings (1.5 A -Europe only-,3A,6A,10A,14A,20A)
l
3 instrument widths : 70 mm for 1.5A up to 10A rated current
l
100 mm for 14A rated current 120 mm for 20A rated current
Wide range of rated voltage (3x208V
l
Shield connection directly at the servo amplifier
l
2 analog setpoint inputs
l
Integrated CANopen (default 500 kBaud), for integration into CAN bus systems and for
l
–10%
to 3x480V
setting parameters for several amplifiers via the PC-interface of one amplifier
Integrated RS232, electrically isolated, integrated pulse-direction interface
l
Synchronous servomotors, linear motors and asynchronous motors can be used
l
Electrical supply
Directly off grounded 3 phase system,
l
-10%
-10%
... 480V ... 480V
230V 208V
+10%
+10%
,50Hz,
,60Hz TN-system or TT-system with grounded neutral point, max. 5000 rms symmetrical amperes. Connection to other mains supply networks only with insulating transformer ð p.48
B6 rectifier bridge, directly off 3-phase earthed (grounded) supply system, integral power input
l
filter and inrush circuit
l
Single-phase supply (e.g. for setup) is possible
l
Fusing: (e.g. fusible cutout) provided by the user
l
Shielding: All shielding connections directly on the amplifier
l
Output stage: IGBT- module with isolated current measurement
l
Regen circuit: with dynamic distribution of the regen power between several
amplifiers on the same DC bus link circuit. Internal regen resistor as standard, external regen resistors if required
l
DC bus link voltage 260 — 900 VDC, can be switched in parallel
l
Interference suppression filter for the supply input (to category 3) is integrated
l
Interference suppression filter for the 24V aux. supply (to category 3) is integrated
+10%
)
Integrated safety
l
Safe electrical separation to EN 50178 between the power input / motor connections and the signal electronics, provided by appropriate insulation/creepage distances and complete electri cal isolation
l
Soft-start, overvoltage recognition, short-circuit protection, phase-failure monitoring
l
Temperature monitoring of servo amplifier and motor (when using our motors with our pre-assembled cables)
16 SERVOSTAR®601...620 Product Manual
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Danaher Motion
Auxiliary supply voltage 24VDC
l
Operation and parameter setting
l
l
l
Completely digital control
l
l
l
l
l
l
07/2007 Technical description
Electrically isolated, internal fusing (3.15 AT), from an external 24VDC psu, e.g. with insulating transformer
With our user-friendly software for setup through the serial interface of a PC
Direct operation by means of two keys on the servo amplifier and a 3-character LED display for status display in case there is no PC available
Fully programmable via RS232 interface
Digital current controller (space vector pulse-width modulation, 62.5 µs)
digital speed controller adaptable to most different load conditions (65µs or 250 µs)
Integral position controller with adaptation possibilities for customer needs (250 µs)
Pulse direction interface integrated for connection of a servomotor to a stepping motor control
Evaluation of the resolver signals and sine-cosine signals of a high-resolution encoder
Encoder simulation (incremental or SSI)
Auxiliary functions
2 analog monitor outputs
l
4 programmable digital inputs (normally, two are defined as limit-switch inputs)
l
2 programmable digital outputs
l
l Freely programmable combinations of all digital signals
Options/Expansions
l
Option -AS-, built-in safety relay (personnel-safety starting lock-out) ð p. 91
l
I/O expansion card ð p. 99
l
PROFIBUS DP expansion card ð p. 102
l
SERCOS expansion card ð p. 103
l
DeviceNet expansion card ð p. 105
l
EtherCat expansion card ð p. 108
l
SynqNet expansion card ð p. 109
l
-2CAN- expansion module, separated connectors for CAN bus and RS232 ð p. 111
l
Third party expansion cards (ModBus, FireWire, LightBus etc. - contact distributors for further information)
SERVOSTAR®601...620 Product Manual 17
Technical description

6.2 Technical data

Rated data DIM 601 603 606 610 610-30 614 620
Rated supply voltage (grounded system)
Rated installed load for S1 operation kVA 1 2 4 7 7 10 14 Rated DC bus link voltage V= 290 - 675 Rated output current (rms value, ± 3%) Peak output current (max. ca. 5s, ± 3%) Clock frequency of the output stage kHz 8 (16 with VDCmax=400V) Technical data for regen circuit — ð p.22 Overvoltage protection threshold V 450...900 Max. load inductance mH 150 75 40 25 24 15 12 Min. load inductance mH 25 12 7.5 4 4 2.5 2 Form factor of the output current (at rated data and min. load inductance) Bandwidth of subordinate current con troller Residual voltage drop at rated current V 5 Quiescent dissipation, output stage dis abled Dissipation at rated current (incl. power supply losses, without regen dissipation)
Inputs
Setpoint 1/2, resolution 14bit/12bit V
Common-mode voltage max. V
Input resistance to AGND Digital inputs V according to IEC 61131 Digital outputs, open collector V according to IEC 61131
BTB/RTO output, relay contacts
Aux. power supply, electrically isolated without brake Aux. power supply, electrically isolated with brake (consider voltage loss!) Min./max. output current, brake A 0,15 / 2
Connections
Control signals — Combicon 5.08 / 18 pole , 2,5mm² Power signals — Power Combicon 7.62 / 4x4 + 1x6-pole, 4mm² Resolver input — SubD 9pole (socket) Sine-cosine encoder input — SubD 15pole (socket) PC-interface, CAN — SubD 9pole (plug) Encoder simulation, ROD (EEO) / SSI — SubD 9pole (plug)
Mechanical
Weight kg 4 5 7.5 Height without connectors mm 275 Width mm 70 100 120 Depth without connectors mm 265
07/2007 Danaher Motion
SERVOSTAR
V~ 3 x 230V V~ 3 x 208V
A
1.5 3 6 10 10 14 20
rms
A
3 6 12 20 30 (2s) 28 40
rms
-10%
-10%
... 480V ... 480V
+10%
+10%
,50Hz ,60Hz
— 1.01
­kHz > 1.2
­W15
W 30 40 60 90 90 160 200
±10 ±10
kW
20
V DC max. 30, AC max. 42
mA 500
V 24 (-0% +15%) A 1 (max. 16) V 24 (-0% +15%) A 3 (max. 16)
18 SERVOSTAR®601...620 Product Manual
Danaher Motion
6.2.1 Recommended torque
Connector Recommended torque
X3, X4 0.5 to 0.6 Nm (4.43 to 5.31 in lb) X0A, X0B, X7, X8, X9 0.5 to 0.6 Nm (4.43 to 5.31 in lb) Ground bolt 3.5 Nm (31 in lb)
6.2.2 Fusing
Internal Fusing
Circuit internal fuse
Auxiliary supply 24V 3.15 AT (FRx-3) Regen resistor electronic

External fusing

07/2007 Technical description
Fusible cutouts or similar (Fuse UL time delay)
AC supply F 24V supply F Regen resistor F
N1/2/3
H1/2/3
B1/2
SERVOSTAR
601/ 603
SERVOSTAR
606/ 610
6 AT (FRx-6) 10 AT (FRx-10) 20 AT (FRx-25)
max. 12 AF (max. FRx-12)
6 AT (FRS-6) 10 AT (FRS-10) 10 AT (FR10-10)
(x=SorS-Rfor480V applications x=NorN-Rfor230V applications)
6.2.3 Ambient conditions, ventilation, mounting position
Storage, hints Transport, hints Supply voltage tolerances
Input power
Aux. power supply
Ambient temperature in operation
Humidity in operation

Site altitude

Pollution level Pollution level 2 to EN60204/EN50178 Vibrations Noise emission Enclosure protection IP 20 Mounting position Ventilation

Make sure that there is sufficient forced ventilation within the switchgear cabinet.
ð p.13 ð p.13
min 3x 230V min 3x 208V
AC / max 3x 480V
-10%
-10%
24 VDC (-0% +15%), check voltage drop 0 to +45°C (32 to 113°F) at rated data +45 to +55°C (113 to 131°F) with power derating
rel. humidity 85%, no condensation up to 1000m a.m.s.l. without restriction 1000 — 2500m a.m.s.l. with power derating
1.5%/100m
Class 3111 according to IEC 721-3-3 max. 45 dB(A)
generally vertical. ð p.36 forced convection by built-in fan
SERVOSTAR
AC / max 3x 480V
614/ 620
+10%
,50Hz
+10%
,60Hz
2.5% / K
SERVOSTAR®601...620 Product Manual 19
Technical description
6.2.4 Conductor cross-sections
Technical data for connection cables ð p.42. 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
Motor cables up to 25 m length*
Motor cables 25 to 100 m length*, with motor choke 3YL Resolver, thermostat-mo tor, max.100m length* Encoder, thermostat-motor, max.50m length* Setpoints, monitors, AGND 0.25 mm² (22awg) twisted pairs, shielded Control signals, BTB, DGND
Holding brake (motor)
+24 V / XGND max. 2.5 mm² (12awg), check voltage drop
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. 42.
* Danaher Motion North America delivers cables up to 39m length.
* Danaher Motion Europe delivers cables up to the maximum length.
SERVOSTAR 601-610: 1.5 mm² (14awg) SERVOSTAR 614/620: 4 mm² (12awg)
SERVOSTAR 601-610: 1.5 mm² (14awg) SERVOSTAR 614/620: 4 mm² (12awg)
SERVOSTAR 601-610: 1-1.5 mm² (14awg) SERVOSTAR 614/620: 2.5 mm² (12awg)
SERVOSTAR 601-606: 1 mm² (14awg) SERVOSTAR 610-620: 2.5 mm² (12awg)
4x2x0.25 mm² (22awg) twisted pairs, shielded,
­capacitance <120pF/m 7x2x0,25 mm² (22 awg) twisted pairs, shielded, capacitance <120pF/m
0.5 mm² (20awg)
min. 0.75 mm² (18awg), 600V,105°C (221°F), shielded, check voltage drop
07/2007 Danaher Motion
600V,105°C (221°F), twisted 600V,105°C (221°F), shielded for lengths>20cm 600V,105°C (221°F), shielded, capacitance <150pF/m 600V,105°C (221°F), shielded, capacitance <150pF/m

6.3 LED display

A 3-character LED display shows the amplifier status after switching on the 24V supply (ð p.86). During operation of the amplifier via the keys on the front panel, the parameter and function num bers (ð p.87) are displayed, as well as the numbers of any errors which occur (ð p.88).
-
20 SERVOSTAR®601...620 Product Manual
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07/2007 Technical description

6.4 Control for motor holding brake

A 24V / max. 2A 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!
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 100ms (DECDIS) the speed setpoint of the servo ampli fier is internally driven down a 10ms ramp to 0. The brake output is switched on when the speed 5rpm (VELO) 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 50 .
A safe (for personnel) operation of the holding brake requires an additional “make” (n.o.) contact in the brake circuit and a suppressor device (varistor) for the recommended brake circuit diagram :
SERVOSTAR
-
SERVOSTAR®601...620 Product Manual 21
Technical description

6.5 Grounding system

AGND — ground for analog inputs/outputs, internal analog/µC ground DGND — ground for digital inputs/outputs, optically isolated XGND — ground for external 24V aux. voltage, optically and inductively isolated PGND — ground for encoder simulation, RS232, CAN, optically isolated
The potential isolation is shown in the block diagram (ð p. 45).

6.6 Regen circuit

During braking with the aid of the motor, energy is fed back to the servo amplifier. This energy is converted into heat in the regen resistor. The regen circuit (thresholds) are adjusted to the supply voltage with the help of the setup software. Our customer service can help you with the calculation of the regen power which is required. A description of the interface can be found on page 50.
Internal regen resistor
SERVOSTAR 601/603 66 W SERVOSTAR 606-620 33 W
External regen resistor
SERVOSTAR 601-620 33 W
07/2007 Danaher Motion
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 regen power, then the servo amplifier will output the status “regen power exceeded” and the regen circuit will be switched off.
At the next internal check of the DC 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.88).
The BTB/RTO contact (terminal X3/2,3) will be opened at the same time (ð p.68)
2.- Several servo amplifiers coupled through the DC bus link circuit (DC+, DC-)
Thanks to the built-in regen circuit, several amplifiers (even with different current ratings) can be operated off a common DC bus link. This is achieved by an automatic adjustment of the regen thresholds (which vary, because of tolerances). The regen energy is distributed equally among all the amplifiers.
The combined power of all the amplifiers is always available, as continuous or peak power. The switch-off takes place as described under 1. (above) for the servo amplifier with the lowest switch-off threshold (resulting from tolerances). The RTO (BTB) contact of this ampli fier (terminals X3/2,3) will be opened at the same time (ð p.68).
-
Technical Data
The technical data depend on the used servo amplifier type and on the mains voltage. See table on the next page.
22 SERVOSTAR®601...620 Product Manual
Danaher Motion
Regen circuit: technical data SERVOSTAR
Supply
voltage
3 x 230 V
3 x 400 V
3 x 480 V
07/2007 Technical description
Rated data DIM 601 - 603 606 - 620
Upper switch-on level of regen circuit V 400 - 430 Switch-off level of regen circuit V 380 - 410 Overvoltage F02 V 450 Continuous power of regen circuit (R Continuous power of regen circuit (R Pulse power, internal (R Pulse power, external (R
max. 1s) kW 2.5 5
Bint
max. 1s) kW 5
Bext
External regen resistor
) W 80 200
Bint
) max. kW 0.25 0.75
Bext
W
33 Upper switch-on level of regen circuit V 720 - 750 Switch-off level of regen circuit V 680 - 710 Overvoltage F02 V 800 Continuous power of regen circuit (R Continuous power of regen circuit (R Pulse power, internal (R Pulse power, external (R
max. 1s) kW 8 16
Bint
max. 1s) kW 16
Bext
External regen resistor
) W 80 200
Bint
) max. kW 0.4 1.2
Bext
W
33 Upper switch-on level of regen circuit V 840 - 870 Switch-off level of regen circuit V 800 - 830 Overvoltage F02 V 900 Continuous power of regen circuit (R Continuous power of regen circuit (R Pulse power, internal (R Pulse power, external (R
max. 1s) kW 10.5 21
Bint
max. 1s) kW 21
Bext
External regen resistor
) W 80 200
Bint
) max. kW 0.5 1.5
Bext
W
33
Suitable external regen resistors can be found in our accessories manual.
SERVOSTAR®601...620 Product Manual 23
Technical description
07/2007 Danaher Motion

6.7 Switch-on and switch-off behavior

This chapter describes the switch-on and switch-off behavior of the SERVOSTAR 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 amplifier 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 out put on a digital output of the servo amplifier and evaluated by the control system, for instance.
Error message if the servo amplifier is to bring the drive to a standstill: Error message F19 is
l
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 online help of the setup software) Motor coasts to a standstill in an uncontrolled manner Motor is braked in a controlled manner
-
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. 21). 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 optional 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 91 onwards.
-
24 SERVOSTAR®601...620 Product Manual
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07/2007 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 online help). The diagram below illustrates the correct functional sequence for switching the servo amplifier on and off.
DC bus link
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.21).
The -AS- option can be used to switch off the drive via a positive-action (approved by the Trade Liability Association) safety relay, so that personnel safety is ensured at the drive shaft (ð p.91).
SERVOSTAR®601...620 Product Manual 25
Technical description
07/2007 Danaher Motion
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 online help). The diagram 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.
(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 (ACTFAULT=1).
26 SERVOSTAR®601...620 Product Manual
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07/2007 Technical description

6.8 Stop/Emergency Stop Function to EN 60204

With the personnel safe restart lock –AS- (see page 91 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.
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 (VDE 0113), paragraphs 9.2.2 and 9.2.5.3.
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 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.
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.
SERVOSTAR®601...620 Product Manual 27
Technical description
07/2007 Danaher Motion
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 oper ate this mechanism.
The Emergency Stop function is defined by EN 60204 (VDE 0113), paragraph 9.2.5.4.
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 swit
l
ched off as fast as possible, without causing any further hazards (e.g. by using mechanical lat ching devices that do not require an external supply of energy, by counter-current braking in Stop Category 1);
the reset must not initiate a restart.
l
If necessary, provision must be made for the additional connection of emergency stop devices (see EN 60204, "Requirements for emergency stop devices").
The Emergency Stop must be effective as a stop of either Category 0 or Category 1. The Emergency Stop Category must be determined by a risk evaluation of the machine.
Category 0
Only hard-wired, electromechanical components may be used for 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.
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.
28 SERVOSTAR®601...620 Product Manual
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07/2007 Technical description
6.8.3 Implementation of the Stop Category 0
Bringing the motor to a standstill by immediately switching off the amplifier power supply (STOPMODE & ACTFAULT parameters set to 1). The switching sequence is precisely deter mined by this circuit in order to avoid undesirable fault messages and servo amplifier failures.
It is not possible to achieve a Category 0 shut-down with the servo amplifier alone, since hard-wired electromechanical components are compulsory for this type of disconnection. A brake that is built into the motor must have an additional electromechanical control circuit, as well as the control through the SERVOSTAR 600, in order to meet Category 0.
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.
Circuit suggestion
(with EMERGENCY STOP Category 0, control function with contactor relays)
-
SERVOSTAR
SERVOSTAR®601...620 Product Manual 29
Technical description
07/2007 Danaher Motion
6.8.4 Implementation of the Stop Category 1
Bringing the motor to a standstill by interrupting the mains supply and using controlled electronic braking (STOPMODE & ACTFAULT parameters set to 1). The 24 V supply for the SERVOSTAR must remain constant.
The drive is braked in a controlled manner during the stopping (disabling) procedure. If the speed VEL0 (see sequence diagram in chapter 6.4) is undershot, the holding brake is applied and the output stage is disabled.
As soon as two separate time periods (set at the time relay) have elapsed, the mains supply and the holding brake are electrically isolated.
Should an internal SERVOSTAR 600 fault occur, the motor is forced to a standstill once K20 drops out.
Circuit suggestion
(with EMERGENCY STOP Category 1, control function with contactor relays)
SERVOSTAR
30 SERVOSTAR®601...620 Product Manual
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