SSI America 601, 620 User Manual

SERVOSTAR® 601...620

Digital Servo Amplifier

Product Manual

Edition 07/2007

Valid for Hardware Revision 05.10

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 sr601_e.***

Previous versions :

	Edition	Remarks
	05/98	First edition
	08/98	a few corrections
	09/98	various minor corrections, parameter description removed, parameter setting for multi-axis systems and
		on/off switching behavior added, Installation/setup divided into two chapters
	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
		S610-30 and options -I/O-14/08- and -2CAN - incorporated, hardware-description incorporated for
	07/01	PROFIBUS and SERCOS, nameplate, motor list and connector assignment corrected, LED-display cor-
		rected, error messages expanded
	02/02	Dimensions BAR corrected
	06/02	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
	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
		Company name updated, expansion cards updated, new sections on EtherCat and SynqNet, chapter l re-
	02/06	structured, 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)
	09/06	Hardware Revision, disposal acc. to WEEE-2002/96/EG, new structure+cover pages, Quickstart integrated
		Part number scheme, servo system graphics expanded, shock-hazard protection new, BISS feedback,
	04/07	feedback expanded, enc. emulation, switch-on/off behavior and AS updated, accessories removed,
		DC-Bus link expanded, fuses regen resistor
	07/07	Timing diagramm motor brake, motor connector, example cat.3 to EN954-1

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

Page

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

SERVOSTAR® 601...620 Product Manual

3

Contents

07/2007

Danaher Motion

Page

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

4	SERVOSTAR® 601...620 Product Manual

Danaher Motion

07/2007

Contents

Page

9 Setup

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

SERVOSTAR® 601...620 Product Manual

5

Contents

07/2007

Danaher Motion

Page

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

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

6	SERVOSTAR® 601...620 Product Manual

Danaher Motion 07/2007 General

1	General
1.1	About this manual
	This manual describes the digital servo amplifiers of the SERVOSTAR® 600 series
	(standard version, 1.5 to 20 Amps nominal current). 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
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 indicated.

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

	Danger to personnel			Danger to maschinery,		Important
	from electricity and its
				general warning		notes
	effects
p.	see page			special emphasis

SERVOSTAR® 601...620 Product Manual

7

General	07/2007	Danaher Motion
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
Rregen (RB)	Regen resistor
RBext	External regen resistor
RBint	Internal regen resistor
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

8	SERVOSTAR® 601...620 Product Manual

Danaher Motion 07/2007 Safety

2	Safety
2.1	Safety Instructions

Only properly qualified personnel are permitted to perform activities such as transport,

installation, setup and maintenance. Properly qualified persons are those who are familiar with the transport, assembly, installation, setup and operation of the product, and who have the appropriate qualifications for their job. The qualified personnel must know and observe:

—IEC 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 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 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 damaged by incorrect handling. Ground yourself before touching the servo amplifier by touching any unpainted metal surface. Avoid contact with highly insulating materials (artificial fabrics, plastic film etc.). Place the servo amplifier on a conductive surface.

The manufacturer of the machine must produce a hazard analysis for the machine and take appropriate measures to ensure that unforeseen movements do not result in personal injury or material damage.

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.

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 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.

SERVOSTAR® 601...620 Product Manual

9

Safety	07/2007	Danaher Motion
2.2	Use as directed
	The servo amplifiers are components which are built into electrical equipment or machines,
	and can only be used as integral components of such equipment.
	The manufacturer of the machine must generate a hazard analysis for the machine, and take
	appropriate measures to ensure that unforeseen movements cannot cause injury or damage to
	any person or property.
	The SERVOSTAR 600 family of servo amplifiers can be connected directly to symmetrically
	earthed (grounded) three-phase industrial mains supply networks [TN-system, TT-system with
	earthed (grounded) neutral point, not more than 5000 rms symmetrical amperes, 480VAC 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) p.48.
	Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo amplifier
	may not exceed 1000V (peak value).
	Transient overvoltages (< 50µs) between the outer conductors may not exceed 1000V.
	Transient overvoltages (< 50µs) between outer conductors and housing may not exceed
	2000V.
	If the servo amplifiers are used in residential areas, or in business or commercial premises,
	then additional filter measures must be implemented by the user.
	The SERVOSTAR 600 family of servo amplifiers is only intended to drive specific brushless
	synchronous servomotors, with closed-loop control of torque, speed and/or position. The rated
	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
	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).

Use only copper wire. Wire size may be determined from EN 60204 (or table 310-16 of the NEC 60°C or 75°C column for AWG size).

We only guarantee the conformance of the servo amplifiers with the standards for industrial areas (page 11), if the components (motors, cables, amplifiers etc) are delivered by Danaher Motion.

Consider the specifications on page 92 when you use the optional personnel safe restart lock -AS-.

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 requirements 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)

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		07/2007	Danaher Motion
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.
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

–25 to +70°C (-13...158°F), max. 20K/hr rate of change max. 95% relative humidity, no condensation

Danaher Motion

07/2007

Handling

4 Handling

4.1 Transport

Only by qualified personnel in the manufacturer’s original recyclable packaging

Avoid shocks

Temperature

Humidity

The servo amplifiers contain electrostatically sensitive components which can be damaged by incorrect handling. Discharge yourself before touching the servo amplifier.

Avoid contact with highly insulating materials (artificial fabrics, plastic films etc.). Place the servo amplifier on a conductive surface.

If the packaging is damaged, check the unit for visible damage. In this case, inform the shipper and the manufacturer.

4.2 Packaging

Cardboard box, can be recycled

Dimensions:	SERVOSTAR 601...610	(HxWxD) 125x415x350 mm
	SERVOSTAR 614 / 620	(HxWxD) 170x415x350 mm

Labeling : nameplate outside at the box

4.3 Storage

Storage only in the manufacturer’s original recyclable packaging

	Max. stacking height	8 cartons
	Storage temperature	-25 to +55°C, max. rate of change 20°C / hour
	Storage humidity	5 ... 95% relative humidity, no condensation
	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

do not immerse or spray

— 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:

Danaher Motion GmbH

Wacholderstr. 40-42

D-40489 Düsseldorf

SERVOSTAR® 601...620 Product Manual

13

Package 07/2007 Danaher Motion

5	Package
5.1	Package supplied

When you order a SERVOSTAR 600 series amplifier (order numbers 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

Accessories: (must be ordered separately; description see accessories manual)

—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 ( p. 113)

—Terminating adapter for encoders with no terminating resistors ( p. 113)

—motor choke 3YL for cable length above 25m

—external regen resistor BAR(U)

—communications cable to the PC( p.69) or Y-adapter ( 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

Serial number

Comments

Enclosure Rating

Danaher Motion GmbH

Customer Support

U

Wacholderstr. 40-42

Europe

Tel. +49 (0)203 / 99790

C

® L

US

D-40489 Düsseldorf

Italy

Tel. +39 (0)362 / 594260

E217428

LISTED

www.DanaherMotion.com

North America Tel. [phone]

IND. CONT. EQ.

Typenbezeichnung

Model Number

Ser. Nr

Ser. No.

Bemerkung 1VD4

Comment

Spannungsversorgung

Power Supply

Nennstrom

Nom. Current

Schutzart

Encl.Rating

Umgebungstemp.

Hardware

Ambient temp.

Revision

example

example

max. ambient

Electrical supply

Output current

Hardware Revision

temperature

Installed load

in S1 operation

14	SERVOSTAR® 601...620 Product Manual

Danaher Motion				07/2007		Package
5.3	Part number scheme
				S 6 0 6 0 0 - S E*
	Family				Expansions
	S6	S600			NA	no expansion
					DN	DeviceNet
	Current rating				PB	PROFIBUS
	01	1A rms			SE	SERCOS
	03	3A rms			SN	SynqNet
	06	6A rms			EC	ETHERCAT
	10	10A rms			IO	I/O-Expansion
	1P	10/30A rms
	14	14A rms
	20	20A rms

	Voltage rating		electr. option
			0	no option
	0	230...480V
			1	AS option

* 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

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-, 3 A , 6 A , 10 A , 14 A, 20 A)

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

100 mm for 14A rated current

120 mm for 20A rated current

Wide range of rated voltage (3x208V –10% to 3x480V +10%)

Shield connection directly at the servo amplifier

2 analog setpoint inputs

Integrated CANopen (default 500 kBaud), for integration into CAN bus systems and for setting parameters for several amplifiers via the PC-interface of one amplifier

Integrated RS232, electrically isolated, integrated pulse-direction interface

Synchronous servomotors, linear motors and asynchronous motors can be used

Electrical supply

Directly off grounded 3 phase system,

230V-10% ... 480V+10%, 50 Hz,

208V-10% ... 480V+10%, 60 Hz

TN-system or TT-system with grounded neutral point, max. 5000 rms symmetrical amperes. Connection to other mains supply networks only with insulating transformer p.48

B6 rectifier bridge, directly off 3-phase earthed (grounded) supply system, integral power input filter and inrush circuit

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

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

Shielding:

All shielding connections directly on the amplifier

Output stage: IGBTmodule with isolated current measurement

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

DC bus link voltage 260 — 900 VDC, can be switched in parallel

Interference suppression filter for the supply input (to category 3) is integrated

Interference suppression filter for the 24V aux. supply (to category 3) is integrated

Integrated safety

Safe electrical separation to EN 50178 between the power input / motor connections and the signal electronics, provided by appropriate insulation/creepage distances and complete electrical isolation

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

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

16	SERVOSTAR® 601...620 Product Manual

Danaher Motion

07/2007

Technical description

Auxiliary supply voltage 24VDC

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

Operation and parameter setting

With our user-friendly software for setup through the serial interface of a PC

Direct operation by means of two keys on the servo amplifier and a 3-character LED display for status display in case there is no PC available

Fully programmable via RS232 interface

Completely digital control

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

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

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

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

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

2 programmable digital outputs

Freely programmable combinations of all digital signals

Options/Expansions

Option -AS-, built-in safety relay (personnel-safety starting lock-out) p. 91

I/O expansion card p. 99

PROFIBUS DP expansion card p. 102

SERCOS expansion card p. 103

DeviceNet expansion card p. 105

EtherCat expansion card p. 108

SynqNet expansion card p. 109

-2CAN- expansion module, separated connectors for CAN bus and RS232 p. 111

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

SERVOSTAR® 601...620 Product Manual

17

Technical description		07/2007							Danaher Motion
6.2	Technical data
							SERVOSTAR
	Rated data		DIM	601	603		606		610		610-30		614	620
	Rated supply voltage (grounded system)		V~		3 x 230V-10% ... 480V+10%, 50 Hz
			V~		3 x 208V-10% ... 480V+10%, 60 Hz
	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%)		Arms	1.5	3		6		10		10		14	20
	Peak output current (max. ca. 5s, 3%)		Arms	3	6		12		20		30 (2s)		28	40
	Clock frequency of the output stage		kHz			8 (16 with VDCmax=400V)
	Technical data for regen circuit		—						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		—					1.01
	(at rated data and min. load inductance)
	Bandwidth of subordinate current con-		kHz					> 1.2
	troller
	Residual voltage drop at rated current		V					5
	Quiescent dissipation, output stage dis-		W					15
	abled
	Dissipation at rated current (incl. power		W	30	40		60		90		90		160	200
	supply losses, without regen dissipation)
	Inputs
	Setpoint 1/2, resolution 14bit/12bit		V						10
	Common-mode voltage max.		V						10
	Input resistance to AGND		k					20
	Digital inputs		V				according to IEC 61131
	Digital outputs, open collector		V				according to IEC 61131
	BTB/RTO output, relay contacts		V			DC max. 30, AC max. 42
			mA					500
	Aux. power supply, electrically isolated		V			24 (-0% +15%)
	without brake		A					1 (max. 16)
	Aux. power supply, electrically isolated		V			24 (-0% +15%)
	with brake (consider voltage loss!)		A					3 (max. 16)
	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

18	SERVOSTAR® 601...620 Product Manual

Danaher Motion

07/2007

Technical description

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

Fusible cutouts or similar

SERVOSTAR

SERVOSTAR

SERVOSTAR

(Fuse UL time delay)

601/ 603

606/ 610

614/ 620

AC supply

FN1/2/3

6 AT (FRx-6)

10 AT (FRx-10)

20 AT (FRx-25)

24V supply

FH1/2/3

max. 12 AF (max. FRx-12)

Regen resistor

FB1/2

6 AT (FRS-6)

10 AT (FRS-10)

10 AT (FR10-10)

(x = S or S-R for 480V applications

x = N or N-R for 230V applications)

6.2.3

Ambient conditions, ventilation, mounting position

Storage, hints

p.13

Transport, hints

p.13

Supply voltage tolerances

Input power

min 3x 230V-10% AC / max 3x 480V+10%, 50 Hz

min 3x 208V-10% AC / max 3x 480V+10%, 60 Hz

Aux. power supply

24 VDC (-0% +15%), check voltage drop

0 to +45°C (32 to 113°F) at rated data

Ambient temperature in operation

+45 to +55°C (113 to 131°F) with power derating

2.5% / K

Humidity in operation

rel. humidity 85%, no condensation

up to 1000m a.m.s.l. without restriction

Site altitude

1000 — 2500m a.m.s.l. with power derating

1.5%/100m

Pollution level

Pollution level 2 to EN60204/EN50178

Vibrations

Class 3111 according to IEC 721-3-3

Noise emission

max. 45 dB(A)

Enclosure protection

IP 20

Mounting position

generally vertical. p.36

Ventilation

forced convection by built-in fan

Make sure that there is sufficient forced ventilation within the switchgear cabinet.

SERVOSTAR® 601...620 Product Manual			19

Technical description			07/2007		Danaher Motion
6.2.4		Conductor cross-sections
		Technical data for connection cables 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	SERVOSTAR 601-610: 1.5 mm²	(14awg)		600V,105°C (221°F),
			SERVOSTAR 614/620: 4 mm²	(12awg)		twisted
			SERVOSTAR 601-610: 1.5 mm²	(14awg)		600V,105°C (221°F),
		DC bus link				shielded for
			SERVOSTAR 614/620: 4 mm²	(12awg)
						lengths>20cm
		Motor cables	SERVOSTAR 601-610: 1-1.5 mm² (14awg)			600V,105°C (221°F),
						shielded,
		up to 25 m length*	SERVOSTAR 614/620: 2.5 mm²	(12awg)
						capacitance <150pF/m
		Motor cables	SERVOSTAR 601-606: 1 mm²	(14awg)		600V,105°C (221°F),
		25 to 100 m length*,				shielded,
			SERVOSTAR 610-620: 2.5 mm²	(12awg)
		with motor choke 3YL				capacitance <150pF/m
		Resolver, thermostat-mo-	4x2x0.25 mm² (22awg) twisted pairs, shielded,
		tor, max.100m length*	capacitance <120pF/m
		Encoder, thermostat-motor,	7x2x0,25 mm² (22 awg) twisted pairs, shielded,
		max.50m length*	capacitance <120pF/m
		Setpoints, monitors, AGND	0.25 mm² (22awg) twisted pairs, shielded
		Control signals, BTB,	0.5 mm² (20awg)
		DGND
		Holding brake (motor)	min. 0.75 mm² (18awg), 600V,105°C (221°F), shielded,
			check voltage drop
		+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 p. 42.
		* Danaher Motion North America delivers cables up to 39m length.
		Danaher Motion Europe delivers cables up to the maximum length.
6.3		LED display
		A 3-character LED display shows the amplifier status after switching on the 24V supply ( p.86).
		During operation of the amplifier via the keys on the front panel, the parameter and function num-
		bers ( p.87) are displayed, as well as the numbers of any errors which occur ( p.88).

20	SERVOSTAR® 601...620 Product Manual

Danaher Motion		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 amplifier 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		07/2007	Danaher Motion
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 ( 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
SERVOSTAR 606-620	33
External regen resistor
SERVOSTAR 601-620	33

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" ( p.88).

The BTB/RTO contact (terminal X3/2,3) will be opened at the same time ( 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 amplifier (terminals X3/2,3) will be opened at the same time ( 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.

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	Regen circuit: technical data			SERVOSTAR
	Supply	Rated data	DIM	601 - 603		606 - 620
	voltage
		Upper switch-on level of regen circuit	V	400 - 430
		Switch-off level of regen circuit	V	380 - 410
		Overvoltage F02	V		450
	3 x 230 V	Continuous power of regen circuit (RBint)	W	80		200
		Continuous power of regen circuit (RBext) max.	kW	0.25		0.75
		Pulse power, internal (RBint max. 1s)	kW	2.5		5
		Pulse power, external (RBext max. 1s)	kW		5
		External regen resistor			33
		Upper switch-on level of regen circuit	V	720 - 750
		Switch-off level of regen circuit	V	680 - 710
		Overvoltage F02	V		800
	3 x 400 V	Continuous power of regen circuit (RBint)	W	80		200
		Continuous power of regen circuit (RBext) max.	kW	0.4		1.2
		Pulse power, internal (RBint max. 1s)	kW	8		16
		Pulse power, external (RBext max. 1s)	kW		16
		External regen resistor			33
		Upper switch-on level of regen circuit	V	840 - 870
		Switch-off level of regen circuit	V	800 - 830
		Overvoltage F02	V		900
	3 x 480 V	Continuous power of regen circuit (RBint)	W	80		200
		Continuous power of regen circuit (RBext) max.	kW	0.5		1.5
		Pulse power, internal (RBint max. 1s)	kW	10.5		21
		Pulse power, external (RBext max. 1s)	kW		21
		External regen resistor			33

Suitable external regen resistors can be found in our accessories manual.

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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	Behavior (see also ASCII reference in the online help of the
			setup software)
	0 (default)	0	Motor coasts to a standstill in an uncontrolled manner
	1	1 (default)	Motor is braked in a controlled manner

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 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 output 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 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 with enabled “holding brake” function

Servo amplifiers with an enabled holding brake function have a special procedure for switching off the output stage ( 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 unintentional restart. The chapter “Personnel safe restart lock -AS-” describes how to use the restart lock –AS-. See page 91 onwards.

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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 ( 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 ( p.91).

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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).

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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.

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6.8.2	Emergency Stop: Standards

The emergency Stop function is used for the fastest possible shut-down of the machine in a dangerous 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 operate 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 situations;

the energy supply to any drive machinery that could cause dangerous situations must be switched off as fast as possible, without causing any further hazards (e.g. by using mechanical latching 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.

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.

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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 determined 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

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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

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