Kollmorgen Seidel SERVOSTAR 600 Series, Assembly, Installation And Commissioning Instructions

Page 1: ...Digital servo amplifier SERVOSTAR 600 Assembly Installation and Commissioning Instructions Edition 02 99 ...

Page 2: ...hines Corp MS DOS is a registered trademark of Microsoft Corp WINDOWS is a registered trademark of Microsoft Corp HIPERFACE is a registered trademark of Max Stegmann GmbH EnDat is a registered trademark of Dr Johannes Heidenhain GmbH SERVOSTAR is a registered trademark of Kollmorgen Corporation Technical changes which improve the performance of the equipment may be made without prior notice Printe...

Page 3: ...tallation II 1 Important instructions 21 II 2 Assembly 22 A 4 031 4 15 II 2 1 Dimensions of SERVOSTAR 600 23 A 4 031 4 14 II 3 Wiring 24 II 3 1 Connection diagram for SERVOSTAR 600 26 A 4 031 1 2 II 3 2 Example of connections for multi axis system 27 A 4 031 1 19 II 3 3 Pin assignments for SERVOSTAR 600 28 A 4 031 4 21 II 3 4 Notes on connection techniques 29 II 3 4 1 Tool list 29 II 3 4 2 Shieldi...

Page 4: ...ce X5 45 A 4 031 1 11 III 6 2 SSI Interface X5 46 A 4 031 1 12 III 7 RS232 interface PC connection X6 47 A 4 031 1 13 14 III 8 CANopen Interface X6 48 A 4 031 1 15 1 36 III 9 Interface for stepper motor controls X5 49 A 4 031 1 10 3 2 III 10 Interface for master slave operation encoder input X5 50 A 4 031 1 16 3 2 IV Commissioning IV 1 Important notes 51 IV 2 Parameter setting 53 IV 2 1 Multi axis...

Page 5: ...This page has been deliberately left blank SERVOSTAR 600 Installation manual 5 Kollmorgen 02 99 ...

Page 6: ...fabrics plastic film etc Place the servo amplifier on a conductive surface l Do not open the units Keep all covers and switchgear cabinet doors closed during operation Otherwise there are deadly hazards with the possibility of severe danger to health or material damage l During operation servo amplifiers according to their degree of enclosure protection may have uncovered live components Control a...

Page 7: ...on Any divergence from the configuration and installation described in this documentation means that you will be responsible for the performance of new measurements to ensure that the regulatory requirements are met UL and cUL Conformance listing in 4 quarter 1998 UL cUL certified servo amplifiers Underwriters Laboratories Inc fulfil the relevant U S and Canadian standard in this case UL 840 and U...

Page 8: ...interface for a PC AT DGND Digital ground DIN Deutsches Institut für Normung Disk Magnetic storage diskette hard disk EEPROM Electrically erasable memory EMV Electromagnetic compatibility EN European standard ESD Electrostatic discharge IEC International Electrotechnical Commission IGBT Insulated Gate Bipolar Transistor INC Incremental Interface ISO International Standardization Organization LED L...

Page 9: ...d of the servo amplifier The servo amplifiers are components which are built into electrical equipment or machines and can only be commissioned as integral components of such equipment The SERVOSTAR 600 family of servo amplifiers is to be used only on earthed three phase industrial mains supply networks TN system TT system with earthed neutral point The servo amplifiers must not be operated on pow...

Page 10: ...ries must be ordered separately if required Servomotor 6SM motor cable pre assembled or both motor connectors separately with motor cable as a cut off length feedback cable pre assembled see manual Servomotors or both feedback connectors separately with feedback cable as length motor chokes for cable length above 25m external regen resistor communications cable to the PC ð III 7 or Y adapter ð IV ...

Page 11: ...on card from 1st quarter 1999 l SERCOS expansion card from 1st quarter 1999 l I O expansion card Open architecture l open hardware and software architecture l slot for an expansion card l integrated macro language including compiler l prepared for all conceivable customer specific extensions I 4 3 Operation directly from supply Electrical supply l Directly off earthed 3 system 230V 10 480V 10 50 6...

Page 12: ... 5 µs l Freely programmable digital speed controller 250 µs l Integral position controller with adaptation possibilities for customer needs 250 µs l Pulse direction interface integrated for connection of a servomotor to a stepping motor control l Evaluation of the resolver signals or sine cosine signals of a high resolution encoder l Encoder emulation incremental ROD 426 compatible or SSI Comfort ...

Page 13: ...I 5 Block diagram A 4 031 1 28 SERVOSTAR 600 Installation manual 13 Kollmorgen 02 99 A 4 031 1 28 General ...

Page 14: ...I 6 Components of a servo system 14 SERVOSTAR 600 Installation manual General 02 99 Kollmorgen 24V supply fuses drive contactor terminals motor SERVOSTAR 600 PC Control PLC ...

Page 15: ... external fusing ð I 7 1 Auxiliary supply 24V internal 3 15 AT Regen resistor internal electronic Inputs Setpoint 1 2 resolution 14bit 12bit V 10 Common mode voltage max V 10 Input resistance kΩ 20 Digital inputs V low 0 7 high 12 36 mA 7 Aux power supply electrically isolated V 20 36 without brake A 1 Aux power supply electrically isolated V 24 0 15 with brake A 3 Max output current brake A 2 Con...

Page 16: ...tion SERVOSTAR 601 610 1 5 mm SERVOSTAR 614 620 4 mm DC link SERVOSTAR 601 610 1 5 mm SERVOSTAR 614 620 4 mm Shielded for lengths 20 cm Motor cables up to 25 m length SERVOSTAR 601 610 1 1 5 mm SERVOSTAR 614 620 2 5 mm shielded Motor cables 25 to 100 m length consult our applications department SERVOSTAR 601 606 1 mm SERVOSTAR 610 620 2 5 mm Shielded with motor choke Resolver thermostat motor 0 25...

Page 17: ...the time and functional relationships between the ENABLE signal speed setpoint speed and braking force During the internal ENABLE delay time of 100ms the speed setpoint of the servo amplifier is internally driven down a 10ms ramp to 0V The brake output is switched on when 3 of the final speed is reached The rise fbrH and fall fbrL times of the holding brake which is built into the motors are diffe...

Page 18: ...ed w characteristic several amplifiers even with different current ratings can be operated off a common DC link This is achieved by an automatic adjustment of the regen thresholds which vary because of tolerances The regen energy is distributed equally among all the amplifiers The combined power of all the amplifiers is always available as continuous or peak power The switch off takes place as des...

Page 19: ...is ensured at the drive shaft The AS option is described in more detail in a special leaflet You will find this leaflet on the CD ROM in German and English The Stop functions are defined in EN 60204 VDE 0113 Para 9 2 2 9 2 5 3 There are three categories of Stop functions Category 0 Shut down by immediately switching off the supply of energy to the drive machinery i e an uncontrolled shut down Cate...

Page 20: ... circuited by resistors connected in a star configuration The drive must be held by an electromagnetical holding device brake Category 1 If hazardous conditions can result from an emergency stop switch off with an unbraked run down then the drive can be switched off by a controlled shut down Stop Category 1 permits electromotive braking with a switch off when zero speed has been reached Safe shut ...

Page 21: ... by EMC regulations If a motor power cable is used which includes cores for brake control the brake control cores must be separately shielded Earth the shielding at both ends ð II 3 1 l Install all heavy current cables with an adequate cross section as per EN 60204 ð I 7 3 l Wire the BTB RTO contact in series into the safety circuit of the installation Only in this way is the monitoring of the ser...

Page 22: ...II 2 Assembly Material 2 or 4 hexagon socket screws to DIN 912 M5 Tool required 4 mm Allen key A 4 031 4 15 22 SERVOSTAR 600 Installation manual Installation 02 99 A 4 031 4 15 Kollmorgen ...

Page 23: ...II 2 1 Dimensions of SERVOSTAR 600 A 4 031 4 14 SERVOSTAR 600 Installation manual 23 Kollmorgen 02 99 A 4 031 4 14 Installation SERVOSTAR 614 620 SERVOSTAR 601 603 606 610 ...

Page 24: ...ound symbol X which you will find in all the wiring diagrams indicates that you must take care to provide an electrically conductive connection with the largest possible area between the unit indicated and the mounting plate in the switchgear cabinet This connection is for the effective grounding of HF interference and must not be confused with the PE symbol W a protective measure to EN 60204 Use ...

Page 25: ...s and control cables separately Wire the BTB RTO contact in series into the safety loop of the installation Connect the digital control inputs to the servo amplifier Connect up AGND Connect the analog setpoint if required Connect up the feedback unit resolver or encoder Connect the encoder emulation if required Connect the expansion card see corresponding manual on the CD ROM Connect the motor lea...

Page 26: ...4 031 1 2 26 SERVOSTAR 600 Installation manual Installation 02 99 A 4 031 1 2 Kollmorgen ð III 7 ð III 8 ð III 1 1 ð III 1 2 ð III 3 ð III 1 3 ð III 2 ð III 4 2 ð III 4 1 ð III 5 1 ð III 5 4 ð III 5 2 ð III 5 3 ð III 6 1 ð III 6 2 ð III 10 ð III 9 ...

Page 27: ...II 3 2 Example of connections for multi axis system A 4 031 1 19 SERVOSTAR 600 Installation manual 27 Kollmorgen 02 99 A 4 031 1 19 Installation ...

Page 28: ...II 3 3 Pin assignments for SERVOSTAR 600 A 4 031 4 21 28 SERVOSTAR 600 Installation manual Installation 02 99 A 4 031 4 21 Kollmorgen ...

Page 29: ... spanners 24 a f SubD connector 9 pole hand crimp tool 64470 II 3 4 2 Shielding connection to the front panel A 4 029 4 25 SERVOSTAR 600 Installation manual 29 Kollmorgen 02 99 A 4 029 4 25 Installation Remove the outer covering of the cable and the shielding braid from the cores for the required length Secure the co res with a cable tie Remove the outer covering of the cable over a length of abou...

Page 30: ...relief must sit well with a good contact on the bared shielding of the cable Place the knurled screws in position Solder the individual cores to the solder buckets of the SubD connector check the core colours according to the connection diagram in Chapter II 3 1 Check the pin assignment afterwards Leaving the first 12mm of the shielding braid free insulate the rear portion with shrink wrap tubing ...

Page 31: ...he shielding sleeve Press the rubber ring into the strain relief Make sure that no shielding strands stick out The O ring seals off the contact area Remove the adhesive tape protective cloth and filling cores Strip the cores Use the appropriate crimp tool to attach the crimp contacts Push the crimp contacts into the plastic insert 10 Caution Check the core colours Place the distance piece 11 betwe...

Page 32: ...over the shielding Push the shrink wrap tubing 30mm long over the shielding so that about 15mm remain exposed Use a hot air blower to shrink it Shorten the cores U V W to 45mm BR1 BR2 to 55mm length Push the core ferrules into the corres ponding terminals in the connector Follow the connection diagram in Chapter II 3 1 Attach bootlace ferrules to the ends of the cores Place the shielding plate in ...

Page 33: ...tems onto the cable The shielding sleeve must be flush with the end of the outer covering Push the shielding braids back over the shielding sleeve Press the clamping ring onto the shielding sleeve Cut off any projecting shielding strands Shorten and strip off the cores Fit the crimp contacts using the proper crimp tool Push the crimp contacts into the plastic insert until they snap into place Push...

Page 34: ... cables Operating life 1 million bending cycles The temperature range shown is the temperature in operation Cores mm Coretype Temperature range C Outside diameter mm Bending radius mm Remarks 4x1 0 F 30 80 10 100 4x1 5 B 30 80 10 5 105 4x2 5 N 5 70 12 6 125 4x4 N 5 70 12 8 130 4x6 N 5 70 16 1 160 4x10 N 5 70 19 0 190 4x16 N 5 70 23 3 230 4x25 N 5 70 32 7 330 4x1 0 2x0 75 F 30 80 10 5 100 4x1 5 2x0...

Page 35: ...out this parameter setting yourself on the amplifier but on a PC with the assistance of the operator software The PC is connected to the servo amplifier by a null modem cable The operator software provides the communication between SERVOSTAR 600 and the PC You will find the operator software on the accompanying diskette and the CD ROM With very little effort you can alter parameters and instantly ...

Page 36: ...WS 95 98 and WINDOWS NT 4 0 WINDOWS FOR WORKGROUPS 3 xx SR600 EXE is not executable under WINDOWS 3 xx DOS OS2 The WINDOWS operator software does not run under DOS or OS2 Emergency operation is possible with an ASCII terminal emulation without user interface Interface setting 9600 kBaud no parity no handshake II 4 2 Installation under WINDOWS 95 98 NT An installation program called SETUP EXE can b...

Page 37: ...vided by the user ð I 7 1 III 1 2 24V auxiliary supply X4 Electrically isolated external 24V DC supply e g with insulating transformer Required current rating ð I 7 Integrated EMC filter for the 24V auxiliary supply III 1 3 DC link X7 Can be connected in parallel thanks to patented circuit to distribute the regen power among all the amplifiers connected to the same DC link circuit Connection examp...

Page 38: ...ox 3YL xx must be wired into the motor lead close to the amplifier please consult our applications department III 3 External regen resistor X8 Remove the plug in link between the terminals X8 1 RB and X8 2 Rbint A 4 031 1 17 18 38 SERVOSTAR 600 Installation manual Interfaces 02 99 A 4 031 1 17 18 Kollmorgen ...

Page 39: ... to connect 2 4 or 6 pole resolvers to the SERVOSTAR 600 If lead lengths of more than 100m are planned please contact our application department The thermostat contact in the motor is connected via the resolver cable to the SERVOSTAR 600 and evaluated there A 4 031 1 26 SERVOSTAR 600 Installation manual 39 Kollmorgen 02 99 A 4 031 1 26 Interfaces ...

Page 40: ...vice for drive tasks which require highly precise positioning or extremely smooth running If lead lengths of more than 100m are planned please consult our applications department The thermostat contact in the motor is connected via the resolver cable to the SERVOSTAR 600 and evaluated there A 4 031 1 27 40 SERVOSTAR 600 Installation manual Interfaces 02 99 A 4 031 1 27 Kollmorgen ...

Page 41: ...bit scalable Standard setting speed setpoint Input SW SETP 2 terminals X3 6 7 Differential input voltage max 10 V resolution 12 bit scalable Standard setting torque setpoint Application examples for setpoint input SW SETP 2 adjustable external current limit reduced sensitivity input for setting up jog operation pre control override Fixing the direction of rotation Standard setting clockwise rotati...

Page 42: ...ro language consult our applications department If an input is freshly assigned to a pre programmed function then the data set must be stored in the EEPROM of the servo amplifier and the 24V auxiliary supply of the servo amplifier must be swit ched off and on again to reset the amplifier software Limit switches PSTOP NSTOP Terminals X3 13 and X3 14 are normally programmed for the connection of lim...

Page 43: ...l X3 16 and DIGITAL OUT2 terminal X3 17 to outputs messages from pre programmed functions that are stored in the servo amplifier You will find a list of the pre programmed functions in the OPERATOR SOFTWARE manual Additional special functions can be defined with the aid of the macro language consult our appli cations department If an input is freshly assigned to a pre programmed function then the ...

Page 44: ...s which are contained in the servo amplifier You will find a list of pre programmed measurements in the OPERATOR SOFTWARE manual Additional special functions can be defined with the aid of the macro language consult our appli cations department Standard setting Monitor 1 Tachometer voltage VTA speed The output delivers 10V at the preset limit speed Monitor 2 Current setpoint IDC torque The IDC mon...

Page 45: ...rence and a zero pulse The resolution can be changed with the RESOLUTION parameter 256 512 1024 pulses per turn for Feedback Resolver 2048 4096 pulses per turn for Feedback EnDat or HIPERFACE You can also adjust and store the position of the zero pulse within one mechanical turn parameter NI OFFSET Because of the compatibility with normal commercial pulse encoders you can only set the zero pulse w...

Page 46: ... 12 bits are held at 1 invalid data until a reference traverse has been carried out and then they will be set to ZERO valid data The interface must be read in as a multi turn encoder but delivers valid single turn data The signal sequence can be output in Gray code standard or in binary code parameter SSI CODE A serial signal is read out from the control with a synchronous clock frequency of max 1...

Page 47: ...use a null modem link cable The interface is electrically isolated through an optocoupler and is at the same potential as the CANopen interface The interface is selected and set up in the operator software Further notes can be found in Chapter II 4 Interface cable between the PC and servo amplifiers of the SERVOSTAR 600 series View looking at the face of the built in SubD connectors this correspon...

Page 48: ...SO 11898 you should use a bus cable with a characteristic impedance of 120 Ω The maximum usable cable length for reliable communication decreases with increasing transmission speed As a guide you can use the following values which we have measured but they are not to be taken as assured limits Cable data Characteristic impedance 100 120 Ω Cable capacity max 60 nF km Lead resistance loop 159 8 Ω km...

Page 49: ...tor software The number of steps can be adjusted so that the servo amplifier can be adjusted to the pulse direction signals of any stepper motor controller Various monitoring signals can be output The analog setpoint inputs are out of action AGND and DGND terminal X3 must be joined together Speed profile and signal diagram A 4 031 1 10 3 2 SERVOSTAR 600 Installation manual 49 Kollmorgen 02 99 A 4 ...

Page 50: ...e controlled by the master via the encoder output The parameters for the slave amplifiers are set up with the aid of the operator software The resolution no of pulses turn can be adjusted The analog setpoint inputs are out of action AGND and DGND terminal X3 must be joined together Signal diagram A 4 031 1 16 3 2 50 SERVOSTAR 600 Installation manual Interfaces 02 99 A 4 031 1 16 3 2 Kollmorgen ...

Page 51: ...ply power Heat sinks and front panels of the amplifier can reach a temperature of up to 80 C in operation Check measure the heat sink temperatue Wait until the heat sink has cooled down below 40 C before touching it Warning If the servo amplifier has been stored for longer than 1 year then the DC link capacitors will have to be re formed To do this disconnect all the electrical connections Supply ...

Page 52: ...otor standstill curent I0 Limit speed maximum is the rated motor speed on nameplate Regen power maximum is the permitted regen resistor dissipation Station address unique address see operator software manual Caution Make sure that any unintended movement of the drive cannot cause danger to machinery or personnel through the ON OFF button of the contactor control 0V on terminals X3 4 5 or X3 6 7 50...

Page 53: ...d to your PC Cable type SR6Y Mat No 90060 Drawing No A 4 031 1 33 With the PC connected to just one servo amplifier you can now use the operator software to select all four amplifiers through the preset station addresses and set up the parameters During commissioning it makes sense to preset the station addresses for the individual amplifiers and the baud rate for communication by means of the key...

Page 54: ...owing functions Key symbol Functions U press once go up one menu item increase number by one press twice in rapid succession increase number by ten U press once go down one menu item decrease number by one press twice in rapid succession decrease number by ten U U press and hold right key then press left key as well enters a number return function A 4 031 3 4 54 SERVOSTAR 600 Installation manual C...

Page 55: ...IV 2 2 2 Structure A 4 031 3 3 SERVOSTAR 600 Installation manual 55 Kollmorgen 02 99 A 4 031 3 3 Commissioning IV 2 1 ...

Page 56: ...5 I t max I t max value exceeded F16 supply BTB RTO 2 or 3 phases missing in the supply feed F17 A D converter error in the analog digital conversion F18 regen regen circuit faulty or incorrect setting F19 supply phase a supply phase is missing can be switched off for 2 phase operation F20 F31 reserved reserved F32 system error system software not responding correctly IV 4 Warning messages Faults ...

Page 57: ...V Accessories V 1 External 24V DC supply for one servo amplifier A 4 012 4 32 SERVOSTAR 600 Installation manual 57 Kollmorgen 02 99 A 4 012 4 32 Accessories ...

Page 58: ...V 2 External 24V DC supply for up to 7 servo amplifiers A 4 012 4 33 58 SERVOSTAR 600 Installation manual Accessories 02 99 A 4 012 4 33 Kollmorgen ...

Page 59: ...V 3 External regen resistor BARxxx A 4 947 4 22 SERVOSTAR 600 Installation manual 59 Kollmorgen 02 99 A 4 947 4 22 Accessories ...

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Page 61: ...ials artificial fabrics plastic films etc Place the servo amplifier on a conductive surface max stacking height for SERVOSTAR 600 10 cartons storage temperature 25 to 55oC max 20 C hr rate of change humidity relative humidity max 95 no condensation storage duration 1 year without restriction 1 year capacitors must be re formed before the servo amplifier is commissioned To do this remove all electr...

Page 62: ...esistor with a higher power rating and adjust the regen power parameter use mains transformer message mains BTB RTO enable was applied although the supply voltage was not present at least 2 supply phases are missing only enable the servo amplifier when the mains supply voltage has been switched on check electrical supply message brake short circuit in the supply cable for the motor holding brake m...

Page 63: ...set up incorrectly correct motor phase sequence set up correct offset angle motor oscillates gain too high speed controller shielding in feedback cable has a break AGND not wired up reduce Kp speed controller replace feedback cable join AGND to CNC GND drive reports following error Irms or Ipeak is set to low setpoint ramp is too long increase Irms or Ipeak keep within motor data shorten setpoint ...

Page 64: ...ake Brake in the motor which can only be used when the motor is at stillstand I I t threshold Monitoring of the actually required r m s current Input drift Temperature and age dependent alteration of an analog input Incremental encoder interface Position signalling by 2 signals with 90 phase difference not an absolute position output Ipeak peak current The effective value of the peak current Irms ...

Page 65: ...dic change of direction Ring core Ferrite rings for interference suppression ROD Interface Incremental position output S Servo amplifier Control device for regulating the position of a servomotor Setpoint ramps Limits for the rate of change of the speed setpoint Short to ground Electrically conductive connection between a phase and PE protective earth Short circuit here electrically conductive con...

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Page 67: ...7 maintenance 61 master slave 50 monitor outputs 44 motor interface 38 motor cable 34 motor choke connection example 27 motor holding brake 17 mounting position 16 multi axis systems connection example 27 N nameplate 10 NSTOP 42 O options 11 other operating systems 36 outputs BTB RTO 43 DIGI OUT 1 2 43 Monitor1 2 44 P Package supplied 10 Parameter setting 53 PC cable 47 PC connection 47 PGND 17 pi...

Page 68: ...46 0 8 640 77 30 Fax 46 0 8 641 09 15 Göteborg SE 42671 Västra Frölunda Tel 46 0 31 69 62 60 Fax 46 0 31 69 62 69 Schweiz Switzerland Suisse Seidel Servo Drives GmbH Eggbühlstr 14 CH 8050 Zürich Tel 41 0 1 300 29 65 Fax 41 0 1 300 29 66 Spanien Spain Espagne Comercial BROTOMATIC S L San Miguel de Acha 2 Pab 3 E 01010 Vitoria Tel 34 945 24 94 11 Fax 34 945 22 78 32 Seidel Servo Drives GmbH Kollmorg...