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Jetter AG

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Summary of Contents for JM-204-480

Page 1: ...User Manual JM 204 480 Digital Servo Amplifier 60870618 We automate your success...

Page 2: ...single case This user manual and the information contained herein have been compiled with due diligence Jetter AG shall not be liable for printing or general errors contained herein or for incidental...

Page 3: ...433 Phone Technical Hotline 49 7141 2550 444 Telefax 49 7141 2550 484 E Mail Sales sales jetter de E Mail Technical Hotline hotline jetter de Internet Address http www jetter de This User Manual is a...

Page 4: ...ble residual risks to persons and property For this reason any person who has to deal with the transport installation operation maintenance and repair of the digital servo amplifier JetMove 204 480 mu...

Page 5: ...ed by a high operating voltage This sign is to indicate hazard of serious physical damage or death due to accidentally touching dangerous parts of the device You are asked to wear goggles Failure to c...

Page 6: ...id unnecessary efforts Enumerations are marked by full stops strokes or scores Operating instructions are marked by this arrow Automatically running processes or results to be achieved are marked by t...

Page 7: ...Hazards after POWER has been turned OFF 19 1 4 Instructions on EMI 20 2 Installing the JetMove 204 480 23 2 1 Scope of Delivery 23 2 2 Mechanical Installation 24 2 3 Electrical Installation 26 2 4 Ch...

Page 8: ...cification 60 7 5 3 Connection diagram 61 7 6 External Ballast Resistor and DC Link Connection 64 7 7 Digital Inputs Logic Power Supply 70 7 8 Connection Details for Digital Outputs 72 7 9 Jetter Syst...

Page 9: ...ion 1 100 13 5 3 Application 2 101 13 5 4 Application 3 102 13 5 5 Application 4 103 13 6 Block Diagram JM 204 480 with the Safe Standstill Function 104 14 Counting Input Option 107 14 1 Function 107...

Page 10: ...Table of Contents 10 Jetter AG Appendix A Recent Revisions 119 Appendix B Glossary 120 Appendix C List of Abbreviations 122 Appendix D List of Illustrations 123 Appendix E Index 124...

Page 11: ...ng between AC 340 V and AC 530 V Thus the digital servo amplifier JetMove 204 480 comes under the EG Low Voltage Directive It is the explicit purpose of the digital servo controller JetMove 204 480 to...

Page 12: ...bility on the part of Jetter AG for any damages resulting from the use of non original parts and equipment is excluded 1 1 5 Servicing and repairs Repairs at the digital servo amplifier JetMove 204 48...

Page 13: ...l In case of obvious damage or erratic behavior the servo amplifier must not be used any more The environmental regulations for the respective country apply to disposing of the digital servo JetMove 2...

Page 14: ...ttached prior to commissioning and checked for proper functioning Before commissioning the machine manufacturer must carry out a danger analysis of the respective machine and take adequate measures so...

Page 15: ...ervo amplifier JetMove 204 480 has got a leakage current greater than 3 5 mA In order to avoid electric shocks a second protective earth conductor will be required For this the following measures must...

Page 16: ...ot install a leakage current protection switch in the supply line If in spite of this a leakage current protection switch is installed same will switch off the digital servo amplifier JetMove 204 480...

Page 17: ...ch the terminals X1 X62 and X63 while the servo amplifier is running In the given context the terminals have the following meaning X1 AC 400 480 V voltage supply X62 DC motor voltage up to 850 V X63 D...

Page 18: ...lifier JetMove 204 480 can be dangerous for persons or damage the manufacturing plant to an amount depending on the respective kind of plant This should be prevented by installing additional safety de...

Page 19: ...s a precaution measure the voltage in the DC link circuit amplifier terminal and wait until it has fallen below DC 40 V Always wait at least 7 minutes after switching off the device before separating...

Page 20: ...e distance between the optional line filters and the digital servo amplifier JetMove 204 480 must be as short as possible When of a motor cable with included brake lines is used these brake lines must...

Page 21: ...sible surface area When male connectors are used The shield impedance shielding must in its entire perimeter be drawn behind the shielding clamp of the metallised connector housing respectively of the...

Page 22: ...to the connector for example by a screw type terminal It is important that shield and strain relief are highly conductive and directly connected to a grounded surface with the greatest possible surfac...

Page 23: ...gth 0 2 m to 5 0 m For details see chapter 7 9 Jetter System Bus page 73 Motor cable refer to chapter 7 2 Motor Connection page 46 Synchronous servo motors e g the Jetter JL JK or JH series HIPERFACE...

Page 24: ...nly possible mounting direction is vertical see Rear and front view of the JetMove 204 480 enclosure with mounting holes on page 25 Please make sure there is a clearance of at least 100 mm under and a...

Page 25: ...JetMove 204 480 2 2 Mechanical Installation Jetter AG 25 Fig 4 Rear and front view of the JetMove 204 480 enclosure with mounting holes DETAIL A 348 5 310 277 21 5 71 5 O 5 5 7 5...

Page 26: ...according to standards Check whether all ground cables are connected double earthing see chapter 1 2 3 Earthing procedure page 15 To connect resolvers or power units you can use prefabricated cables a...

Page 27: ...caused by high operating voltage and electric shock Extremely hazardous voltages of up to 850 V may occur Please observe the following precautions in order to avoid muscle cramps burns unconsciousness...

Page 28: ...JetMove 204 480 against accidental contact with conductive parts and components Only connect devices or electrical components to the signal lines of the digital servo amplifier JetMove 204 480 Enable...

Page 29: ...ge Time 1 Year Ambient temperature 0 45 C 45 C 55 C with derating of 2 5 K Take care for sufficient cooling DIN EN 50178 Air humidity 5 85 No condensing DIN EN 50178 Pollution degree 2 DIN EN 50178 Co...

Page 30: ...r to Fig 4 page 25 For sufficient air flow there must be a clearance of 100 mm above and below the device Electrical Safety Conditions Reference Protection class I DIN EN 50178 Dielectric strength Pow...

Page 31: ...79 dB V Frequency band 0 5 30 MHz limit 73 dB V DIN EN 61800 3 Important This is a product of restricted availability according to IEC EN 61800 3 This module can cause radio interferences in residenti...

Page 32: ...d potential Criterion B DIN EN 61800 3 DIN EN 61000 4 5 Interference Immunity Process Measuring and Control Lines Parameters Value Reference Conducted radio disturbances Frequency 0 15 80 MHz Test vol...

Page 33: ...JetMove 204 480 4 Physical Dimensions Jetter AG 33 4 Physical Dimensions Fig 5 Mounting dimensions of the JetMove 204 480 in mm...

Page 34: ...4 Physical Dimensions 34 Jetter AG...

Page 35: ...use 10 A M medium time lag motor circuit breaker 10 A For systems with UL approval use overload protection devices that are UL listed acc to UL 508 NKJH self protected combination motor controller Spe...

Page 36: ...oltage output of the power supply unit must comply with the SELV or PELV type Inrush current limitation of the processor logics The JM 204 480 is equipped with a 220 F capacitor for buffering The inru...

Page 37: ...s that are related to the same potential as the power supply of the controller logic Can be switched by the control program of PLC or by operating system of JetMove 204 480 together with software enab...

Page 38: ...hold for heat sink temperature monitoring The duration of operation by maximum motor current is evaluated by a starting temperature of 45 C Note 2 A line filter can supply several digital servo amplif...

Page 39: ...ominal current which is the minimum of nominal motor current and nominal servo amplifier current current overload factor and time constant of the motor are programmed correctly Compatible AC Servo Mot...

Page 40: ...virtually not change any more The time till error stop x 100 is a result of the following formula After reset the values of the important parameters are the following ones With these parameters the 1...

Page 41: ...imes higher than the trip current the overload protection must switch off the motor after at least 20 seconds This protection error message 31 will occur can be parameterised only through the nominal...

Page 42: ...5 Technical Data 42 Jetter AG...

Page 43: ...JetMove 204 480 Jetter AG 43 6 Drive Controller Structure Fig 7 Block diagram of drive controller structure...

Page 44: ...controller Cycle time Speed pre control 250 s adjustable Position setpoint generator Sine square and linear acceleration deceleration ramps Setpoint output cycle position feedback controller interpola...

Page 45: ...Nm 10 6 13 3 lbf inch Ambient temperature max 45 C Field wiring Specifications of Connecting Cable Cable size min 4 1 0 mm AWG 18 Material Copper Temperature class 60 C Shielding Not required Fig 8 Po...

Page 46: ...m and the motor Always connect brake lines to a separate power supply unit DC 24 V if brake and motor lines are run together in one bunch of cables and are not separately shielded Important Measures t...

Page 47: ...Shielding Braided copper shield of 80 coverage Connection of the motor to the digital servo amplifier JetMove 204 480 has to be done following the wiring diagram below Connection of the brake is optio...

Page 48: ...the Jetter motor series JH2 JH3 JH4 JH5 JL2 JL3 JL4 JK4 JK5 JK6 without brake Art no 15100105 Motor mating connector for the Jetter motor series JH2 JH3 JH4 JH5 JL2 JL3 JL4 JK4 JK5 JK6 with brake Not...

Page 49: ...able Confection No 26 1 Field Wiring Terminals of the JetMove 204 480 Shielding Mating Connector of the Motor female solder side 4 x 1 5 mm2 AWG 16 4 Shielded highly flexible 4 wire cable with PE GND...

Page 50: ...the Motor female solder side 4 x 1 5 mm2 2 x 1 5 mm2 AWG 16 6 Highly flexible 6 wire cable with PE GND separately shielded brake lines and all over shielding The wires are equipped with wire end ferr...

Page 51: ...Jetter AG by supplying the following particulars Article no 60860443 Motor mating connector for the motor series JL5 JL6 JL7 JL8 and JK7 Note The motor power cable with mating connector SM matching th...

Page 52: ...le Confection No 201 Field Wiring Terminals of the JetMove 204 480 Shielding Mating Connector of the Motor female solder side 4 x 4 mm2 AWG 12 4 Shielded highly flexible 4 wire cable with PE GND The w...

Page 53: ...of the Motor female solder side 4 x 4 mm 2 x 0 5 mm2 AWG 12 4 AWG 20 2 Highly flexible 6 wire cable with PE GND separately shielded brake lines and all over shielding The wires are equipped with wire...

Page 54: ...motor connectors Connection Assignment of Terminal Box for the Jetter Motor Series Field Wiring Terminals of the Amplifier Motor Terminal Box Terminal Assignment X62 U2 PIN 1 Phase 1 X62 V2 PIN 2 Phas...

Page 55: ...able length 50 m 7 3 2 Resolver cable with mating connector Mating connector of the resolver solder side Fig 12 View on the RC series mating connector of the resolver internal thread M23 Note The reso...

Page 56: ...Attaching screws must have a metric thread Connect shield with the greatest possible surface area Use metallized housing only Pin Signal Core Color Pin 8 Cosine red 1 3 Cosine blue 2 2 Sine yellow 3 7...

Page 57: ...V and voltage supply The shield must be connected to the connector housings on both ends of the cable with the greatest possible surface area Material Copper Temperature class 60 C Max cable length 50...

Page 58: ...7 Description of Connections 58 Jetter AG HIPERFACE mating connector solder side Fig 13 RC series HIPERFACE mating connector internal thread M23 Solder Side 12 9 11 5 7 8 6 4 10 2 1 3...

Page 59: ...hing screws must have a metric thread Connect shield with the greatest possible surface area Use metallized housing only Pin Signal Core Color Pin unassigned 1 unassigned 2 7 Sine white 3 2 Reference...

Page 60: ...ing Connector for X61 ENCODER 9 pin male SUB D connector Metallized enclosure Sin Cos Encoder Cable Specifications Cable size 2 2 0 14 mm 2 0 5 mm AWG 26 4 AWG 20 2 if there is no index signal Cable s...

Page 61: ...JetMove 204 480 7 5 Sin Cos Encoder Connection Jetter AG 61 7 5 3 Connection diagram Fig 14 Sin cos encoder connection with adapter...

Page 62: ...apter JM 200 ENC ADAP Shielding Attaching screws must have a metric thread Connect shield with the greatest possible surface area Use metallized housing only Pin Signal 7 Sine 2 Reference sine 8 Cosin...

Page 63: ...is reversed in the following cases Case 1 The signal sine is exchanged with the signal cosine and the signal reference sine is exchanged with the signal reference cosine Case 2 The signal sine is exc...

Page 64: ...Resistor and DC link Circuit of Another JM 204 480 Field Wiring Terminals X63 Connector Pin Assignment UB Negative pole of the DC link voltage UB Positive pole of the DC link voltage BRint Connection...

Page 65: ...livered condition by Jetter AG The JetMove 204 480 is measuring the load of the ballast resistor and sets a warning bit if the ballast load reaches a specific value If the resistor is overloaded an er...

Page 66: ...of the amplifier In order to prevent this a third variety of a configuration can be chosen Use of external ballast resistor instead of the internal ballast resistor Fig 17 Wiring of X63 for connectin...

Page 67: ...ling DC Link Circuits of Two or Three JetMove 204 480 Another way uf utilizing the braking energy of the motor is to couple the DC links of several JetMove 204 480 In most cases not all axes of a mach...

Page 68: ...Requirements on the coupling of DC link circuits Before connecting a coupled JetMove 204 480 completely connect all wires of X63 Otherwise the device could be damaged Do not couple more than three Je...

Page 69: ...possible to combine coupled DC links with external ballast resistors In this case it is important to use identical resistors and cables for all coupled JetMove 204 480 The minimum cable size for a DC...

Page 70: ...be supplied the power supply has to be connected before software enable A low signal de energizes the motor immediately DC 24 V 7 5 mA max Operating point 6 V low 15 V high REF Reference switch input...

Page 71: ...and supply of the logic DC 24 V Power supply for the controller logic DC 20 30 V I 0 8 A BRAKE 1 Braking relay contact Br1 Relay contact for motor holding brake The relay can be operated either by the...

Page 72: ...onnection details for digital outputs Digital Outputs Terminals X31 on the Amplifier Side Signal Specification DC 24 V Power supply for the outputs DC 20 30 V with I max 2 A max 0 5 A per output 1 2 3...

Page 73: ...B D connector Metallized housing System bus cable specification For manufacturing a system bus cable the following minimum requirements have to be considered System Bus Cable Technical Data Function D...

Page 74: ...m 3 m 500 kBaud 100 m 1 m 39 m 250 kBaud 200 m 3 m 78 m 125 kBaud 200 m System Bus Cable Cable Confection Number 530 Shielding BUS OUT Connect shield with the greatest possible surface area Use metall...

Page 75: ...display modes are set by the Motion Setup Mode 0 default is used for normal operation and mode 1 for commissioning 5 V L 2 L 3 L 1 JetMove 204 480 7 Segment Display Mode 0 Normal Operation Color Statu...

Page 76: ...d L Flashing L OS loader gets loaded P Flashing P OS is transferred to the flash memory U Flashing U The boot sector waits for OS update JetMove 204 480 7 Segment Display Mode 0 Normal Operation JetMo...

Page 77: ...tages are beyond their limits Immediate motor power disable Cut drive controller from power lines Return the amplifier for repair F 02 Mains phase error Failure of one of the mains phases Immediate mo...

Page 78: ...maximum temperature Also refer to Built in temperature sensor page 39 Immediate motor power disable Let the motor cool down After cooling down acknowledge the error Reduce the average load of motor F...

Page 79: ...ive by means of the software Acknowledge the error F16 Power input overcurrent The current at the power input is too high Immediate motor power disable Check input voltage Reduce mechanical power of t...

Page 80: ...th emergency stop ramp Check the drive mechanism Check steepness of acceleration deceleration ramps and amplifier parameters in relation to the parameters tracking error limit and tracking window time...

Page 81: ...the definition according to UL See chapter 5 2 3 Motor overload protection according to UL page 40 Immediate motor power disable Let the motor cool down Acknowledge the error Reduce the average load o...

Page 82: ...82 Jetter AG...

Page 83: ...6 A DC24V 1 2 3 4 0V X31 Digital outputs X1 3 x AC 400 V Br Br 1 2 PE L3 L2 L1 Filter L1 L2 L3 U2 V2 W2 Contactor Load for digital outputs X10 Dig inputs logic power supply Bus cable coming from the p...

Page 84: ...0 6 A DC24V 1 2 3 4 0V X31 Digital outputs X1 3 x AC 400 V Br Br 1 2 PE L3 L2 L1 Filter L1 L2 L3 U2 V2 W2 Contactor Load for digital outputs X10 Dig inputs Logic power supply Bus cable coming from pre...

Page 85: ...ms 1 Line filter optional refer to Line filter on page 36 2 Mains protection refer to Overload protection on page 35 3 Motor 4 Motor holding brake optional 5 Position transducer resolver or absolute e...

Page 86: ...86 Jetter AG...

Page 87: ...controller This way it is possible for example to realize a pressure control loop in which the motor controlled by the JetMove generates the pressure In this case a pressure sensor in the machine conn...

Page 88: ...e 2 0 14 mm min AWG 26 2 Cores have to be twisted and shielded Shielding has to be connected to the connector housings on both sides Material Copper Temperature class 60 C Pin Assignment of the Analog...

Page 89: ...Jetter system bus 12 2 Description of Connections The digital servo amplifier JetMove 204 480 OEM is connected with the Ethernet by the RJ45 female connector X71 There are two types of interconnectin...

Page 90: ...through a switch straight through cables have to be used The LEDs of the JetMove 204 480 OEM Ethernet Designation Function ACT Activity The JetMove 204 480 OEM transmits or receives data via the Ethe...

Page 91: ...ase of an initialization error at the Ethernet interface RUN green LED Flashes regularly at correct functioning of the Ethernet interface LED Error Messages Following power up the red LED ERR and the...

Page 92: ...12 4 1 Fixed IP address At activating the controller while the DIP switches 1 to 8 are set to OFF the JetMove 204 480 OEM has got the IP address 192 168 10 15 If at the other possibilities of setting...

Page 93: ...asePort 50000 IP_DNS 192 118 210 209 Register s Alternative access to the configuration memory is possible via registers 10131 through 10145 In order to make a change via registers first the password...

Page 94: ...s being read in during the start up procedure The present setting of DIP switches 1 through 8 can be read out of register 10180 10137 Subnet mask 3SB 255 10138 Subnet mask 2SB 255 10139 Subnet mask LS...

Page 95: ...y restart of the motion system is blocked Notes and descriptions on this can be found in this manual For controlling this function there exist the terminals Enable1 COM and Enable2 In order to make du...

Page 96: ...ports and transmit them if necessary Usually the motor has been mounted at or within a machine outside the control cabinet It is connected via a cable to the JetMove 204 480 For reporting the position...

Page 97: ...no torque respectively stop rotating immediately 5 Re activate the Enable1 input at terminal X73 clear errors within the amplifier 6 Re enable the same axis Drive the axis in case the torque cannot be...

Page 98: ...n case of switching off via time relay JM 2xx S1 Performance Level Classification to EN ISO 13849 1 Performance level e is based on the following data CCF Portion Within the framework of this classifi...

Page 99: ...test pulses have a length of 1 ms and a repetition frequency of 100 Hz At applying a control logic with OSSD signals errors e g short circuits or shorts between contacts can be recognized by the logic...

Page 100: ...he digital servo amplifier switches off the motor power supply safely By opening the contact the safety function can be tested Deactivating the input leads to immediate switching off the motor Stop Ca...

Page 101: ...ch off Deactivating the inputs leads to immediate switching off the motor Stop Category 0 By means of the wiring technology a short both between the contacts of the emergency stop device and between t...

Page 102: ...off the motor safely dual channel switch off Deactivating the inputs leads to immediate switching off the motor Stop Category 0 Possible errors such as short circuits shorts between contacts or a qua...

Page 103: ...to a standstill due to the braking process that has been triggered Deactivating the Enable1 and Enable2 inputs leads to switching off the motor immediately after a pre defined delay time respectively...

Page 104: ...Standstill function has been illustrated It consists of two mainly identical yet independent signal paths 1 and 2 Each path consists of a DC DC converter which creates an output voltage of 5 Volt out...

Page 105: ...resistors of apt design and values at their interface The broken line marks the border between the safety relevant components Fig 31 Possible rotation angle in case of defective IGBTs In the risk anal...

Page 106: ...13 Safe Standstill Option 106 Jetter AG...

Page 107: ...of an actual position can be read via a JetMove register by the controller program or processed by the firmware of the JetMove in the controllers Yet the actual position of an SSI encoder cannot be u...

Page 108: ...the greatest possible surface area Material Copper Temperature class 60 C Maximum cable length 100 m 14 2 3 EnDat cable with mating connector HIPERFACE mating connector solder side Fig 32 EnDat mating...

Page 109: ...taching screws must have a metric thread 5 2 0 25 mm2 Connect shield with the greatest possible surface area Use metallized enclosure only Pin Signal Core color Pin Unassigned 1 Unassigned 2 7 DATA RS...

Page 110: ...he maximum cable length or in a minimum cable cross section Example At a cable cross section of 0 34 mm2 there results a maximum cable length of or at a cable length of 80 m the following cross sectio...

Page 111: ...wing signal lines must be twisted in pairs Clock und Clock DATA and DATA 0 V and voltage supply The shield must be connected to the connector enclosures on both ends of the cable with the greatest pos...

Page 112: ...f the Cable Encoder signal 5 V difference signal Maximum cable length 100 m Attaching screws must have a metric thread Connect shield with the greatest possible surface area Use metallized enclosure o...

Page 113: ...st be included in an overall shielding The following signal lines must be twisted in pairs K0 und K0 K1 und K1 K2 und K2 0 V and voltage supply The shield must be connected to the connector enclosures...

Page 114: ...Shielding Specification of the Cable Encoder signal 5 V Difference signal Maximum cable length 100 m Attaching screws must have a metric thread Connect shield with the greatest possible surface area...

Page 115: ...of the JetMove 2xx series at the JetControl 24x Article no 60866114 jetmove_2xx_at_nano_bi_xxxx_user_information pdf User information on configuration and operation of the JetMove 2xx series at the N...

Page 116: ...15 Ordering Information 116 Jetter AG...

Page 117: ...JetMove 204 480 Appendices Jetter AG 117 Appendices...

Page 118: ...Appendices 118 Jetter AG...

Page 119: ...vised Added Deleted Title page 1 2 Signal word Danger instead of Warning 2 2 Mechanical installation 2 5 and 2 6 Signal word Danger instead of Warning 2 7 Note on decommissioning 11 2 Technical data o...

Page 120: ...nt that converts linear or rotary position absolute or incremental into a digital signal HIPERFACE HIPERFACE is the name of a transducer system developed by Max Stegmann GmbH The SinCos motor feedback...

Page 121: ...se On JETTER controllers usually these are 32 bit wide storage positions in a remanent RAM Resolver Built on accessory of an electric motor serving as position transducer A resolver is a position tran...

Page 122: ...kabel 1 System Bus Cable The numeral 2 stands for PROCESS PLC and JetControl 200 LED Light Emitting Diode n Speed PE Protective Earth PELV Protective Extra Low Voltage PFC Power Factor Control PV Powe...

Page 123: ...ctor internal thread M23 58 Fig 14 Sin cos encoder connection with adapter 61 Fig 15 Wiring of X63 for connecting the internal ballast resistor 65 Fig 16 Wiring of X63 for connecting the internal and...

Page 124: ...oller specification 44 E Earthing procedure 15 Electrical specification 35 EMC Emitted interference 31 Enclosure 31 EnDat cable KAY 0723 xxxx 108 Error messages 77 Ethernet interface option 89 H HIPER...

Page 125: ...les 70 Repairs 12 Residual Dangers Electric shock 19 27 28 Residual dangers High operating voltage 17 Hot surfaces 17 Mechanic force 18 Potentially explosive atmosphere 18 Resolver cable Cable confect...

Page 126: ...Jetter AG Graeterstrasse 2 71642 Ludwigsburg Germany Phone 49 7141 2550 0 Fax 49 7141 2550 425 info jetter de www jetter de We automate your success...

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