Kollmorgen SERVOSTAR 400 Assembly & Installation Download Page 72

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7.4

Order numbers

Product

Order numbers Europa

SERVOSTAR 403M-CANopen

102111

SERVOSTAR 406M-CANopen

102117

SERVOSTAR 443M-CANopen

102832

SERVOSTAR 446M-CANopen

102833

SERVOSTAR 403A-CANopen

102112

SERVOSTAR 406A-CANopen

102118

SERVOSTAR 403M-PROFIFIBUS

102113

SERVOSTAR 406M-PROFIFIBUS

102119

SERVOSTAR 443M-PROFIFIBUS

102834

SERVOSTAR 446M-PROFIFIBUS

102835

SERVOSTAR 403A-PROFIFIBUS

102114

SERVOSTAR 406A-PROFIFIBUS

102120

SERVOSTAR 403M-SERCOS

102115

SERVOSTAR 406M-SERCOS

102121

SERVOSTAR 443M-SERCOS

102976

SERVOSTAR 446M-SERCOS

102977

SERVOSTAR 403A-SERCOS

102116

SERVOSTAR 406A-SERCOS

102122

Mating connector X0 -SR4X0- (part of delivery)

102583

Mating connector X1 -SR4X1- (part of delivery)

102584

Mating connector X3 -SR4X3- (part of delivery)

102585

Mating connector X6 -SR4X6- (part of delivery)

107466

SubD 15 poles, male (X2)

on request

SubD 9 poles, male (X5)

81783

SubD 9 poles, female (X4, X7, X8)

81784

Add-on fan -SR4BV-

102582

RS232 cable

90067

Motor cables

see accessories catalogue,

(in preparation - available from Nov 05)

Resolver cables

see accessories catalogue,

(in preparation - available from Nov 05)

Encoder cables

see accessories catalogue,

(in preparation - available from Nov 05)

Fieldbus cables

see accessories catalogue,

(in preparation - available from Nov 05)

Power supply unit 24V/ 5A

83034

Power supply unit 24V/20A

81279

Regen resistor BAR(U)250-33

106254

Regen resistor BAR(U)500-33

106255

Product CDROM

90079

SERVO

STAR

400 Installation Manual

Appendix

07/05

Kollmorgen

Summary of Contents for SERVOSTAR 400

Page 1: ...www DanaherMotion com Digital Servo Amplifier SERVOSTAR 400 Assembly Installation Setup Edition 07 05 File sr400_d xxx Order No 102530...

Page 2: ...red 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 Kollmorge...

Page 3: ...cross sections 17 2 10 Motor holding brake control 18 2 11 Regen circuit 19 2 11 1 LED display 19 2 12 Grounding system 19 2 13 Switch on off behaviour 20 2 13 1 Stop function as per EN 60204 VDE 011...

Page 4: ...Interface for stepper motor controls pulse direction 49 4 9 1 Connection of stepper motor controls with 5V signal level X4 50 4 9 2 Connection of stepper motor controls with 24V signal level X3 50 4...

Page 5: ...ilable from us at extra cost This manual makes the following demands on qualified personnel Transport only by personnel with knowledge of handling electrostatically sensitive components Installation o...

Page 6: ...mission 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 rot...

Page 7: ...t 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 operatio...

Page 8: ...5000A symmetrical rated current If the servo amplifiers are used in residential areas or in business or commercial premi ses then additional filter measures must be implemented by the user The SERVOS...

Page 9: ...plant is responsible for ensuring that they meet the limits required by the EMC regulations Advice on the correct installation for EMC such as shielding grounding arrangement of connectors and cable...

Page 10: ...conformance with the U S and Cana dian standard is determined by an independent UL cUL inspector through the type testing and regular checkups Apart from the notes on installation and safety in the d...

Page 11: ...otor linear or rotary Motor lead pre assembled or motor cable as cut off length loose connectors motor and amplifier side Feedback cable pre assembled or both feedback connectors loose with feedback c...

Page 12: ...s permitted 3 x 115V AC SERVOSTAR 40xM only unearthed operation is permitted 1 x 230V AC SERVOSTAR 40xM only unearthed operation is permissible 3 x 230V AC all types unearthed operation is permissible...

Page 13: ...l fully programmable via RS232 interface Completely digital control l digital current controller space vector pulse width modulation 62 5 s l freely programmable digital speed controller 62 5 s or 250...

Page 14: ...2 8 Components of a servo system 14 SERVOSTAR 400 Installation Manual Technical description 07 05 Kollmorgen 24V supply fuses drive contactor terminals motor SERVOSTAR 400 PC Control PLC...

Page 15: ...p at rated current V 5 5 Quiescent dissipation output stage disabled W 12 15 12 15 12 15 12 15 Dissipation at rated current without regen dissipation W 35 60 30 40 35 60 30 40 Inputs outputs Analog in...

Page 16: ...plug 2 9 3 Recommended tightening torques Connector Tightening torque X1 X3 X6 0 3 Nm X0 1 3 Nm Earthing bolts 3 5 Nm lower mounting bolt 3 5 Nm 2 9 4 Fusing 2 9 4 1 Internal fusing Function Auxiliary...

Page 17: ...2 as per EN 60204 EN 50178 Enclosure rating IP 20 Mounting position normally vertical p 25 Ventilation SERVOSTAR4x3 free convection SERVOSTAR4x6 add on fan p 66 Make sure that there is adequate force...

Page 18: ...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 at the latest after 1 second The rise...

Page 19: ...h the error message overvoltage p 60 The BTB RTO contact terminals X1 1 2 will be opened simultaneously p 44 Technical data Supply voltage Rated data DIM Value 3 x 230 V Upper switch on threshold for...

Page 20: ...nctions are defined in EN 60204 VDE 0113 Paras 9 2 2 and 9 2 5 3 Categories of Stop functions Category 0 Shut down by immediate switch off of the supply of energy to the drive machinery i e an uncontr...

Page 21: ...must be determined by a risk evaluation of the machine Category 0 Only hard wired electromechanical components may be used for an Emergency Stop function to Category 0 The action must not depend on sw...

Page 22: ...This page has been deliberately left blank 22 SERVOSTAR 400 Installation Manual Technical description 07 05 Kollmorgen...

Page 23: ...rference immunity required 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...

Page 24: ...otor housing and CNC GND of the controls Notes on connection techniques are on page 32 Wiring Route power leads separately from control cables Wire the BTB RTO contact in series into the safety loop C...

Page 25: ...th 40mm make sure there is a conductive connection to the mounting plate Mount the protective cover 7mm on the left side of the system Tools required Screwdriver with approx 5 mm blade width SERVOSTAR...

Page 26: ...3 3 1 Dimensions 26 SERVOSTAR 400 Installation Manual Installation 07 05 Kollmorgen SERVOSTAR 400M SERVOSTAR 400A...

Page 27: ...e first time during commissioning Note The ground 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 la...

Page 28: ...m master 28 SERVOSTAR 400 Installation Manual Installation 07 05 Kollmorgen p 37 p 52 p 51 p 47 p 38 p 40 p 39 p 41 p 42 p 43 p 44 p 38 p 39 SERVOSTAR 400M Follow the safety instructions p 7 and the u...

Page 29: ...ing diagram axis module SERVOSTAR 400 Installation Manual 29 Kollmorgen 07 05 Installation p 52 p 47 p 38 p 40 p 39 p 41 p 42 p 43 SERVOSTAR 400A Follow the safety instructions p 7 and the use as dire...

Page 30: ...connections for multi axis system 30 SERVOSTAR 400 Installation Manual Installation 07 05 Kollmorgen SERVOSTAR 400A SERVOSTAR 400A SERVOSTAR 400M M M M Follow the safety instructions p 7 and the use...

Page 31: ...3 4 4 Connector assignments SERVOSTAR 400 Installation Manual 31 Kollmorgen 07 05 Installation...

Page 32: ...400 are provided with an overall metal ferrule at the amplifier end that is electrically connected to the shielding Thread a cable tie through each slot in the shielding strip front panel of the serv...

Page 33: ...le designation indicate the shielding All cables are suitable for use as trailing cables The technical data refer to the use as moveable cables operating life 1 million bending cycles The permissible...

Page 34: ...rameter 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 serial cable The setup software provides t...

Page 35: ...98 2000 ME XP or WINDOWS NT 4 0 Emergency operation is possible with an ASCII terminal emulation Interface setting 9600 bps databit 8 stopbit 1 no parity no handshake Unix Linux DRIVE EXE does not wo...

Page 36: ...nts all the important interfaces divided between master and axis module The precise location of the connectors and terminals can be seen on page 31 4 1 Block diagram 36 SERVOSTAR 400 Installation Manu...

Page 37: ...fusing e g fusible cut outs to be provided by the user p 16 4 2 1 2 Single phase supplies Directly to supply filter is integrated fusing e g fusible cut outs to be provided by the user p 16 SERVOSTAR...

Page 38: ...15 Integrated EMC filter for the 24V auxiliary supply 4 3 DC Bus link DC bus X0 Can be connected in parallel with further identical masters via terminals DC and RBext 4 4 Motor connection with brake...

Page 39: ...olvers built in as a standard It is possible to connect 2 to 32 pole resolvers to SERVOSTAR 400 If lead lengths of more than 25m are planned please consult our customer support The thermostat contact...

Page 40: ...rive tasks that require highly precise positio ning or extremely smooth running If lead lengths of more than 25m are planned please consult our customer support The thermostat contact in the motor is...

Page 41: ...oltage range for both inputs 10 V supplementary Analog input terminals X3 2 3 Input voltage max 10 V 14 bit resolution scalable Standard setting Speed Setpoint Fixing the direction of rotation Standar...

Page 42: ...EEPROM of the servo amplifier and the 24V auxiliary supply for the servo amplifier must be switched off and then on again to reset the amplifier software Limit switches PSTOP NSTOP Terminals X3 6 and...

Page 43: ...d DIGITAL OUT2 terminal X3 9 to output messages from pre programmed functions that are stored in the servo amplifier A list of the pre programmed functions can be found in the Online Help If an input...

Page 44: ...In the inhibited state low signal the motor which is attached does not have any torque Ready to operate contact BTB RTO Operational readiness terminals X1 1 and X1 2 is signalled via a floating relay...

Page 45: ...the RESOLUTION parameter Encoder function Feedback system Resolution Zero position ROD 1 Resolver 16 1024 one per revolution only if A B 1 EnDat HIPERFACE 16 4096 and 8192 524288 2n one per revolutio...

Page 46: ...able The following table shows the allocation of the SSI date Revolution Resolution 11 10 9 8 7 6 5 4 3 2 1 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 The signal sequence can be output in Gray code or in...

Page 47: ...cy Please contact our customer support for information on connecting external SSI enco ders Signal diagram for encoders with RS422 or 24V outputs 4 8 3 1 Connection to SERVOSTAR 400 master 5V level X4...

Page 48: ...sition speed tv 0 1 sec AGND terminal X3 1 must be connected to the ground of the control system 4 8 3 3 Connection for Sin Cos encoder X2 You can use this interface to set up the SERVOSTAR 400 as a s...

Page 49: ...ber of steps can be adjusted so that the servo ampli fier can be adjusted to the pulse direction signals of any stepper motor controller Various monitoring signals can be output The analog input is in...

Page 50: ...o the ground of the control system 4 9 2 Connection of stepper motor controls with 24V signal level X3 You can use this interface to connect the servo amplifier to a stepper motor control with a 24V s...

Page 51: ...interface on the PC do not use a null modem link cable The interface has the same potential as the internal logic and uses AGND as the ground reference The interface is selected and set up in the setu...

Page 52: ...t be connected to the control system ground for potential equalization CAN bus cable To meet ISO 11898 you should use a bus cable with a 120 W characteristic impedance The maximum usable cable length...

Page 53: ...ocol can be found in the manual Communication profile PROFIBUS DP The selection of cables cable routing shielding bus connectors bus termination and propagation times are described in the Setup guidel...

Page 54: ...RCOS Phase 1 or the axis cannot be operated although the RT LED is lighting up cyclically Err indicates that SERCOS communication is faulty or suffering from interference If this LED is very bright th...

Page 55: ...s live Capacitors can still have residual charges with dangerous levels up to 300 seconds after switching off the supply power Heat sinks and front panels of the amplifier can reach a temperature of u...

Page 56: ...voltage of the amplifier Motor pole no must match the feedback unit in the motor IRMS maximum is the motor standstill current I0 nameplate IPEAK maximum is 4 x motor standstill current I0 Limit speed...

Page 57: ...es The PC cable only has to be connected to the master The internal address assignment is carried out automatically so that it is only necessary to set up the basic station address for the master Afte...

Page 58: ...id succession decrease number by ten U U press and hold right key then press left key as well enters a number return function 5 3 2 2 Status display on the axis module Each axis module is fitted with...

Page 59: ...5 3 2 3 Status display on the master SERVOSTAR 400 Installation Manual 59 Kollmorgen 07 05 Setup...

Page 60: ...2 motor phase motor phase missing cable break or similar F13 internal temperature internal temperature too high F14 output stage fault in the output stage F15 I t max I t max value exceeded F16 supply...

Page 61: ...1 n07 Sw limit switch 2 passed software limit switch 2 n08 motion task error a faulty motion task was started n09 no reference point no reference point set at start of motion task n10 PSTOP PSTOP limi...

Page 62: ...This page has been deliberately left blank 62 SERVOSTAR 400 Installation Manual Setup 07 05 Kollmorgen...

Page 63: ...15AT Output voltage 24V 1 Max output current 5A Residual ripple 150mVss Switching peaks 240mVss Output fusing short circuit proof Temperature range 0 to 60 C Mounting method DIN rail vertical mounting...

Page 64: ...0 Input current approx 1 1A Frequency 50 60Hz Primary fusing none Output voltage 24V 1 Max output current 20A Residual ripple 0 1 Output fusing short circuit proof Test voltage to VDE 0550 Temperature...

Page 65: ...nal regen resistor BAR U xyz Caution Surface temperature may exceed 200 C Observe the requested free space Do not mount to combustible surface SERVOSTAR 400 Installation Manual 65 Kollmorgen 07 05 Acc...

Page 66: ...the housing The electrical connection takes place automatically when mounting the fan Please consider that a mounted fan increases the required space underneath the amplifier p 25 The drawing below s...

Page 67: ...ischarge 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 max stacking...

Page 68: ...s loose or break in feedback cable wait until motor has cooled down then check why it became so hot tighten connector or new feedback cable F07 message aux voltage the aux voltage produced by the serv...

Page 69: ...t ramp motor overhea ting Irms Ipeak set too high reduce Irms Ipeak drive too soft Kp speed controller too low Tn speed controller too high PID T2 too high T Tacho too high increase Kp speed controlle...

Page 70: ...en the motor is at standstill I I t threshold Monitoring of the r m s current that is actually required incremental encoder interface Position signalling by 2 signals with 90 phase difference not an a...

Page 71: ...of direction ring core Ferrite rings for interference suppression ROD interface Incremental position output S servo amplifier Control device for regulating the speed torque and position of a servomoto...

Page 72: ...delivery 102583 Mating connector X1 SR4X1 part of delivery 102584 Mating connector X3 SR4X3 part of delivery 102585 Mating connector X6 SR4X6 part of delivery 107466 SubD 15 poles male X2 on request...

Page 73: ...This page has been deliberately left blank SERVOSTAR 400 Installation Manual 73 Kollmorgen 07 05 Appendix...

Page 74: ...r simulations 45 equipment description 11 error messages 60 F fault finding 68 fieldbus interface 52 forming 55 fusing 16 G glossary 70 ground symbol 27 grounding system 19 guide installation wiring 2...

Page 75: ...connection 32 shielding installation 24 wiring diagram 28 site altitude 17 SSI interface 46 stacking height 67 standards 9 status display 58 stop function 20 storage 67 storage duration 67 storage te...

Page 76: ...orth America Visit the North American Danaher Motion web site at www DanaherMotion com for Setup Software upgrades application notes technical publications and the most recent version of our product m...

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