Kollmorgen SERVOSTAR 640 Instruction Manual Download Page 1

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Instructions Manual

Edition 12/2010
Translation of the original manual.
Valid for Hardware Revision 02.10

SERVO

STAR

640 / 670

Digital Servo Amplifier

File sr640_e.***

Keep all manuals as a product component
during the life span of the product.
Pass all manuals to future users / owners
of the product.

Summary of Contents for SERVOSTAR 640

Page 1: ...on of the original manual Valid for Hardware Revision 02 10 SERVOSTAR 640 670 Digital Servo Amplifier File sr640_e Keep all manuals as a product component during the life span of the product Pass all...

Page 2: ...different mains supply networks expanded removed feedback expanded enc emulation switch on and switch off behavior ex panded AS expanded accessories removed DC Bus link expanded 07 2007 Timing diagram...

Page 3: ...series SERVOSTAR 640 670 19 6 2 Technical data 21 6 2 1 Recommended torques 22 6 2 2 Fusing 22 6 2 3 Ambient conditions ventilation mounting position 22 6 2 4 Conductor cross sections 23 6 3 LED disp...

Page 4: ...er master with 24 V signal level X3 58 8 12 3 Connection to a sine cosine encoder master X1 59 8 12 4 Connection to a SSI encoder X5 60 8 12 5 Connection to stepper motor controllers step and directio...

Page 5: ...connections for a multi axis system 91 9 5 Key operation LED display 92 9 5 1 Key operation 92 9 5 2 Status display 92 9 5 3 Standard menu structure 93 9 5 4 Extended menu structure 93 9 6 Error mess...

Page 6: ...ch 108 10 7 3 Node LED table 108 10 7 4 SynqNet Connection Connector X21B C RJ 45 108 10 7 5 Digital inputs outputs connector X21A SubD 15 pin socket 109 10 7 6 Connection diagram digital inputs outpu...

Page 7: ...only by electrically qualified personnel Setup only by qualified personnel with extensive knowledge of electrical engineering and drive technology The qualified personnel must know and observe the fo...

Page 8: ...4 2 IEC International Electrotechnical Commission IGBT Insulated Gate Bipolar Transistor INC Incremental Interface ISO International Standardization Organization LED Light emitting diode MB Megabyte N...

Page 9: ...l 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...

Page 10: ...h closed loop control of torque speed and or posi tion The rated voltage of the motors must be at least as high as the DC bus link voltage of the servo amplifier The motor must have integral thermal p...

Page 11: ...the fulfillment by design of air and insulation creepage spacings for electrical equipment and printed circuit boards 3 2 EC conformance Conformance with the EC EMC Directive 2004 108 EC and the Low V...

Page 12: ...3 2 1 EC Declaration of Conformity 12 SERVOSTAR 640 670 Instructions Manual Approvals 12 2010 Kollmorgen...

Page 13: ...property Standards to be applied for conformance with the EC Low Voltage Directive 2006 95 EC EN 60204 1 Safety and Electrical Equipment in Machines EN 60439 1 Low Voltage Switchgear Combinations Stan...

Page 14: ...3 3 GOST R Conformance Certificate for servo amplifiers and accessories cover page 14 SERVOSTAR 640 670 Instructions Manual Approvals 12 2010 Kollmorgen...

Page 15: ...rox ca 25 Kg l Labeling nameplate outside at the box 4 3 Storage l Storage only in the manufacturer s original recyclable packaging l Max stacking height 3 cartons l Storage temperature 25 to 55 C max...

Page 16: ...assembling Remove the fan housing and disassemble the servo amplifier reverse of the procedure described in chapter Mechanical installation 4 6 Repair Repair of the servo amplifier must be done by the...

Page 17: ...length feedback cable pre assembled or both feedback connectors separately with feedback cable as length external brake resistor BAS usually required communications cable to the PC p 68 or Y adapter...

Page 18: ...art Number SERVOSTAR 640 S64001 NA SERVOSTAR 670 S67001 NA 18 SERVOSTAR 640 670 Instructions Manual Package 12 2010 Kollmorgen Family S6 S600 Voltage rating 0 230 480V Current rating 40 40A rms 70 70A...

Page 19: ...y with insulating transformer p 46 l BB6 rectifier bridge off 3 phase earthed grounded supply integral inrush circuit l Fusing e g fusible cutout provided by the user l All shielding connections direc...

Page 20: ...motor control l Evaluation of the resolver signals and sine cosine signals of a high resolution encoder l Encoder simulation incremental or SSI Comfort functions l 2 analog monitor outputs l 4 progra...

Page 21: ...Inputs Outputs Setpoint 1 2 resolution 14bit 12bit V 10 Common mode voltage max V 10 Input resistance to AGND kW 20 Digital inputs V low 0 7 high 12 36 mA 7 Digital outputs open collector V max 30 mA...

Page 22: ...ion Storage hints p 15 Transport hints p 15 Supply voltage tolerances Input power p 46 Aux power supply min 3x230V 10 AC max 3x 480V 10 50 Hz min 3x208V 10 AC max 3x 480V 10 60 Hz 24 VDC 0 15 check vo...

Page 23: ...esistor p 41 min 10 mm 6 awg shielded 1000V 80 C 176 F For multi axis systems please note the special operating conditions in your installation To reach the max permitted cable length observe cable re...

Page 24: ...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 100 ms DECDIS the speed se...

Page 25: ...patented power distribution several amplifiers even with different current ratings can be operated off a common DC bus link This is achieved by an auto matic adjustment of the brake thresholds which...

Page 26: ...ns tance l 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...

Page 27: ...servo amplifier on and off Devices which are equipped with a selected Brake function use a special sequence for switching off the output stage p 24 The built in restart lock AS can be used to switch o...

Page 28: ...ne 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 interven...

Page 29: ...hereby 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...

Page 30: ...y 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 com mands vi...

Page 31: ...4 4 41 Regulations for installation and EN 60204 Electrical equipment of machinery residual current circuit breakers called FI below can be used provided the requisite regulations are complied with Th...

Page 32: ...This page has been deliberately left blank 32 SERVOSTAR 640 670 Instructions Manual Technical description 12 2010 Kollmorgen...

Page 33: ...es which produce magnetic field with distance to the servo amplifiers and or shield the magnetic fields 7 2 Guide to mechanical installation The following notes should assist you to carry out the mech...

Page 34: ...ce for information for pass through mounting Material 4 hexagon socket screws to EN 4762 M6 Tool required 5 mm Allen key A 4 038 4 12 34 SERVOSTAR 640 670 Instructions Manual Mechanical Installation 1...

Page 35: ...7 4 Dimensions SERVOSTAR 640 670 Instructions Manual 35 Kollmorgen 12 2010 Mechanical Installation...

Page 36: ...This page has been deliberately left blank 36 SERVOSTAR 640 670 Instructions Manual Mechanical Installation 12 2010 Kollmorgen...

Page 37: ...and 24V supply must be installed by the user best values are given on p 22 Hints for use of Residual current circuit breakers FI p 31 Correct wiring is the basis for reliable functioning of the servo...

Page 38: ...eldbuses are used Connect the analog setpoint if required Connect up the feedback unit resolver and or encoder Connect the encoder emulation if required Connect the expansion card see corresponding ma...

Page 39: ...d in all the wiring diagrams indicates that you must take care to provide an electrically conductive connection with the largest possible surface area between the unit indicated and the mounting plate...

Page 40: ...from the cores for the required length Secure the cores with a cable tie Remove the outer covering of the cable over a length of about 30mm without damaging the shielding braid Pull a cable tie throug...

Page 41: ...h you must use cable material which meets the requirements on the capacity given below Insulation material Sheathing PUR polyurethane code 11Y Core insulation PETP polyesteraphtalate code 12Y Capacita...

Page 42: ...ollmorgen 24V power supply Fuses Drive contactor Terminals Motor PC Control PLC Mains choke Fuses Mains filter Brake resistor Cables drawn bold are shielded Electrical ground is drawn with dash dotted...

Page 43: ...8 5 Block diagram The block diagram below is just an overview SERVOSTAR 640 670 Instructions Manual 43 Kollmorgen 12 2010 Electrical Installation...

Page 44: ...8 6 Pin assignments 44 SERVOSTAR 640 670 Instructions Manual Electrical Installation 12 2010 Kollmorgen...

Page 45: ...tions Manual 45 Kollmorgen 12 2010 Electrical Installation SERVOSTAR 640 670 Reference Safety Instructions p 9 and Use As Directed p 10 p 68 p 69 p 47 p 47 p 48 p 70 p 48 p 50 p 64 p 65 p 66 p 67 p 62...

Page 46: ...lating transformer is always required for 400 480V mains networks without earth ground and for networks with asymmetrical earth ground 46 SERVOSTAR 640 670 Instructions Manual Electrical Installation...

Page 47: ...cuit to distribute the brake power among all the amplifiers connected to the same DC bus link circuit Connection example p 91 Only servo amplifiers with mains supply from the same mains identical main...

Page 48: ...ble cross section see motor documentation 8 10 External brake resistor X0 Fusing and brake resistor provided by the user 48 SERVOSTAR 640 670 Instructions Manual Electrical Installation 12 2010 Kollmo...

Page 49: ...detailed description of the ASCII parameters please refer to the online help of the setup soft ware The table below provides an overview of the supported feedback types their corresponding para meters...

Page 50: ...he resolver cable to the SERVOSTAR and evaluated there If cable lengths of more than 100 m are planned please contact our customer service FBTYPE 0 3 The pin assignment shown on the encoder side relat...

Page 51: ...e signals are used The thermal control in the motor is connected via the encoder cable to X1 and evaluated there All signals are connected using our pre assembled encoder connection cable If cable len...

Page 52: ...re All signals are connected using our pre assembled encoder connection cable If cable lengths of more than 50 m are planned please consult our customer service Frequency limit sin cos 250 kHz Encoder...

Page 53: ...via the encoder cable to X1 and evaluated there If lead lengths of more than 50 m are planned please consult our customer service Frequency limit sin cos 250 kHz Encoder type FBTYPE Remarks SinCos 5V...

Page 54: ...s complete feedback system combined with an additional Hall encoder All signals are connected to X1 If cable lengths of more than 25 m are planned please consult our customer service Frequency limit A...

Page 55: ...cted via the ComCoder cable to X1 and evaluated there If cable lengths of more than 25 m are planned please consult our customer service Frequency limit A B 250 kHz RS422 with Hall FBTYPE 12 The pin a...

Page 56: ...r X2 see p 50 If lead lengths of more than 50 m are planned and for questions concerning the power supply of the encoder please consult our customer service AGND and DGND connector X3 must be joined t...

Page 57: ...der X5 p 60 7 17 Pulse and Direction 5V X5 p 61 4 14 Pulse and Direction 24V X3 p 61 1 11 adjustable via terminal screen of the setup software The follwing table shows the allowed feedback combination...

Page 58: ...e joined together 8 12 2 Connection to incremental encoder master with 24 V signal level X3 This interface can be used to operate the SERVOSTAR 640 670 as a slave mastered by an enco der with 24 V sig...

Page 59: ...ine encoder master slave operation The connector X1 must be used If cable lengths of more than 25 m are planned please consult our customer service Frequency limit 250 kHz AGND and DGND connector X3 m...

Page 60: ...otor controllers step and direction This interface can be used to connect the servo amplifier to a third party stepper motor controller The parameters for the servo amplifier are set up with the aid o...

Page 61: ...t be joined together 8 12 5 2 Step Direction with 24 V signal level X3 This interface can be used to connect the servo amplifier to a stepper motor controller with 24 V signal level The digital inputs...

Page 62: ...r function ENCMODE Feedback system Resolution Zero position ROD 1 Resolver 256 4096 one per revolution only if A B 1 Encoder 256 524288 28 219 one per revolution only if A B 1 ROD interpolation 3 Enco...

Page 63: ...6 pole resolvers it is within a third of a turn Exception If an encoder with a commutation track is used as the feedback unit then the upper 12 bits are set to 1 data invalid until a homing run is pe...

Page 64: ...point Input Analog In2 terminals X3 6 7 Differential input voltage max 10 V resolution 12 bit scalable Standard setting torque setpoint Application examples for setpoint input Analog In2 adjustable ex...

Page 65: ...log Out 1 Tachometer voltage nact speed The output delivers 10 V at the preset limit speed Analog Out 2 Current actual value Iact torque The output delivers 10 V at the preset peak current effective r...

Page 66: ...freshly assigned to a pre programmed function then the data set must be stored in the EEPROM of the servo amplifier and the 24 V auxiliary supply of the servo amplifier must be swit ched off and on ag...

Page 67: ...tputs DIGITAL OUT 1 2 You can use the digital outputs DIGITAL OUT1 terminal X3 16 and DIGITAL OUT2 terminal X3 17 to outputs messages from pre programmed functions that are stored in the servo amplifi...

Page 68: ...tocoupler and is at the same potential as the CANopen interface The interface is selected and set up in the setup software Further notes can be found on page 78 With the optional expansion card 2CAN t...

Page 69: ...r X3 must be joined together CAN bus cable To meet ISO 11898 you should use a bus cable with a characteristic impedance of 120 W The maximum usable cable length for reliable communication decreases wi...

Page 70: ...d by the Trade Liability Association Moving single axis groups in setting up operation In setting up operation people will frequently be within the danger zone of the machinery Axes will normally be m...

Page 71: ...cts KSO1 2 for all servo amplifiers are wired into the control signal loop The AS restart lock may only be controlled by a CNC if the control of the internal safety relay is arranged for redundant mon...

Page 72: ...he servo amplifier is ready for operation If the drive is electronically braked the servo amplifier is disabled and the motor holding brake is on then the safety relay is energized manually or by the...

Page 73: ...loads 2 Activate the restart lock AS 3 Open protective screens but do not enter hazardous area 4 Pull off the X10 connector from an amplifier the mains contactor must drop out 5 Reconnect X10 Switch...

Page 74: ...le category 1 according to EN 954 1 Flowchart for stop and emergency stop category 0 8 17 8 1 Control circuit 8 17 8 2 Mains supply circuit 74 SERVOSTAR 640 670 Instructions Manual Electrical Installa...

Page 75: ...le category 3 according to EN 954 1 Flowchart for stop and emergency stop category 1 8 17 9 1 Control circuit 8 17 9 2 Mains supply circuit SERVOSTAR 640 670 Instructions Manual 75 Kollmorgen 12 2010...

Page 76: ...must exceed the deceleration ramp The drive must have been brought to a safe standstill by the time t K10t and t K20t have elapsed After this point active braking with the servo amplifier is no longe...

Page 77: ...can reach a temperature of up to 80 C 176 F in operation Check measure the heat sink temperature Wait until the heat sink has cooled down below 40 C 104 F before touching it Only professional personn...

Page 78: ...assistance of the setup software The PC is connected to the servo amplifier by a null modem cable p 68 The setup software provides the communication between SERVOSTAR 640 670 and the PC You will find...

Page 79: ...DOS OS2 DRIVE EXE is not executable under WINDOWS 3 xx DOS and OS2 In emergency operation is possible through an ASCII terminal emulation without user interface Interface settings 9600 bps no parity n...

Page 80: ...2 Documents You need access to these documents located on the product CD ROM you can download the latest editions from our website l Instructions Manual this manual l CANopen Communication Profile Man...

Page 81: ...r functionality of your application it just shows the required wiring for drive testing without load SERVOSTAR 640 670 Instructions Manual 81 Kollmorgen 12 2010 Setup Motor Feedback Motor Power Motor...

Page 82: ...on page 94ff If there is fault fix the problem Double Click the DRIVE EXE icon on your Windows desktop to start the software You can work offline or online with Work ONLINE now Select the interface wh...

Page 83: ...o all parameters the servo amplifier can work with Key F1 Starts online help for the actual screen page Menu Bar or Online HTML Help Starts online help with table of contents Tool Bar Save to EEPROM r...

Page 84: ...AC voltage Mains Phase Missing You can select either warning n05 or error F19 in case of phase loss The setting F19 disables the output stage n05 is just a message Units Acceleration Velocity Positio...

Page 85: ...ck OK If your motor has a built in brake click Yes otherwise No If Software Enable is active a warning appe ars You can proceed but after the amplifier is restarted you must check whether the holding...

Page 86: ...tion change cannot be performed Click OK on the warnings press F12 SW disab le and start the Feedback procedure again If everything was ok the same procedure para meter upload that has been described...

Page 87: ...s EEPROM automatically and a reset command restarts the amplifier takes a few seconds For example this happens after motor or feedback selection Other parameters changed No warning appears Parameters...

Page 88: ...E and the current rating e g for Enable 40 amps l Click the icon Oscilloscope l Select Service Mode Speed F6 then click Parameter button l Enter a safe speed The sign defines the direction of movemen...

Page 89: ...or messages A description of errors war nings can be found on page 94 Now you have setup and tested the basic functions of the drive successfully 9 3 10 Monitor Click the icon Monitor The Monitor scre...

Page 90: ...on addresses for the individual amplifiers and the baud rate for communication by means of the keypad on the front panel p 93 9 4 2 Baud rate for CAN bus After changing the station address and baud ra...

Page 91: ...xample of connections for a multi axis system SERVOSTAR 640 670 Instructions Manual 91 Kollmorgen 12 2010 Setup SERVOSTAR 640 670 SERVOSTAR 640 670 Reference Safety Instructions p 9 and Use As Directe...

Page 92: ...hing on the 24V supply 9 5 1 Key operation The two keys can be used to perform the following functions Key symbol Functions press once go up one menu item increase number by one press twice in rapid s...

Page 93: ...ded menu structure Keep the right key pressed while switching on the 24V supply SERVOSTAR 640 670 Instructions Manual 93 Kollmorgen 12 2010 Setup see p 90 the entry will be stored automatically when y...

Page 94: ...ed F16 Supply BTB RTO 2 or 3 phases missing in the mains supply feed F17 A D converter Error in the analog digital conversion normally caused by ex treme electromagnetic interferences F18 Brake Brake...

Page 95: ...loaded n13 Slot warning 24V supply of the I O expansion board is missing n14 SinCos feedback SinCos commutation wake shake not completed will be canceled when amplifier is enabled and wake shake carr...

Page 96: ...check brake control check mechanism set no of motor poles set up feedback correctly motor oscillates gain too high speed controller shielding in feedback cable broken AGND not wired up reduce Kp speed...

Page 97: ...h as screws fall into the open option slot l Push the expansion card carefully into the provided guide rails of the main slot without twisting it l Press the expansion card firmly into the slot until...

Page 98: ...a Control inputs 24V 7mA PLC compatible EN 61131 Signal outputs 24V max 500mA PLC compatible EN 61131 Supply inputs EN 61131 24V 18 36V 100mA plus total current of the outputs depends on the input wir...

Page 99: ...art Continues the motion task that was previously interrupted The motion task can also be continued by an appropriately configured digital input on the basic unit 2 In Start_MT I O Start of the motion...

Page 100: ...10 2 6 Connection diagram AGND and DGND connector X3 must be joined together 100 SERVOSTAR 640 670 Instructions Manual Expansion Cards 12 2010 Kollmorgen SERVOSTAR 640 670 I O 14 08...

Page 101: ...allel The supply voltage for the expansion card is provided by the servo ampli fier 10 3 1 Front view 10 3 2 Connection technology Cable selection cable routing shielding bus connector bus termination...

Page 102: ...ence If this LED is very bright then communication is suffering strong interference or is non existent Check the SERCOS transmission speed for the controls and the servo amplifier BAUDRATE and the fib...

Page 103: ...tion is not possible The SBAUD parameter can be used to set the baud rate where is the baud rate If the optical power is not set correctly errors occur in telegram transmission and the red LED on the...

Page 104: ...munication Profile 10 5 1 Front view 10 5 2 Connection technology Cable selection cable routing shielding bus connector bus termination and transmission times are all described in the DeviceNet Specif...

Page 105: ...front of the expansion card to a value higher than 63 Now you can set up the station address by using the ASCII commands DNMACID x SAVE COLD START whereby x stands for the station address l Set the ro...

Page 106: ...t R 20KW Absolute max voltage range 25 V to 18 V CAN_H CAN_L The voltages for CAN_H and CAN_L refer to the ground pin of the transceiver The voltage is higher than that on the V terminal by the amount...

Page 107: ...onfiguration single flash Unsolicited State Change double flash Watchdog Timeout off No Error RUN on Device is in state OPERATIONAL blinking Device is in state PRE OPERATIONAL single flash Device is i...

Page 108: ...ying build options to the application program 10 7 3 Node LED table LED Name Function LED1 green LINK_IN ON receive valid IN port OFF not valid power off or reset LED2 yellow CYCLIC ON network cyclic...

Page 109: ...ture input fast 5 In IN_04 Digital input 6 In IN_01 Digital input 7 In HOME Reference switch 8 In POSLIM Limit switch positive direction 9 In GND Power supply 10 Out OUT_00 Digital output 11 Out OUT_0...

Page 110: ...0 8 1 Installation The modul must be placed onto the option slot after levering off the cover of the option slot l Screw the distance pieces into the fixing lugs of the option slot l Place the expansi...

Page 111: ...RS232 CAN1 CAN2 X6A Pin Signal X6B X6C Pin Signal 1 Vcc 1 2 RxD 2 CAN Low 3 TxD 3 CAN GND 4 4 5 GND 5 6 6 7 7 CAN High 8 8 9 9 10 8 5 Connection diagram SERVOSTAR 640 670 Instructions Manual 111 Kollm...

Page 112: ...This page has been deliberately left blank 112 SERVOSTAR 640 670 Instructions Manual Expansion Cards 12 2010 Kollmorgen...

Page 113: ...AY code Special method of representing binary numbers H Holding brake 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...

Page 114: ...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...

Page 115: ...nsion card DeviceNet DE 103571 OPT DN Expansion card PROFIBUS DP DE 90056 OPT PB Expansion card SERCOS DE 90879 OPT SE Expansion card I 0 14 08 DE 90057 OPT EI Expansion card EtherCAT DE 108350 OPT EC...

Page 116: ...94 3444 Please advice dispatch information for please select Repair Disposal of these products Product Serial number Reason fault return or similar to this address Company Street Zip Town Country Spec...

Page 117: ...e 79 K Key operation 92 L LC Display 92 Leakage current 31 Limit Switch Inputs 66 M Mains supply connection interface 47 Mains supply networks 46 Maintenance 15 Master Slave 57 Motor holding brake 24...

Page 118: ...are of your local sales representative please contact the Customer Support Europa Kollmorgen Customer Support Europe Internet www kollmorgen com E Mail technik kollmorgen com Tel 49 0 2102 9394 2250 F...

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