Danaher Motion Kollmorgen SERVOSTAR 300 Series User manual

Assembly, Installation, Setup
Keep all product manuals as a product component
during the life span of the servo amplifier.
Pass all product manuals to future
users / owners of the servo amplifier.
Edition 12/05
File sr300_e.xxx
Digital Servo Amplifier
SERVOSTAR®300
www.DanaherMotion.com

Previous versions:
Edition Remarks
06/04 First edition
04/05 Restart lock -AS-, UL-listing, new pinning for X8, several corrections
04/05a order numbers 400V types for NA updated
11/05
Chapter 1 updated, ComCoder wiring corrected, Acuro(BISS)-Interface new, max. station ad-
dress changed to 127, motor choke changed, SynqNet and EtherCat expansion cards added,
chapter 6 restructured, order codes restructured
12/05 Feedback section, termination resistors X1/X5, CE section
WINDOWS is a registered trademark of Microsoft Corp.
HIPERFACE is a registered trademark of Max Stegmann GmbH
EnDat is a registered trademark of Dr. Johannes Heidenhain GmbH
SERVOSTAR is a registered trademark of Danaher Motion Corporation
Technical changes which improve the performance of the equipment may be made without prior
notice!
Printed in the Federal Republic of Germany
All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm
or any other method) or stored, processed, copied or distributed by electronic means without the written per-
mission of Danaher Motion.

1 General
1.1 About this manual ....................................................................... 7
1.2 Symbols used in this manual ............................................................... 7
1.3 Abbreviations used in this manual ........................................................... 8
2 Technical description
2.1 Safety Instructions ....................................................................... 9
2.2 Use as directed ........................................................................ 10
2.3 European Directives and Standards......................................................... 11
2.4 CE conformance ....................................................................... 11
2.5 Conformance with UL and cUL ............................................................ 12
2.6 Nameplate ............................................................................ 13
2.7 Instrument description ................................................................... 13
2.7.1 Package supplied.................................................................. 13
2.7.2 The SERVOSTAR 300 family of digital servo amplifiers .................................... 14
2.8 Connection to various electrical supply networks............................................... 16
2.9 Components of a servo system ............................................................ 17
2.10 Technical data ......................................................................... 18
2.10.1 Technical data for 110/230 V (types S3_ _6_)............................................ 18
2.10.2 Technical data for 400/480 V (types S3_ _0_)............................................ 19
2.10.3 Inputs / outputs ................................................................... 20
2.10.4 Recommended tightening torques ..................................................... 20
2.10.5 Fusing .......................................................................... 20
2.10.5.1 Internal fusing ................................................................. 20
2.10.5.2 External fusing ................................................................ 20
2.10.6 Permissible ambient temperatures, ventilation, mounting position............................. 21
2.10.7 Conductor cross-sections............................................................ 21
2.10.8 LED display ...................................................................... 21
2.11 Grounding system ...................................................................... 22
2.12 Control circuit for motor-holding brake ....................................................... 22
2.13 Regen circuit .......................................................................... 23
2.14 Switch-on and switch-off behavior .......................................................... 25
2.14.1 Stop function as per EN 60204 (VDE 0113).............................................. 25
2.14.2 Emergency Stop strategies .......................................................... 26
3 Installation
3.1 Important notes ........................................................................ 27
3.2 Guide to installation and wiring ............................................................ 28
3.3 Assembly ............................................................................. 29
3.3.1 Dimensions ...................................................................... 30
3.4 Wiring................................................................................ 31
3.4.1 Connection diagram................................................................ 32
3.4.2 Connector assignments ............................................................. 33
3.4.3 Notes on connection technology ...................................................... 34
3.4.3.1 Shielding connection to the front panel .............................................. 34
3.4.3.2 Technical data for connecting cables ............................................... 35
3.5 Setup software ......................................................................... 36
3.5.1 General ......................................................................... 36
3.5.1.1 Use as directed ................................................................ 36
3.5.1.2 Software description ............................................................ 36
3.5.1.3 Hardware requirements.......................................................... 37
3.5.1.4 Operating systems ............................................................. 37
3.5.2 Installation under WINDOWS 2000 / XP ................................................ 37
SERVOSTAR®300 Installation Manual 3
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4 Interfaces
4.1 Block diagram ......................................................................... 39
4.2 Electrical supply ........................................................................ 40
4.2.1 Mains electrical supply connection (X0)................................................. 40
4.2.1.1 Three phase .................................................................. 40
4.2.1.2 Single phase without neutral ...................................................... 40
4.2.1.3 Single phase with neutral ........................................................ 40
4.2.2 24V auxiliary supply (X4) ............................................................ 41
4.2.3 DC bus link (X8)................................................................... 41
4.3 Motor connection with brake (X9)........................................................... 42
4.4 External regen resistor (X8) ............................................................... 42
4.5 Feedback ............................................................................. 43
4.5.1 Resolver (X2) ..................................................................... 43
4.5.2 Comcoder (X1).................................................................... 44
4.5.3 Incremental or sine encoder with hall sensors (X1) ........................................ 45
4.5.4 Encoder with EnDat or HIPERFACE (X1) ............................................... 46
4.5.5 ACURO encoder, BISS interface (X1) .................................................. 47
4.5.6 Incremental Encoder (X5) ........................................................... 48
4.5.7 Encoder without data channel (X1) .................................................... 49
4.6 Control signals ......................................................................... 50
4.6.1 Analog inputs (X3) ................................................................. 50
4.6.2 Digital inputs (X3/X4) ............................................................... 51
4.6.3 Digital outputs (X3) ................................................................ 52
4.7 Encoder emulation ...................................................................... 53
4.7.1 Incremental encoder output (X5) ...................................................... 53
4.7.2 SSI output (X5) ................................................................... 54
4.8 Master-slave operation, encoder master control ............................................... 55
4.8.1 Connection to a SERVOSTAR master, 5V signal level (X5) ................................. 55
4.8.2 Connection to incremental-encoder master with 24V signal level (X3)..........................56
4.8.3 Connection to a sine-cosine encoder master (X1) ......................................... 56
4.9 Interface for stepper motor controllers (step and direction) ....................................... 57
4.9.1 Connection to a stepper controller with 5V signal level (X5) ................................. 58
4.9.2 Connection to a stepper controller with 24V signal level (X3) ................................ 58
4.10 RS232 interface, PC connection (X6) ....................................................... 59
4.11 CANopen interface (X6) .................................................................. 60
4.12 Personnel safe restart lock -AS-............................................................ 61
4.12.1 Technical data and pinning .......................................................... 61
4.12.2 Environment...................................................................... 61
4.12.3 Wiring........................................................................... 61
4.12.4 Functional description .............................................................. 62
4.12.4.1 Signal diagram (sequence) ....................................................... 63
4.12.4.2 Control circuit ................................................................. 64
4.12.4.3 Functional test................................................................. 65
4.12.4.4 Mains supply circuit............................................................. 65
5Setup
5.1 Important notes ........................................................................ 67
5.2 Guide to setup ......................................................................... 68
5.3 Parameter setting....................................................................... 69
5.3.1 Multi-axis systems ................................................................. 69
5.3.1.1 Station address for CAN-bus...................................................... 69
5.3.1.2 Baud rate for CAN-bus .......................................................... 69
5.3.2 Keypad operation / LED display....................................................... 69
5.3.2.1 Keypad operation .............................................................. 70
5.3.2.2 Status display ................................................................. 70
5.3.2.3 Standard menu ................................................................ 71
5.3.2.4 Advanced menu ............................................................... 71
5.4 Error messages ........................................................................ 72
5.5 Warning messages ..................................................................... 73
4 SERVOSTAR®300 Installation Manual
Contents 12/05 Kollmorgen
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6 Expansions and Accessories
6.1 Expansion Cards ....................................................................... 75
6.1.1 Guide to installation of expansion cards................................................. 75
6.1.2 Expansion card -I/O-14/08- .......................................................... 76
6.1.2.1 Front view .................................................................... 76
6.1.2.2 Technical data................................................................. 76
6.1.2.3 LEDs ........................................................................ 76
6.1.2.4 Entering a motion block number ................................................... 76
6.1.2.5 Connector assignments.......................................................... 77
6.1.2.6 Connection diagram ............................................................ 78
6.1.3 Expansion card -PROFIBUS-......................................................... 79
6.1.3.1 Front view .................................................................... 79
6.1.3.2 Connection technology .......................................................... 79
6.1.3.3 Connection diagram ............................................................ 79
6.1.4 Expansion card -SERCOS- .......................................................... 80
6.1.4.1 Front view .................................................................... 80
6.1.4.2 LEDs ........................................................................ 80
6.1.4.3 Connection technology .......................................................... 80
6.1.4.4 Connection diagram ............................................................ 81
6.1.4.5 Modifying the station address ..................................................... 81
6.1.4.6 Modifying the baud rate and optical power ........................................... 81
6.1.5 Expansion card -DEVICENET- ....................................................... 82
6.1.5.1 Front view .................................................................... 82
6.1.5.2 Connection technology .......................................................... 82
6.1.5.3 Connection diagram ............................................................ 82
6.1.5.4 Combined module/network status-LED.............................................. 83
6.1.5.5 Setting the station address (device address) ......................................... 83
6.1.5.6 Setting the transmission speed .................................................... 83
6.1.5.7 Bus cable .................................................................... 84
6.1.6 Expansion card -ETHERCAT- ........................................................ 85
6.1.6.1 Front view .................................................................... 85
6.1.6.2 LEDs ........................................................................ 85
6.1.6.3 Connection diagram ............................................................ 85
6.1.7 Expansion card -SYNQNET- ......................................................... 86
6.1.7.1 Front view .................................................................... 86
6.1.7.2 NODE ID Switch ............................................................... 86
6.1.7.3 Node LED table ............................................................... 86
6.1.7.4 SynqNet Connection, Connector X21B/C (RJ-45)...................................... 86
6.1.7.5 Digital inputs/outputs, connector X21A (SubD 15-pin, socket) ............................ 87
6.1.7.6 Connection diagram digital inputs/outputs, connector X21A .............................. 87
6.1.8 Expansion module -2CAN-........................................................... 88
6.1.8.1 Installation .................................................................... 88
6.1.8.2 Front view .................................................................... 88
6.1.8.3 Connection technology .......................................................... 88
6.1.8.4 Connector assignments.......................................................... 89
6.1.8.5 Connection diagram ............................................................ 89
6.2 Accessories ........................................................................... 90
6.2.1 External power supply 24V DC / 5A.................................................... 90
6.2.2 External power supply 24V DC / 20A................................................... 91
6.2.3 External regen resistor BAR(U)xxx .................................................... 92
6.2.4 Motor chokes 3YLNxx .............................................................. 93
7 Appendix
7.1 Transport, storage, maintenance, disposal ................................................... 95
7.2 Finding and removing faults ............................................................... 96
7.3 Glossary.............................................................................. 99
7.4 Order codes .......................................................................... 101
7.4.1 Servo amplifier, expansion cards ..................................................... 101
7.4.2 Mating connectors ................................................................ 101
7.4.3 Motor cables with connectors........................................................ 101
7.4.4 Feedback cables with connectors .................................................... 102
7.4.5 Power supplies................................................................... 102
7.4.6 Regen resistors .................................................................. 102
7.4.7 Motor chokes .................................................................... 102
7.5 Index ............................................................................... 103
SERVOSTAR®300 Installation Manual 5
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6 SERVOSTAR®300 Installation Manual
12/05 Kollmorgen

1 General
1.1 About this manual
This manual describes the SERVOSTAR®300 series of digital servo amplifiers
(standard version: 1.5A ...10A rated current).
In this manual you can find information about:
lGeneral Chapter 1
lTechnical description Chapter 2
lAssembly / installation Chapter 3
lInterfaces Chapter 4
lSetup Chapter 5
lAccessories Chapter 6
lTransport, storage, maintenance and disposal Chapter 7
A more detailed description of the expansion cards that are currently available and the
digital connection to automation systems can be found, together with our applications
notes, in Acrobat-Reader format on the accompanying CD-ROM (system requirements:
WINDOWS, Internet Browser, Acrobat Reader) in different languages.
You can print out this documentation on any standard commercial printer. A printed copy
of the documentation is available from us at extra cost.
This manual addresses personnel with the following qualifications:
Transport : only by personnel with knowledge of handling
electrostatically sensitive components.
Installation : only by electrically qualified personnel.
Setup : only by qualified personnel with extensive knowledge
of electrical engineering and drive technology
1.2 Symbols used in this manual
danger to personnel from
electricity and its effects
general warning
general instructions
mechanical hazard
ðp. see page (cross-reference) lspecial emphasis
Keys on the panel of the servo amplifier :
U
press once : move up one menu item, increase number by one
press twice in rapid succession: increase number by ten
U
press once: move down one menu item, decrease number by one
press twice in rapid succession: decrease number by ten
U
U
hold right key pressed, and then press left key as well:
to enter a number, “Return” function
SERVOSTAR®300 Installation Manual 7
Kollmorgen 12/05 General

1.3 Abbreviations used in this manual
The abbreviations used in this manual are explained in the table below.
Abbrev. Meaning
AGND Analog ground
AS Restart lock, option
BTB/RTO Ready to operate
CAN Fieldbus (CANopen)
CE Communité Europeenne
CLK Clock signal
COM Serial interface for a PC-AT
DGND Digital ground (for 24V and digital I/O)
DIN German Institute for Industrial Standards
Disk Magnetic storage (diskette, hard disk)
EEPROM Electrically erasable programmable memory
EMC Electromagnetic compatibility
EMI Electromagnetic interference
EN European Standard
ESD Electrostatic discharge
IEC International Electrotechnical Commission
IGBT Insulated-gate bipolar transistor
INC Incremental interface
ISO International Organization for Standardization
LED Light-emitting diode
MB Megabyte
NI Zero pulse
PC Personal computer
PELV Protected low voltage
PLC Programmable logic controller
PWM Pulse-width modulation
RAM Volatile memory
RBallast / RBR Ballast resistor (= regen resistor)
RBext External regen resistor
RBint Internal regen resistor
RES Resolver
ROD digital encoder
S1 continuous operation
S3 Intermittent operation
SRAM Static RAM
SSI Synchronous serial interface
UL Underwriters Laboratories
V AC Alternating voltage
V DC DC voltage
VDE Society of German Electrical Technicians
8 SERVOSTAR®300 Installation Manual
General 12/05 Kollmorgen

2 Technical description
2.1 Safety Instructions
lOnly properly qualified personnel are permitted to perform activities such as
transport, installation, setup and maintenance. Properly qualified persons are
those who are familiar with the transport, assembly, installation, setup and
operation of the product, and who have the appropriate qualifications for their
job. Qualified personnel must know and observe:
IEC 364 and CENELEC HD 384 or DIN VDE 0100
IEC-Report 664 or DIN VDE 0110
National Accident Prevention Regulations or BGV A3
lRead this documentation before carrying out installation and setup. Incorrect
handling of the servo amplifier can lead to personal injury or material damage.
It is vital that you keep to the technical data and information on connection re-
quirements (on the nameplate and in the documentation).
lThe manufacturer of the machine must generate a hazard analysis for the ma-
chine, and take appropriate measures to ensure that unforeseen movements
cannot cause injury or damage to any person or property.
lThe servo amplifiers contain electrostatically sensitive components that may
be damaged by incorrect handling. Ground yourself before touching the servo
amplifier, by touching any unpainted metal surface that is itself grounded.
Avoid contact with highly insulating materials such as artificial fabrics or plas-
tic film. Place the servo amplifier on a conductive surface.
lDo not open the units. Keep all covers and control cabinet doors closed during
operation. Otherwise there are deadly hazards, with the risk of death, severe
danger to health, or material damage.
lServo amplifiers may have uncovered live parts during operation, depending
on their degree of enclosure protection. Control and power connections may
be live, even when the motor is not rotating.
lServo amplifiers may have hot surfaces during operation. Temperatures may
rise to above 80°C (176°F).
lNever undo the electrical connections to the servo amplifier while it is live. In
unfavorable circumstances this may cause electrical arcing with damage to
contacts and danger to persons.
lAfter disconnecting the servo amplifier, wait at least five minutes before tou-
ching live sections of the equipment, such as contacts, or undoing any con-
nections. Capacitors can still have dangerous voltages present up to five minu-
tes after switching off the supply voltages. To be sure, measure the voltage in
the DC bus link circuit and wait until it has fallen below 40V.
SERVOSTAR®300 Installation Manual 9
Kollmorgen 12/05 Technical description

2.2 Use as directed
Servo amplifiers are components that are built into electrical plant or machines, and can
only be operated as integral components of such plant or machines.
The manufacturer of the machine must generate a hazard analysis for the machine, and
take appropriate measures to ensure that unforeseen movements cannot cause injury or
damage to any person or property.
Servo amplifiers in the SERVOSTAR 300 series can be supplied from 3-phase grounded
(earthed) industrial supply networks (TN-system, TT-system with grounded neutral point,
no more than 5000A symmetrical rated current at 230V or 480V+10%).
The servo amplifiers must not be operated directly on non-grounded supply networks or
on asymmetrically grounded supplies with a voltage >230V. Connection to other types of
supply networks (with an additional isolating transformer) is described on p. 16.
Periodic overvoltages between phases (L1, L2, L3) and the housing of the servo amplifier
must not exceed 1000V crest.
In accordance with EN 61800, voltage spikes (< 50µs) between phases must not exceed
1000V. Voltage spikes (< 50µs) between a phase and the housing must not exceed
2000V.
If the servo amplifiers are used in residential areas, in business/commercial areas, or in
small industrial operations, then additional filter measures must be implemented by the
user.
The SERVOSTAR 300 family of servo amplifiers is exclusively intended for driving suit-
able brushless synchronous servomotors and asynchronous motors with closed-loop con-
trol of torque, speed and/or position. The rated voltage of the motors must be at least as
high as the DC bus link voltage produced by the servo amplifier.
The servo amplifiers must only be operated in a closed control cabinet, taking into
account the ambient conditions defined on page 21. Ventilation or cooling may be neces-
sary to keep the temperature within the cabinet below 40°C.
Use only copper conductors for wiring. The conductor cross-sections can be derived from
the standard EN 60204 (alternatively for AWG cross-sections: NEC Table 310-16, 60°C
or 75°C column).
We only guarantee the conformance of the servo system with the standards cited on p.11
if the components (servo amplifier, motor, cables etc.) are those supplied by us.
Restart lock for personnel safety
The servo amplifier has an integrated personnel safe restart lock, which meets the requi-
rements of safety category 3 according to EN 954-1.
The conceptual examination of the function "safe stop" (called restart lock AS in the follo-
wing) was accomplished by the BG-Institute for Occupational Safety and Health and the
classification in category 3 according to EN 954-1 was confirmed.
Please consider the specifications on page 61 when you use this function
10 SERVOSTAR®300 Installation Manual
Technical description 12/05 Kollmorgen