Danaher Motion Kollmorgen SERVOSTAR SP3 User manual

Danaher Motion
SERVOSTAR® SP3 Power Block
Installation Manual
KOLLMORGEN
giving our customers freedom of design
M-SS-010-0104
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Record of Manual Revisions
ISSUE NO. DATE REVISIONS
1 08/01/01 Initial Release
2 01/16/02 Correction to AC wiring description; addition of Watchdog description
3 February, 2003 Rename connector C8 to C5
Hardware spec: remove reference to C7 (Weidmuller)
Troubleshooting: add description of “F” fault (PWM Frequency)
4 February, 2003 Maximum PWM frequency is 15.5kHz
Added definition of C5 mating connector
Copyright Information
Copyright 2001 Kollmorgen - All rights reserved.
NOTICE:
This document is proprietary information of Kollmorgen that is furnished for customer use
ONLY. No other uses are authorized without written permission of Kollmorgen. Information in
this document is subject to change without notice and does not represent a commitment on the
part the Kollmorgen Corporation. Therefore, information contained in this manual may be
updated from time-to-time due to product improvements, etc., and may not conform in every
respect to former issues.
Not for use or disclosure outside of Kollmorgen except under written agreement. All rights are
reserved. No part of this book shall be reproduced, stored in retrieval form, or transmitted by any
means, electronic, mechanical, photocopying, recording, or otherwise without the written
permission from Kollmorgen. While every precaution has been taken in the preparation of the
book, the publisher assumes no responsibility for errors or omissions. Neither is any liability
assumed for damages resulting from the use of the information contained herein.
Kollmorgen GOLDLINE®, SILVERLINE®, PLATINUM®, and SERVOSTAR®are a
registered trademarks of the Kollmorgen Corporation. PMAC® and Accessory 8F®are registered
trademarks of Delta Tau Data Systems, Inc.
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Safety Instructions
Only qualified personnel are permitted to transport, assemble, commission, and maintain this equipment.
Properly qualified personnel are persons who are familiar with the transport, assembly, installation,
commissioning and operation of motors, and who have the appropriate qualifications for their jobs. The
qualified personnel must know and observe the following standards and regulations:
IEC 364 resp. CENELEC HD 384 or DIN VDE 0100
IEC report 664 or DIN VDE 0110
National regulations for safety and accident prevention or VBG 4
Read all available documentation before assembling and commissioning. Incorrect handling of products
in this manual can result in injury and damage to persons and machinery. Strictly adhere to the technical
information regarding installation requirements.
It is vital to ensure that all system components are connected to earth ground. Electrical safety is
provided through a low-resistance earth connection.
The SERVOSTAR®product contains static sensitive components that can be damaged by incorrect
handling. Avoid contact with high insulating materials (artificial fabrics, plastic film, etc.). Place the
product on a conductive surface. Ground yourself (discharge any possible static electricity build-up) by
touching an unpainted, metal, grounded surface.
Keep all covers and cabinet doors shut during operation. Otherwise, potential hazards could cause severe
personal injury or damage to the product.
Be aware that during operation, the product has electrically charged components and hot surfaces.
Control and power cables can carry a high voltage, even when the motor is not rotating.
Never disconnect or connect the product while the power source is energized to avoid electric arcing and
hazards to personnel and electrical contacts.
After removing the power source from the equipment, wait at least 10 minutes before touching or
disconnecting sections of the equipment that normally carry electrical charges (e.g., capacitors, contacts,
screwed connections). To be safe, measure the electrical contact points with a meter before touching the
equipment.
Safety symbols indicate a potential for personal injury or equipment damage if the recommended
precautions and safe operating practices are not followed. Read and be familiar with the safety notices in
this manual before attempting installation, operation, or maintenance to avoid serious bodily injury,
damage to the equipment, or operational difficulty. The safety-alert symbols are:
"Warning" identifies hazards that could result in personal injury or death.
"Caution" identifies hazards that could result in personal injury or equipment
damage.
"Note" identifies information required for your understanding or use of the
equipment.
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Directives and Standards
The SERVOSTAR®SP3 Power Block has been successfully tested and evaluated to meet UL/cUL 508C
for the U.S. and Canadian markets. This standard outlines the minimum requirements for electrically
operated power conversion equipment (frequency converters and servo amplifiers), which are intended to
eliminate the risk of fire, electric shock, or injury to persons, being caused by such equipment.
CE Mark Conformance
Servo drives are incorporated in electrical plants and machines for industrial use. When the servo drives
are built into machines or plants, the operation of the drive is prohibited until the machine or plant meets
the requirements of the EC Directive on Machines 89/392/EEC and the EC Directive on EMC
(89/336/EEC). Directives EN 60204 and EN 292 must also be met.
In connection with the Low Voltage Directive 73/23/EEC, the harmonized standards of the EN 50178
series are applied to the amplifiers, together with EN 60439-1, EN 60146 and EN 60204.
The manufacturer of the machine or plant is responsible for ensuring that they meet the limits; which are
required by the EMC regulations. Advice on the correct installation for EMC - such as shielding,
grounding, arrangement of filters, treatment of connectors and the lay out of cabling can be found in this
documentation.
Conformance with the EC Directive on EMC 89/336/EEC and the Low Voltage Directive 73/23/EEC is
mandatory for the supply of servo drives within the European Community.
The servo drives have been tested by an authorized testing laboratory in a defined configuration with the
system components deSP3 Power Blockribed in this documentation. Kollmorgen is not responsible for
any divergence from the configuration and installation deSP3 Power Blockribed in this documentation
and is not responsible for the performance of new measurements or ensuring that regulatory requirements
are met.
Kollmorgen’s SERVOSTAR SP Power Block has been successfully tested and evaluated to the limits
and requirements of the EC Directive on EMC (89/336/EEC) and the EC Directive on Low Voltage
(72/73/EEC). The product lines have been evaluated to EN50178 and EN60204 as a component of a
machine and other relevant standards.
The Electromagnetic Compatibility (EMC) of a system is identified in two parts: emissions and
immunity. Emission refers to the generation of electromagnetic interference (EMI), and immunity refers
to the suSP3 Power Blockeptibility levels of the equipment. Limits are derived from generic standards
EN55081-2 and EN55082-2 for heavy industrial environment. The SERVOSTAR series of drives and
bus modules have been tested for radiated emissions, conducted emissions, EFT, ESD, surge, conducted
immunity, and radiated immunity. These tests have been in accordance with EN55011, EN61000-4-2,
ENV50140, IEC 1000-4-4, EN61000-4-5, and ENV50141.
Installation of the equipment is critical in designing system and machine
electromagnetic compatibility (EMC). The user must apply the installation
recommendations in this manual (see the sections on Installation and CE
Filtering Techniques when mounting and installing the drive system for CE
conformance.
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Kollmorgen Safety Instructions
SERVOSTAR®SP3 Power Block i
Table of Contents
READ BEFORE INSTALLING...................................................................................................1
UNPACKING AND INSPECTING..............................................................................................3
WARRANTY INFORMATION ............................................................................................................3
USE AS DIRECTED ..........................................................................................................................3
PART NUMBER...............................................................................................................................4
ELECTRICAL SPECIFICATIONS ........................................................................................................5
MOUNTING...................................................................................................................................7
HARDWARE SPECIFICATIONS .........................................................................................................7
OUTLINE DIMENSIONS ...................................................................................................................8
MOUNTING PRACTICES ..................................................................................................................8
CE FILTERING TECHNIQUES ..........................................................................................................9
Input Power Filtering................................................................................................................9
Motor Line Filtering ...............................................................................................................10
I/O Filtering ............................................................................................................................11
GROUNDING.................................................................................................................................12
BONDING .....................................................................................................................................12
Non-insulated Cable Clamp....................................................................................................13
Alternative Bonding Methods..................................................................................................13
SYSTEM WIRING ......................................................................................................................15
MAIN POWER CONNECTOR ..........................................................................................................15
24V LOGIC POWER CONNECTOR (OPTIONAL)..............................................................................16
STANDARD OPTION......................................................................................................................17
Standard Option Block Diagram.............................................................................................18
INTEGRATED 8F OPTION CONNECTOR .........................................................................................18
Integrated 8F Option Block Diagram .....................................................................................19
SYSTEM INTERCONNECT...............................................................................................................19
Connector C1: Hall Effect Device Feedback ..........................................................................19
Connector C2: Encoder Feedback..........................................................................................20
Connector C3: PMAC Interface..............................................................................................21
Connector C4: User Flags ......................................................................................................22
Connector C5 User Flags .......................................................................................................22
DIP SWITCHES ......................................................................................................................22
TROUBLESHOOTING ..............................................................................................................23
DISPLAY ......................................................................................................................................23
WATCHDOG .................................................................................................................................24
F FAULT (MAXIMUM PWM FREQUENCY) ....................................................................................24
FAULT CODE TRANSMISSION .......................................................................................................24
OVER-CURRENT SHUT-DOWN......................................................................................................25
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Kollmorgen Safety Instructions
SERVOSTAR®SP3 Power Block ii
CURRENT SCALING ......................................................................................................................25
CUSTOMER SUPPORT ...................................................................................................................26
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Kollmorgen Read Before Installing
SERVOSTAR®SP3 Power Block 1
READ BEFORE INSTALLING
This manual is provided with your product to assist you in getting your SERVOSTAR®SP3
Power Block installed and operational.
High voltage can be hazardous to personnel and equipment. Be sure a qualified
electrician works on this equipment. To ensure safety, follow all national and local
codes during installation as well as the safety precautions outlined in the front of
this documentation.
1. Open the box(es) and remove all the contents. Check to ensure there is no visible damage
to any of the equipment.
2. Mount the SP3 Power Block to the back panel. Refer to the Outline Dimensions for
additional details. Metal-to-metal contact is important for electrical noise control!
3. Wire the SP3 Power Block according to the System Wiring Diagram. Pay particular
attention to the pinout connector details.
4. Connect solid earth ground to frames of all components.
5. Wire the main power (24 VDC).
6. Wire the motor and feedback. Refer to the Feedback Wiring Diagram for additional
information.
7. Wire the Regen Resistor kit, if applicable.
8. Verify that all wiring is correct.
9. Verify that earth grounds are connected.
10. Verify all electrical and safety codes are met.
11. For the integrated 8F option:
A. Connect the halls cable to connector C1.
B. Connect the feedback connector C2.
C. Connect the connector C3 to PMAC (The SP3 works with the standard PMAC
motion controller).
D. Connect the user flags connector C4.
E. Connect the user flags connector C5.
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Kollmorgen Read Before Installing
SERVOSTAR®SP3 Power Block 2
12. For the Standard option:
A. Connect the cable C2.
B. Connect the 8F Delta Tau accessory.
13. Configure the SP3 Power Block for your particular motor, if this was not done at the
factory.
14. Tune the SP3 Power block for the load and desired performance.
15. Enable the system.
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Kollmorgen Unpacking and Inspecting
SERVOSTAR®SP3 Power Block 3
UNPACKING AND INSPECTING
Open the box and remove all the contents. Check to ensure there is no visible damage to any of
the equipment.
Electronic components in this amplifier are design-hardened to reduce static
sensitivity. However, proper procedures should be used when handling to avoid
damage to equipment.
Remove all packing material and equipment from the shipping container. Be aware
that some connector kits and other equipment pieces may be quite small and can be
accidentally discarded if care is not observed when unpacking the equipment. Do not
dispose of shipping materials until the packing list has been checked.
Upon receipt of the equipment, inspect components to ensure that no damage has
occurred in shipment. If damage is detected, notify the carrier immediately. Check all
shipping material for connector kits, documentation, diskettes, CD-ROM, or other
small pieces of equipment.
WARRANTY INFORMATION
All products covered in this manual are warranted to be free of defects in material and
workmanship and to conform to the specifications stated either in this document or product
catalog description. All Kollmorgen brushless motors and electronics are warranty for a period of
24 months from the time of installation or 30 months from time of shipment, which ever comes
first. There are no other warranties, expressed or implied (including the warranty of
merchantability and fitness for a particular purpose, which extends beyond this warranty.
Kollmorgen warrants that the products covered in the manual are free from patent infringement
when used for normal purposes.
USE AS DIRECTED
The following guidelines describe the restrictions for proper use of the SERVOSTAR SP3
Power Block:
1. The amplifiers are components built into electrical equipment or machines and can only
be used as integral components of such equipment.
2. The servo amplifiers are to be used only on earthed three-phase industrial mains supply
networks (TN-system, TT-system with earthed neutral point).
3. The servo amplifiers must not be operated on power supply networks without an earth or
with an asymmetrical earth.
4. If the servo amplifiers are used in residential areas, or in business or commercial
premises, you must implement additional filter measures.
5. The servo amplifiers are only intended to drive brushless synchronous servomotors with
closed-loop control of torque, speed, and position. The rated voltage of the motors must
be at least as high as the DC-link voltage of the servo amplifier.
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Kollmorgen Unpacking and Inspecting
SERVOSTAR®SP3 Power Block 4
6. The servo amplifiers may only be operated in a closed switch gear cabinet, taking into
account the ambient conditions defined in the environmental specifications.
7. Danaher Motion Kollmorgen guarantees the conformance of the servo amplifiers with the
standards for industrial areas stated in the front of this manual only if Danaher Motion
Kollmorgen delivers the components (motors, cables, amplifiers etc).
PART NUMBER
CP3 03 25 8
Current Rating
03: 3 Amp. continuous; 9 Amp. peak
06: 6 Amp. continuous; 18 Amp. peak
10: 10 Amp. continuous; 20 Amp. peak
Product Designator
SERVOSTAR SP3 Model Number
0: without 8F
1: with integrated 8F
25: logic power generated internally
26: 24V external logic power
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