Danaher SERVOSTAR 300 Series User manual

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Product Manual
Edition 10/2007
Valid for Hardware Revision 02.01
SERVOSTAR®300
Digital Servo Amplifier
Keep all manuals as a product component
during the life span of the product.
Pass all manuals to future users / owners
of the product.
File sr300_e.***

Record of Document Revisions:
Revision 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
02/06 Error messages and warnings updated, additional information (SERCOS), AWG cross-sections
added, inch dimensions added, analog-in circuit updated, cross section (awg)
05/06 CAN baud rate coding updated, LED display structure updated, input analog-in updated, BISS
interface updated, hardware revision added, Errors/Warnings updated
09/06 New document structure, new cover design, warning n24, Quickstart integrated
03/07
New part number scheme, termination resistors CAN interface and X5 corrected, branding upda-
ted, chapter leakance current new, chapter "servo system graphics" expanded and moved,
chapter "various mains supply networks" moved, trouble shooting reduced, Feedback expanded
and restructured, enc emulation, DC-Link expanded, AS restructured, accessories removed
07/07 Timing diagramm motor brake, standards updated (EMC and LVD)
10/07 Target group, use as directed, standards
Hardware Revision (HR) History
Hardware Revision usable Firmware Revision usable DRIVEGUI.EXE Revision
02.01 >= 2.18 <= 1.30 Build 0056
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
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 Target group ....................................................................7
1.3 Hints for the online edition (PDF format) ..............................................7
1.4 Symbols used ...................................................................7
1.5 Abbreviations used ...............................................................8
2 Safety
2.1 Safety Instructions ...............................................................9
2.2 Use as directed.................................................................10
2.3 Prohibited use..................................................................10
3 Standards
3.1 Approvals of the servo amplifiers ...................................................11
3.1.1 CE conformance ...........................................................11
3.1.2 Conformance with UL and cUL ................................................11
3.2 European Directives and Standards for the machine builder..............................12
3.3 American Directives and Standards for the machine builder ..............................12
3.4 Asian Directives and Standards for the machine builder .................................12
4 Handling
4.1 Transport .....................................................................13
4.2 Packaging .....................................................................13
4.3 Storage .......................................................................13
4.4 Maintenance, Cleaning...........................................................13
4.5 Disposal ......................................................................13
5 Package
5.1 Package supplied ...............................................................14
5.2 Nameplate ....................................................................14
5.3 Part number scheme ............................................................15
6 Technical description
6.1 The SERVOSTAR 300 family of digital servo amplifiers .................................16
6.2 Technical data .................................................................18
6.2.1 Technical data for 110/230 V (types S3_ _6_) ....................................18
6.2.2 Technical data for 400/480 V (types S3_ _0_) ....................................19
6.2.3 Inputs / outputs ............................................................20
6.2.4 Recommended tightening torques .............................................20
6.2.5 Fusing ...................................................................20
6.2.6 Ambient conditions, ventilation, mounting position .................................21
6.2.7 Conductor cross-sections ....................................................21
6.3 Motor holding brake .............................................................22
6.4 LED display....................................................................23
6.5 Grounding system ..............................................................23
6.6 Electrical braking (regen circuit) ....................................................23
6.7 Switch-on and switch-off behavior ..................................................25
6.7.1 Behavior in standard operation ................................................26
6.7.2 Behavior in the event of an error (with standard setting) ............................27
6.8 Stop- / Emergency Stop- Function to EN 60204 .......................................28
6.8.1 Stop: Standards............................................................28
6.8.2 Emergency Stop: Standards ..................................................29
6.8.3 Implementation of the Stop Category 0..........................................30
6.8.4 Implementation of the Stop Category 1..........................................31
6.8.5 Implementation of the Stop Category 2..........................................32
6.9 Shock-hazard protection..........................................................33
6.9.1 Leakage current ...........................................................33
6.9.2 Residual-current circuit breakers (FI) ...........................................33
6.9.3 Isolating transformers .......................................................34
7 Mechanical Installation
7.1 Important notes.................................................................35
7.2 Guide to mechanical installation....................................................35
7.3 Assembly .....................................................................36
7.4 Dimensions ....................................................................37
SERVOSTAR®300 Product Manual 3
Danaher Motion 10/2007 Contents
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8 Electrical installation
8.1 Important notes.................................................................39
8.2 Guide to electrical installation......................................................40
8.3 Wiring ........................................................................41
8.3.1 Important Notes............................................................41
8.3.2 Shielding connection to the front panel..........................................42
8.3.3 Technical data for connecting cables ...........................................43
8.4 Components of a servo system ....................................................44
8.5 Block diagram..................................................................45
8.6 Connector assignments ..........................................................46
8.7 Connection diagram (Overview)....................................................47
8.8 Electrical supply ................................................................48
8.8.1 Connection to various mains supply networks ....................................48
8.8.2 Mains supply connection (X0) .................................................49
8.8.2.1 Three phase ...........................................................49
8.8.2.2 Two phase without neutral ................................................49
8.8.2.3 Single phase with neutral .................................................49
8.8.3 24V auxiliary supply (X4).....................................................50
8.8.4 DC bus link (X8) ...........................................................50
8.9 Motor connection with brake (X9)...................................................51
8.10 External regen resistor (X8) .......................................................51
8.11 Feedback .....................................................................52
8.11.1 Resolver (X2) .............................................................53
8.11.2 Sine Encoder with BISS (X1) .................................................54
8.11.3 Sine Encoder with EnDat 2.1 .................................................55
8.11.4 Sine Encoder with HIPERFACE (X1) ...........................................56
8.11.5 Sine Encoder without data channel (X1).........................................57
8.11.6 Sine Encoder with Hall (X1) ..................................................58
8.11.7 ROD (AquadB) 5V (X1)......................................................59
8.11.8 ROD (AquadB) 5V with Hall (X1) ..............................................60
8.11.9 ROD (AquadB) 5V (X5)......................................................61
8.11.10 ROD (AquadB) 5V with Hall (X5/X1)............................................62
8.11.11 ROD (AquadB) 24V (X3).....................................................63
8.11.12 ROD (AquadB) 24V with Hall (X3/X1)...........................................64
8.11.13 SSI Encoder (X5) ..........................................................65
8.11.14 Hall sensors (X1)...........................................................66
8.12 Electronic Gearing, Master-slave operation ...........................................67
8.12.1 Connection to a SERVOSTAR master, 5 V signal level (X5) .........................67
8.12.2 Connection to stepper motor controllers (step and direction) .........................68
8.12.2.1 Step/Direction with 5 V signal level (X5)......................................68
8.12.2.2 Step/Direction with 24 V signal level (X3).....................................69
8.13 Encoder emulation ..............................................................70
8.13.1 Incremental encoder output - A quad B (X5) .....................................70
8.13.2 SSI encoder output (X5) .....................................................71
8.14 Digital and analog inputs and outputs ...............................................72
8.14.1 Analog inputs (X3)..........................................................72
8.14.2 Digital inputs (X3/X4)........................................................73
8.14.3 Digital outputs (X3) .........................................................74
8.15 RS232 interface, PC connection (X6) ...............................................75
8.16 CANopen interface (X6) ..........................................................76
8.17 Personnel safe restart lock -AS-....................................................77
8.17.1 Safety instructions ..........................................................77
8.17.2 Use as directed ............................................................78
8.17.3 Technical data and pinning ...................................................78
8.17.4 Enlosure .................................................................78
8.17.5 Wiring ...................................................................78
8.17.6 Functional description .......................................................79
8.17.6.1 Signal diagram (sequence) ................................................80
8.17.6.2 Control circuit ..........................................................81
8.17.6.3 Functional test..........................................................82
8.17.6.4 Mains supply circuit......................................................82
4 SERVOSTAR®300 Product Manual
Contents 10/2007 Danaher Motion
page

9Setup
9.1 Important notes.................................................................83
9.2 Setup software .................................................................84
9.2.1 General ..................................................................84
9.2.1.1 Use as directed .........................................................84
9.2.1.2 Software description .....................................................84
9.2.1.3 Hardware requirements...................................................85
9.2.1.4 Operating systems ......................................................85
9.2.2 Installation under WINDOWS 2000 / XP.........................................85
9.3 Quickstart .....................................................................86
9.3.1 Preparation ...............................................................86
9.3.1.1 Unpacking, Mounting and Wiring the Servo Amplifier ...........................86
9.3.1.2 Documents ............................................................86
9.3.1.3 Minimum Wiring for Drive Test .............................................87
9.3.2 Connect ..................................................................88
9.3.3 Important Screen Elements...................................................89
9.3.4 Setup Wizard..............................................................90
9.3.4.1 Basic Setup ............................................................90
9.3.4.2 Units/Mechanical........................................................91
9.3.4.3 Motor (rotary) / Feedback .................................................92
9.3.4.4 Motor (linear) / Feedback (Encoder) ...................................................92
9.3.4.5 Save Parameters and Restart..............................................93
9.3.5 Motion Service (Jog Mode) ...................................................93
9.3.6 More Setup Screens ........................................................94
9.4 Multi-axis systems ..............................................................95
9.4.1 Station address for CAN-bus .................................................95
9.4.2 Baud rate for CAN-bus ......................................................95
9.5 Keypad operation / LED display ....................................................95
9.5.1 Keypad operation ..........................................................95
9.5.2 Status display .............................................................96
9.5.3 Standard menu ............................................................96
9.5.4 Advanced menu ...........................................................97
9.6 Error messages ................................................................98
9.7 Warning messages..............................................................99
9.8 Trouble Shooting ..............................................................100
10 Expansions Cards
10.1 Guide to installation of expansion cards.............................................101
10.2 Expansion card -I/O-14/08- ......................................................102
10.2.1 Front view ...............................................................102
10.2.2 Technical data ............................................................102
10.2.3 LEDs ...................................................................102
10.2.4 Entering a motion block number (example) .....................................102
10.2.5 Connector assignments ....................................................103
10.2.6 Connection diagram (default) ................................................104
10.3 Expansion card -PROFIBUS-.....................................................105
10.3.1 Front view ...............................................................105
10.3.2 Connection technology .....................................................105
10.3.3 Connection diagram .......................................................105
10.4 Expansion card -SERCOS- ......................................................106
10.4.1 Front view ...............................................................106
10.4.2 LEDs ...................................................................106
10.4.3 Connection technology .....................................................106
10.4.4 Connection diagram .......................................................107
10.4.5 Modifying the station address ................................................107
10.4.6 Modifying the baud rate and optical power ......................................107
SERVOSTAR®300 Product Manual 5
Danaher Motion 10/2007 Contents
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10.5 Expansion card -DEVICENET-....................................................108
10.5.1 Front view ...............................................................108
10.5.2 Connection technology .....................................................108
10.5.3 Connection diagram .......................................................108
10.5.4 Combined module/network status-LED ........................................109
10.5.5 Setting the station address (device address) ....................................109
10.5.6 Setting the transmission speed ...............................................109
10.5.7 Bus cable................................................................110
10.6 Expansion card -ETHERCAT- ....................................................111
10.6.1 Front view ...............................................................111
10.6.2 LEDs ...................................................................111
10.6.3 Connection diagram .......................................................111
10.7 Expansion card -SYNQNET- .....................................................112
10.7.1 Front view ...............................................................112
10.7.2 NODE ID Switch ..........................................................112
10.7.3 Node LED table ..........................................................112
10.7.4 SynqNet Connection, Connector X21B/C (RJ-45) ................................112
10.7.5 Digital inputs/outputs, connector X21A (SubD 15-pin, socket) .......................113
10.7.6 Connection diagram digital inputs/outputs, connector X21A ........................113
10.8 Expansion module -2CAN-.......................................................114
10.8.1 Installation ...............................................................114
10.8.2 Front view ...............................................................114
10.8.3 Connection technology .....................................................114
10.8.4 Connector assignments ....................................................115
10.8.5 Connection diagram .......................................................115
11 Appendix
11.1 Glossary .....................................................................117
11.2 Order codes ..................................................................119
11.2.1 Servo amplifiers...........................................................119
11.2.2 Expansion cards ..........................................................119
11.2.3 Mating connectors .........................................................119
11.3 Index ........................................................................120
6 SERVOSTAR®300 Product Manual
Contents 10/2007 Danaher Motion
page

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).
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.
Technical data and dimensional drawings of accessories such as cables, regen resistors,
mains supplies, etc., can be found in the accessories manual.
You can print out this documentation on any standard commercial printer. A printed copy
of the documentation is available from us at extra cost.
1.2 Target group
This manual addresses personnel with the following qualifications:
Transport : only by personnel with knowledge of handling electrostatically sensitive
components.
Unpacking: only by electrically qualified personnel.
Installation : 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 following standards:
IEC 60364 or DIN VDE 0100
IEC 60664 or DIN VDE 0110
national accident prevention regulations or BGV A3
The operator must ensure that the safety instructions in this manual are followed.
The operator must ensure that all personnel responsible for working with the servo
amplifier have read and understood the product manual.
1.3 Hints for the online edition (PDF format)
Bookmarks:
Table of contents and index are active bookmarks.
Table of contents and index in the text:
The lines are active cross references. Click on the desired line and the appropriate page
is indicated.
Page/chapter numbers in the text:
Page/chapter numbers with cross references are active. Click at the page/chapter num-
ber to reach the indicated target.
1.4 Symbols used
Danger to personnel
from electricity and its
effects
Danger to maschinery,
general warning
Important
notes
ðp. see page lspecial emphasis
SERVOSTAR®300 Product Manual 7
Danaher Motion 10/2007 General

1.5 Abbreviations used
Abbrev. Meaning
AGND Analog ground
AS Restart lock
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
F-SMA Fiber Optic Cable connector according to IEC 60874-2
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 Product Manual
General 10/2007 Danaher Motion

2 Safety
2.1 Safety Instructions
lOnly properly qualified personnel are permitted to carry out activities such as
transport, installation, commissioning and maintenance. Properly qualified per-
sons are those who are familiar with the transport, assembly, installation, com-
missioning and operation of the product, and who have the appropriate qualifi-
cations for their job. The qualified personnel must know and observe the
following standards and regulations:
— IEC 60364 or DIN VDE 0100
— IEC 60664 or DIN VDE 0110
— national accident prevention regulations or BGV A3
lCheck the Hardware Revision Number of the product (see product label). This
revision number must match the Hardware Revision Number on the cover page
of the manual.
lRead this documentation before carrying out the installation and commissio-
ning. 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 requirements (nameplate and documentation).
lDischarge your body before touching the servo amplifier. The servo amplifiers
contain electrostatically sensitive components which may be damaged by in-
correct handling. Avoid contact with highly insulating materials (artificial fab-
rics, plastic film etc.). Place the servo amplifier on a conductive surface.
lThe manufacturer of the machine must produce a hazard analysis for the ma-
chine and take appropriate measures to ensure that unforeseen movements do
not result in personal injury or material damage.
lDo not open or touch the equipment during operation. Keep all covers and ca-
binet doors closed during operation. Touching the equipment is allowed du-
ring installation and commissioning for properly qualified persons only. Other-
wise, there are deadly hazards, with the possibility of death, severe injury or
material damage.
— During operation, servo amplifiers may have uncovered live
components, depending on their level of enclosure protection.
— Control and power connections may be live, even though the
motor is not rotating.
— Servo amplifiers may have hot surfaces during operation.
Surface can reach temperatures above 80°C.
lNever undo any electrical connections to the servo amplifier while it is live.
There is a danger of electrical arcing with damage to contacts and personal in-
jury.
Wait at least five minutes after disconnecting the servo amplifier from the main
supply power before touching potentially live sections of the equipment (e.g.
contacts) or undoing any connections. Capacitors can still have dangerous
voltages present up to five minutes after switching off the supply power. To be
sure, measure the voltage in the DC Bus link and wait until it has fallen below
40V.
SERVOSTAR®300 Product Manual 9
Danaher Motion 10/2007 Safety