Georgii Kobold KSV 6HE User manual

KSV 6HE
Servo Amplifier for Brushless Motors
KSV 1,5/5 to KSV 12/30
19 inch, 6 height units, front connection
Operating Instructions 221052E, V 1.3b 09/01
These operating instructions apply to
CKSV 6HE KSV 1,5/5 to KSV 12/30 servo amplifiers (19" plug-in module)(even numbers)
C2800140000 power supply (19" plug-in module)
C038100050Z, 038100070Z, 038100090Z and 038100130Z mains transformers
Caccessories
GEORGII KOBOLD
AUGUST HEINE GmbH & Co
Fasanenweg 6 – 8
D-70771 Leinfelden-Echterdingen
Federal Republic of Germany
Tel. [phone]
Fax [phone] E-mail [e-mail] www.georgii-kobold.de

2 Operating Instructions 221052E, V 1.3b
GEORGIIKOBOLD,D-70771Leinfelden-Echterdingen,phone[phone],fax[phone]
Versions of the document
30.11.99 V 1.3, MH First English version, based on 221059 V 1.3 and
221055E V 1.5a; similar to German version 1.3
12.01.00 V 1.3a, MH values for I time constant on Z4 add-on module ad-
justed; figure 11 new; corrections; document styles
similar to German version V 1.3a
24.09.01 V 1.3b, MH OEM preparation; corrections
similar to German version V 1.3b
O:\!pdf\Vorlagen\GK\221052E_15a.wpd
Copyright by GEORGII KOBOLD AUGUST HEINE GmbH & Co, D-70771 Leinfelden-
Echterdingen, Germany
All rights reserved, including those of translation. No part of these operating instructions
may be copied, reproduced, stored or processed in an information system, or transmitted
in any other form, without prior written permission by GEORGII KOBOLD AUGUST HEINE
GmbH & Co.
These operating instructions have been prepared with care. However, GEORGII KOBOLD
AUGUST HEINE GmbH & Co can accept no liability for any errors in these operating
instructions or possible consequences. Neither can any liability be accepted for direct or
indirect damage resulting from abuse of the device.
The relevant regulations concerning safety technology and electromagnetic compatibility
must be complied with when using the device.
Subject to alteration.

Operating Instructions 221052E, V 1.3b 3
GEORGIIKOBOLD,D-70771Leinfelden-Echterdingen,phone[phone],fax[phone]
Contents
Chapter 1: General information
1 Preliminary remarks ................................................ 9
1.1 About this description ........................................... 9
1.2 KSV 6HE Servo Drive Packages .................................. 9
2 Safety instructions ................................................ 11
2.1 Typeofinstruction ............................................ 11
2.2 Technicalstaff ............................................... 11
2.3 Use for the intended purpose .................................... 12
2.4 Protectiveearthing ......................................... 12
2.5 Hazardwarnings.............................................. 13
2.6 CEmarking.................................................. 13
2.7 Preconditions for commissioning ................................. 14
2.8 Working with the amplifier or the power supply ...................... 14
Chapter 2: Servo amplifier
3 Technical specifications ........................................... 15
3.1 Typecode................................................... 15
3.2 Technicalspecifications ........................................ 16
3.3 Details...................................................... 17
3.3.1 Design ............................................. 17
3.3.2 Chassis............................................. 17
4 Connection: Assignment of connectors and details ..................... 20
4.1 Connector assignments ........................................ 20
4.1.1 Motor and power supply (Combicon connector X1) ........... 20
4.1.2 Control signals “Steuersignale” (SUB-D fem. connector X2, 15-pin)
.................................................... 20
4.1.2.1 Version without add-on module ................. 20
4.1.2.2 Version with Z1 add-on module ................. 21
4.1.2.3 Version with Z2 add-on module ................. 21
4.1.2.4 Version with Z4 add-on module ................. 22
4.1.3 Position sensor “Lagegeber” (SUB-D female connector X3, 9-pin) 22
4.1.4 Encoder signals “Gebersignale” (SUB-D male connector X4, 9-pin)
.................................................... 23
4.2 Details about the signals ....................................... 23

4 Operating Instructions 221052E, V 1.3b
GEORGIIKOBOLD,D-70771Leinfelden-Echterdingen,phone[phone],fax[phone]
4.2.1 Auxiliary voltage outputs ................................ 23
4.2.2 Setpointthroughdifferentialamplifier...................... 23
4.2.3 Switching inputs and switching outputs .................... 24
4.2.3.1 Properties of the switching inputs and outputs ...... 24
4.2.3.2 Switching input “Controller enable” ............... 25
4.2.3.3 Switching input “Reset fault” .................... 25
4.2.3.4 Switching output “Fault” or “Ready” .............. 26
4.2.3.5 Switching output “Overload” .................... 26
4.2.3.6 Switching output “Motor standstill” or “Power circuit ready”
........................................... 27
4.2.4 Analogoutputs ....................................... 28
4.2.5 Encoder signals, holding function ......................... 28
4.2.6 Positionsensor....................................... 28
4.2.7 Motortemperaturesensor .............................. 29
4.2.8 Sensorfaultdetection.................................. 29
4.2.9 Blockprotection ...................................... 29
4.2.10 Faultmemory ........................................ 30
4.3 Interfacedetails .............................................. 32
4.3.1 Connector X2, control signals, switching towards zero ......... 32
4.3.2 Connector X2, control signals, PLC-compatible .............. 33
4.3.3 Connector X4, encoder signals, 5-volt version ............... 34
4.3.4 Connector X4, encoder signals, 24-volt version .............. 35
4.4 Connection directions .......................................... 36
4.4.1 Installation on the mounting plate ......................... 36
4.4.2 Installationina19"racksystem.......................... 39
4.4.3 Potential equilization cables ............................. 39
4.4.4 Mains connection ..................................... 40
4.4.4.1 Connection mains – mains transformer ........... 40
4.4.4.2 Connections mains transformer – RFI-filter– power supply
........................................... 41
4.4.4.3 Connection power supply – servo amplifier ........ 41
4.4.5 Motor connection, general information ..................... 42
4.4.6 Motorchoke ......................................... 43
4.4.7 Shield connection of the external shunt resistor cable ......... 43
4.4.8 Connection, shielding and laying of the control leads .......... 43
4.4.9 Setpoint connection ................................... 44
4.4.10 Connection of the encoder signals ........................ 44
4.4.11 Connecting the position sensor (resolver) .................. 45
4.4.12 Connection of the motor temperature sensor ................ 46

Operating Instructions 221052E, V 1.3b 5
GEORGIIKOBOLD,D-70771Leinfelden-Echterdingen,phone[phone],fax[phone]
5 Adjustment and display elements .................................... 47
5.1 Trimpotentiometers ........................................... 47
5.2 Current limiting and “Current” rotary switch ......................... 47
5.3 LEDs....................................................... 49
6 Modular fittings and expansions ..................................... 50
6.1 Customer module Kx .......................................... 50
6.2 Add-on modules Zx ........................................... 50
6.2.1 Add-on module Z1 .................................... 51
6.2.2 Add-on module Z2 .................................... 52
6.2.3 Add-on module Z4 .................................... 53
6.2.4 Further add-on modules ................................ 55
6.3 Polarity module Px ............................................ 55
6.4 Encoder modules G1 to G4 ..................................... 55
6.4.1 Pulsesetting......................................... 56
6.4.2 Index pulse adjustment ................................. 56
6.5 Function module Fx ........................................... 57
6.5.1 HoldfunctionF1 ...................................... 57
6.5.2 Field weakening mode F2 ............................... 58
6.6 Option E1 external supply of control circuit ......................... 59
7 Shutting down the motor and safety shutdown ......................... 60
7.1 Shuttingdownoptions ......................................... 60
7.2 Estimatingthebrakingdistance .................................. 61
7.3 Emergency stop and safety regulations ............................ 61
8 Commissioning ................................................... 63
8.1 Precautions.................................................. 63
8.2 Switchingonforthefirsttime .................................... 63
8.3 Setting the speed ............................................. 64
8.4 Setting the feedback: normal case ................................ 64
8.5 Setting the feedback: critical applications ........................... 65
8.6 Setting the feedback with Z4 add-on module ........................ 65
8.7 Settingthecurrentlimit......................................... 66
8.8 Settingtheoffset.............................................. 66
8.9 Setting the holding control loop amplification ........................ 67
Chapter 3: Power supply and accessories
9 Power supply of the servo amplifiers ................................. 68
9.1 Load factor .................................................. 68

6 Operating Instructions 221052E, V 1.3b
GEORGIIKOBOLD,D-70771Leinfelden-Echterdingen,phone[phone],fax[phone]
9.2 Power supply ................................................ 68
9.2.1 Design ............................................. 68
9.2.2 Shunt regulator ....................................... 69
9.2.3 Connection assignment (terminal blocks X5 and X6) .......... 69
9.2.4 LEDs............................................... 71
9.2.5 Technical specifications of the power supply ................ 71
9.2.6 External shunt resistor ................................. 71
9.3 Mainstransformers............................................ 72
9.3.1 General information ................................... 72
9.3.2 Connections ......................................... 73
9.3.3 Technicalspecificationsofthemainstransformers ........... 73
10 Accessories ..................................................... 75
10.1 Available accessories and order numbers .......................... 75
10.2 Descriptionofaccessories ...................................... 75
10.2.1 Chassis............................................. 75
10.2.2 Connector sets 099066020Z and 099066010Z .............. 76
10.2.3 Motor connection cables 535246...Z and 535264...Z .......... 76
10.2.4 Resolver/Encoder connection cable 535245...Z .............. 77
10.2.5 Ferrite ring 042103010 ................................. 78
10.2.6 Motor chokes 038096010Z and 038097010Z ................ 78
10.2.7 RFI-filters 002057020Z and 002057040Z ................... 80
10.2.8 Shield connection plate 089159 .......................... 80
Chapter 4: Notes for specialists
11 Modifications to the servo amplifier .................................. 81
11.1 Modifyingthecontrollercircuitry.................................. 81
11.1.1 Speed control range ................................... 81
11.1.2 Numberofmotorpolepairs ............................. 82
11.1.3 Current control instead of speed control .................... 83
11.1.4 Changing the direction of rotation ......................... 84
11.2 Modifications to the feedback .................................... 85
11.2.1 Resettime .......................................... 85
11.2.2 Dcircuit............................................. 85
11.3 Modifications to the Z1, Z2, and Z4 add-on modules .................. 85
11.3.1 Locationofthesolderbridges ........................... 85
11.3.2 Former versions of modules Z1 and Z2 .................... 87
11.3.3 “Power circuit ready” signal instead of “Motor standstill” signal . . 87
11.3.4 Switching off the peak current rise ........................ 88
11.3.5 Switchingoffactivebrakingatcontrollerdisable ............. 88

Operating Instructions 221052E, V 1.3b 7
GEORGIIKOBOLD,D-70771Leinfelden-Echterdingen,phone[phone],fax[phone]
11.3.6 Activatingtherampfunction ............................. 88
11.3.7 Adjusting and limiting the I component of the speed controller . . 88
11.4 Modifications to the polarity module ............................... 89
11.4.1 “Ready” signal instead of “Fault” signal .................... 89
12 Documentation of the settings ...................................... 90
Appendix
Appendix A EC Declaration of Conformity ............................... 91
Appendix B Terms of warranty ........................................ 92
Appendix C Table of faults ........................................... 92

8 Operating Instructions 221052E, V 1.3b
GEORGIIKOBOLD,D-70771Leinfelden-Echterdingen,phone[phone],fax[phone]
Figures
Fig. 1: Rack mount chassis 84 units wide ................................... 19
Fig.2:Controlsignals,switchingtowardszero(interfacedetails) ................ 32
Fig.3:Controlsignals,PLC-compatible(interfacedetails)...................... 33
Fig. 4: Encoder signals, 5-volt version (interface details) ....................... 34
Fig. 5: Encoder signals, 24-volt version (interface details) ...................... 35
Fig. 6: Connection directions ............................................ 37
Fig. 7: Laying of the motor cables and earthing of their shields .................. 38
Fig. 8: Setpoint potentiometer connection for commissioning ................... 64
Fig.9:Motorchokes................................................... 79
Fig.10:RFI-filter...................................................... 80
Fig. 11: Location of the jumpers on the board ............................... 83
Fig. 12: Location of the jumpers on the customer module ...................... 84
Fig. 13: Solder bridges on the Z1 module ................................... 86
Fig. 14: Solder bridges on the Z2 module ................................... 86
Fig. 15: Solder bridges on the Z4 module ................................... 87
Fig. 16: Solder bridges on the P1 and P2 modules ........................... 89

Operating Instructions 221052E, V 1.3b 9
GEORGIIKOBOLD,D-70771Leinfelden-Echterdingen,phone[phone],fax[phone]
Chapter 1: General information
1 Preliminary remarks
1.1 About this description
These operating instructions explain the characteristics, connection,
installation and setting up of
Cthe KSV 6HE servo amplifiers, designed as 19" plug-in modules
(6 units height),
Cthe associated power supplies, 19" plug-in module design (6 units
height), for the connection to 3 × 230 V three-phase current,
Cthemainstransformersfortheconnectionto3×400V three-phase
current and the RFI-filter,
Caccessories,
Cand provides notes for specialists.
The operation instructions are divided up into 4 chapters and 12
sections.After the safetyinstructionsandthetechnicalspecifications,
the connection of the servo amplifier is described. In some cases you
will require details which are not explained more fully until later. It is
therefore important that you should read the sections important for
your application in a sequence commensurate with your previous
knowledge.
The chapter “Notes for the specialist” describes changes which can
be carried out on site by specially qualified electronicsexperts attheir
own risk, providing that all precautions have been taken.
1.2 KSV 6HE Servo Drive Packages
KSV 6HE servo drive packages in 19" design consist of:
Cthe brushless motor with coupled resolver as a speed and position
sensor,
Cthe analog servo amplifier as 19" plug-in module (6 units height),
Cthe 19" plug-in module power supply (6 units height) with mains
transformer connected in series.
The series described here comprises
Camplifiers for 5 different currents (1.5 Arms to 12 Arms),
Camplifiers with different specifications (optional),

10 Operating Instructions 221052E, V 1.3b
GEORGIIKOBOLD,D-70771Leinfelden-Echterdingen,phone[phone],fax[phone]
Cpower supplies for 19" rack system (“plug-in power supplies”),
Cmains transformers for the plug-in power supplies,
CRFI-filters,
C19" chassis.
We construct the multi-axis servo amplifier matched to your applica-
tion using chassis. Use these operating instructions for connecting
and commissioning.
We evaluate the servo drive matched to your application and
Cdeliver the matching servo motor.
– They have separate operatinginstructions and terminal connec-
tion diagrams.
As well as the series in 19" plug-in module design, there is also a
series in compact design for installation on the mounting plate of a
control cabinet (KSV 1,5/5 compact design to KSV 12/30 compact
design amplifiers) with separate operating instructions.