Jetter JetMove 225-480 User manual

JetMove 225-480
Digital Servo Amplifier
60874967

Introduction JetWeb
2Jetter AG
Item # 60874967
Revision 2.01
October 2012 / Printed in Germany
Jetter AG reserves the right to make alterations to its products in the interest of
technical progress. These alterations will not necessarily be documented in every
single case.
This manual and the information contained herein have been compiled with due
diligence. Jetter AG shall not be liable for printing or general errors contained herein
or for damages arising from such errors.
The brand names and product names used in this manual are trade marks or
registered trade marks of the respective title owner.

JetMove 225-480 Introduction
Jetter AG 3
How to Contact us:
Jetter AG
Gräterstrasse 2
D-71642 Ludwigsburg
Germany
Phone - Switchboard: ++49 7141/2550-0
Phone - Sales: ++49 7141/2550-433
Phone - Technical Hotline: ++49 7141/2550-444
Fax: ++49 7141/2550-484
E-Mail - Sales: [email protected]
E-Mail - Technical Hotline: [email protected]
Internet Address: http://www.jetter.de
This User Manual is an Integral Part of
the JetMove 225-480:
To be entered by the customer:
Model:
Serial No.:
Year of Manufacture:
Order No:
Inventory No:
Place of Operation:

Introduction JetWeb
4Jetter AG
Significance of this User Manual
This user manual is an integral part of the digital servo amplifier JetMove 225-480.
• Therefore it must be kept in a way that it is always at hand until the digital servo
amplifier JetMove 225-480 will be disposed of.
• Pass this manual on if the JetMove 225-480 is sold or loaned/leased out.
In any case you encounter difficulties to clearly understand this user manual, please
contact the manufacturer.
We would appreciate any suggestions and contributions on your part and would ask
you to contact us. This will help us to produce manuals that are more user-friendly
and to address your wishes and requirements.
From the servo amplifier JetMove 225-480 module may result unavoidable residual
risks to persons and property. For this reason, any person who has to deal with the
transport, installation, operation, maintenance, and repair of the digital servo
amplifier JetMove 225-480 must have been familiarised with it and must be aware of
these dangers.
Therefore, this person must carefully read, understand and observe this manual, and
especially the safety instructions.
Missing or inadequate knowledge of the manual results in the loss of any claim of
liability on part of Jetter AG. Therefore, the operating company is recommended to
have the instruction of the persons concerned confirmed in writing.
History
Revision Meaning
1.00 Original issue of the user manual
1.01 New photo on the title page
2.00 Modifications, see Appendix A of user manual rev. 2.00
2.01 Style and spelling have been revised

JetMove 225-480 Introduction
Jetter AG 5
Description of Symbols
Danger
This sign is to indicate a possible impending danger of serious physical damage
or death.
Attention
This sign is to indicate a possible impending danger of light physical damage.
This sign is also to warn you of material damage.
This sign indicates hazard of life due to electric shock caused by a high operating
voltage.
This sign is to indicate hazard of serious physical damage or death due to
accidentally touching dangerous parts of the device.
You have to wear goggles. Failure to comply may lead to bodily injuries.
This sign is to warn you of material damage due to applying hard blows or shocks
to the motor flange and shaft.
Important!
This sign is to indicate a possible impending situation which might bring damage
to the product or to its surroundings.
It also identifies requirements necessary to ensure faultless operation.

Introduction JetWeb
6Jetter AG
Note!
You will be informed of various possible applications and will receive further
useful suggestions.
It also gives you words of advice on how to efficiently use hardware and software
in order to avoid unnecessary efforts.
· / - Enumerations are marked by full stops, strokes or scores.
Operating instructions are marked by this arrow.
Automatically running processes or results to be achieved are marked by this
arrow.
Illustration of PC and user interface keys.
This symbol informs you of additional references (data sheets, literature, etc.)
associated with the given subject, product, etc. It also helps you to find your way
around this manual.

JetMove 225-480 Table of Contents
Jetter AG 7
Table of Contents
1 Safety Instructions 11
1.1 General Information 11
1.1.1 Intended conditions of use 11
1.1.2 Usage other than intended 11
1.1.3 Qualified staff 12
1.1.4 Modifications and alterations to the module 12
1.1.5 Repairing and servicing the servo amplifier JetMove 225-480 13
1.1.6 Decommissioning and disposal of the JetMove 225-480 14
1.2 Ensure Your Own Safety 15
1.2.1 Malfunctions 15
1.2.2 Information signs and labels 15
1.2.3 Earthing procedure 16
1.3 Residual Dangers 18
1.3.1 Hazards during operation 18
1.3.2 Hazards after POWER has been turned OFF 20
1.4 Instructions on EMI 21
2 Installing the JetMove 225-480 25
2.1 Scope of Delivery 25
2.2 Mechanical Installation 26
2.3 Electrical Installation 28
2.4 Checking the Installation 29
2.5 Notes on Safety as regards the Installation 29
2.6 Safety Instructions for Commissioning 30
3 Operating Conditions 31
4 Mounting Dimensions 35
5 Technical Data 37
5.1 Electrical Specifications 37
5.2 Motor Protection 41
5.2.1 Built-in thermal sensor 41
5.2.2 I²t calculation 41
5.2.3 Motor overload protection according to UL 43
6 Drive Controller Structure 45
7 Description of Connections 47
7.1 Connection of the Power Supply 47
7.2 Motor Connection 48

Table of Contents JetWeb
8Jetter AG
7.2.1 General information 48
7.2.2 Specifications 49
7.2.3 Motor power cable with mating connector SC 50
7.2.4 Motor power cable with mating connector SM 53
7.2.5 Connection assignment of terminal box 56
7.3 Resolver Connection 57
7.3.1 Specifications 57
7.3.2 Resolver cable with mating connector 57
7.4 HIPERFACE Connection 59
7.4.1 Specifications 59
7.4.2 HIPERFACE cable with mating connector 59
7.5 Sin-Cos Encoder Connection 62
7.5.1 Adapter 62
7.5.2 Specifications 62
7.5.3 Connection diagram 63
7.6 External Ballast Resistor and DC Link Connection 66
7.7 Digital Inputs, Logic Power Supply 71
7.8 Connection Details for Digital Outputs 73
7.9 Jetter System Bus 74
7.9.1 Specifications of the Jetter system bus cable 74
8 Status Monitoring 77
9 Diagnostics 79
9.1 Error Messages 79
9.2 Alarms 83
10 Connection Diagrams 85
11 Analog Input (Option) 89
11.1 Function 89
11.2 Technical Data 89
11.3 Description of Connections 90
12 Ethernet Interface (Option) 91
12.1 Function 91
12.2 Description of Connections 91
12.3 Logic Circuit LEDs, Switches 93
12.3.1 LEDs 93
12.3.2 The DIP switches 94
12.4 Setting the IP Address 94
12.4.1 Default IP address 94

JetMove 225-480 Table of Contents
Jetter AG 9
12.4.2 IP address out of the configuration memory 95
12.4.3 IP address taken from the switch position 96
13 Safe Standstill (Option) 97
13.1 Introduction 97
13.2 Motion System JM-225-480-S1 98
13.3 Safety Instructions 99
13.4 Performance Test 99
13.5 Demands on the Safety System 99
13.5.1 Control variants for "Safe Standstill" 101
13.5.2 Application 1 102
13.5.3 Application 2 102
13.5.4 Application 3 103
13.5.5 Application 4 104
13.6 Block Diagram of the JM-225-480 with the "Safe Standstill"
Function 105
14 Counting Input (Option) 107
14.1 Function 107
14.2 EnDat 2.2 107
14.2.1 Technical data 107
14.2.2 Description of connections 108
14.2.3 EnDat cable with mating connector 108
14.2.4 Power Supply of the Encoder 110
14.3 Synchronous Serial Interface (SSI) 111
14.3.1 Technical data 111
14.3.2 Description of connections 111
14.3.3 SSI cable 112
14.4 Incremental Encoder 113
14.4.1 Technical data 113
14.4.2 Description of connections 113
14.4.3 Incremental encoder cable 114
15 Ordering Information 115
15.1 List of Documentation 115
15.2 Options 115
Appendix
Appendix A: Recent Revisions 119
Appendix B: Glossary 120
Appendix C: List of Abbreviations 122

Table of Contents JetWeb
10 Jetter AG
Appendix D: Index of Illustrations 123
Appendix E: Index 124

JetMove 225-480 1.1 General Information
Jetter AG 11
TableofContents 1 Safety Instructions
1.1 General Information
The digital servo amplifier JetMove 225-480 fulfils the accepted safety regulations
and standards. Special emphasis was given to the safety of the users.
The following additional regulations apply to the user:
• pertinent accident prevention regulations;
• accepted safety rules;
• EC guidelines and other country-specific regulations.
1.1.1 Intended conditions of use
Usage as intended includes operation in accordance with the operating instructions.
The digital servo amplifier JetMove 225-480 may only be operated in the closed
control cabinet and within the range of the set values.
Do not apply a voltage to the digital servo amplifier JetMove 225-480 that is
higher than the prescribed operating voltage.
Each of the three phases of the digital servo amplifier JetMove 225-480 has got an
operating voltage ranging between AC 340 V and AC 530 V. Thus, the digital servo
amplifier JetMove 225-480 comes under the EG Low Voltage Directive.
It is the explicitpurpose of the digital servo controller JetMove 225-480 to
torque-, speed- and/or position-control, and to drive brushless synchronous
servo motors. The rated voltage of the motors must be higher than, or at least
equal to, the DC link voltage supplied by the servo amplifier.
The digital servo amplifier JetMove 225-480 is used to control machinery, such as
conveyors, production machines, and handling machines.
1.1.2 Usage other than intended
The digital servo amplifier JetMove 225-480 must not be used in technical
systems which to a high degree have to be fail-save, e. g. ropeways and
aeroplanes.
Do not apply the integrated brake control in safety-relevant systems.
If the digital servo amplifier JetMove 225-480 is to be run under operating conditions,
which differ from the conditions mentioned in
chapter 3 "Operating Conditions", page 31, the manufacturer is to be contacted
beforehand.

1 Safety Instructions JetWeb
12 Jetter AG
1.1.3 Qualified staff
Depending on individual phases of the product life cycle, there are different demands
on the personnel being involved. These demands have to be met, in order to grant
safety in handling the JetMove 225-480 at each phase of the product life cycle.
1.1.4 Modifications and alterations to the
module
Due to safety reasons, no modifications and alterations to the digital servo
amplifier JetMove 225-480 and its functions are allowed.
Any modifications to the servo amplifier JetMove 225-480 not expressly authorised
by the manufacturer will result in a loss of any liability claims to Jetter AG.
The original parts are specifically designed for the servo amplifier
JetMove 225-480. Parts and equipment from other manufacturers are not
tested on our part, and are, therefore, not released by us.
The installation of such parts may impair the safety and the proper functioning of the
digital servo amplifier JetMove 225-480.
Any liability on the part of Jetter AG for any damages resulting from the use of non
original parts and equipment is excluded.
Phase of the Product Life Cycle
Transport / Storage: Only properly trained and instructed
personnel with knowledge of correctly
handling electrostatically sensitive
components
Mounting / Installation: Trained personnel specified in electrical
engineering, such as industrial electronics
engineers
Commissioning / Programming: Trained and instructed specialist
personnel having got broad knowledge
and experience in electrical engineering /
motion systems, such as industrial
electronics engineers of automation
engineering
Operation: Only trained, instructed and authorized
personnel with knowledge of correctly
handling electrostatically sensitive devices
Decommissioning Trained personnel specified in electrical
automotive engineering, such as industrial
electronics engineers

JetMove 225-480 1.1 General Information
Jetter AG 13
1.1.5 Repairing and servicing the servo
amplifier JetMove 225-480
Repairs at the digital servo amplifier JetMove 225-480 must not be carried out by the
operator. The digital servo amplifier JetMove 225-480 does not contain any parts to
be repaired by the operator.
For being repaired, the servo amplifier JetMove 225 -480 must be sent to Jetter AG.
The digital servo amplifier JetMove 225-480 is maintenance-free. Therefore,
absolutely no inspection or maintenance works are required for the operation of this
device.

1 Safety Instructions JetWeb
14 Jetter AG
1.1.6 Decommissioning and disposal of the
JetMove 225-480
The environmental regulations for the respective country apply to decommissioning
and disposing of the digital servo amplifier JetMove 225-480 amplifier on the
operating company’s premises.
You can disassemble the digital servo amplifier JetMove 225-480 into its main
components by unscrewing it (aluminium heat sink and side plate, steel casing cover,
electronic boards).

JetMove 225-480 1.2 Ensure Your Own Safety
Jetter AG 15
1.2 Ensure Your Own Safety
1.2.1 Malfunctions
1.2.2 Information signs and labels
Danger
Isolate the digital servo amplifier JetMove 225-480 from the mains, if
maintenance works have to be carried out. By doing so, you will prevent
accidents resulting from electric voltage and moving parts.
Please note chapter 1.3 "Residual Dangers", page 18.
Safety and protective devices, e.g. the barrier and cover of the terminal
box must never be shunted or by-passed.
Dismantled protective equipment, such as the fuses and the thermal motor
circuit-breakers, must be reattached prior to commissioning and checked
for proper functioning.
Before commissioning, the machine manufacturer must carry out a danger
analysis of the respective machine and take adequate measures so that
inadvertent motions will not lead to personal injury and to material
damage.
In the case of malfunctions or other faults, please immediately
separate the digital servo amplifier JetMove 225-480 from the mains.
Please note chapter 1.3 "Residual Dangers", page 18.
Malfunctions or other damages have to be reported to a responsible
person at once.
Secure the digital servo amplifier JetMove 225-480 against misuse or
accidental use.
Markings, information signs, and labels always have to be observed by all
means and kept readable.
Damaged or unreadable information signs and labels have to be replaced.

1 Safety Instructions JetWeb
16 Jetter AG
1.2.3 Earthing procedure
Fig. 1: Double earthing
Screw the enclosure of the digital servo amplifier JetMove 225-480 onto a
highly conducting, earthed panel.
Do only use the digital servo amplifier JetMove 225-480 at the three-
phase, earthed industrial network (TN network, TT network with earthed
neutral, 5,000 A max, symmetric rated current at 400 / 480 V + 10 %).
The digital servo amplifier must not be operated when connected to
unearthed networks and to unsymmetrically earthed networks.
The digital servo amplifier JetMove 225-480 has got a leakage current
greater than 3.5 mA. In order to avoid electric shocks, a second
protective earth conductor is required.
For this, the following measures have to be taken:
• The protective earth bus has to be connected to the PE (GND) bolt (1)
located at the top side of the rack as well as to the PE (GND) terminal
X1 (2) (please refer to Fig. 1).
The diameter of the two earthing conductors has to be equal to the
diameter of the supply lines (min. 2.5 mm²/ AWG 14).
• A durable connection with the power supply of the digital servo amplifier
JetMove 225-480 must be provided.
• Correct cabling of the PE (GND) bus according to the connection
diagram (cf. chapter 10 "Connection Diagrams", page 85) has to be
carried out.

JetMove 225-480 1.2 Ensure Your Own Safety
Jetter AG 17
Important!
Do not install an earth-leakage current breaker in the mains power
supply.
Do not install an earth-leakage current breaker in the supply line.
If, in spite of this, an earth-leakage current breaker is installed, it will switch off
the digital servo amplifier JetMove 225-480, although there is no fault.
When an earth-leakage current breaker needs to be installed in the
JetMove 225-480, an isolating transformer must be used.

1 Safety Instructions JetWeb
18 Jetter AG
1.3 Residual Dangers
1.3.1 Hazards during operation
Danger
HAZARD caused by high operating voltage!
Extremely hazardous voltages of up to 850 V may occur!
These voltages lead to muscle cramps, burns, unconsciousness, respiratory
standstill, and death.
During operation, all coverings and control cabinet doors have to be kept
closed.
Do not open the device.
Do by no means disconnect the electric connections of the digital servo
amplifier JetMove 225-480 when it is live.
Danger
Do not touch the terminals X1, X62, and X63 while the servo amplifier
is running.
In the given context, the terminals have the following meaning:
X1: AC 400/480 V voltage supply
X62: DC motor voltage up to 850 V
X63: DC link voltage up to 850 V
Danger
CAUTION! Hot surfaces!
During operation, the surfaces, respectively the heat sinks of the digital servo
amplifier JetMove 225-480 can heat up. The internal heat sink can reach
temperatures of up to 85 °C.
Do by no means touch the enclosure of the digital servo amplifier
JetMove 225-480 near the internal heat sink during operation and
during the cooling-off period after switching off the device.
Ensure that no temperature sensitive parts are attached to the digital servo
amplifier JetMove 225-480.

JetMove 225-480 1.3 Residual Dangers
Jetter AG 19
Danger
DANGER in a potentially explosive atmosphere!
Do not operate the digital servo amplifier JetMove 225-480 in a
potentially explosive atmosphere.
Caution
DANGER of injuries caused by mechanic force!
The digital servo amplifier JetMove 225-480 runs a servo motor. This servo
motor moves mechanic parts or sharp edges. Therefore, failure or malfunctioning
of the digital servo amplifier JetMove 225-480 can be dangerous for man or
damage the manufacturing plant to an amount depending on the respective kind
of plant. This should be prevented by installing additional safety devices.
• One safety precaution is to install a second set of limit switches to interrupt the
power supply of the motor.
• Another safety precaution would be installing a guard.
Make sure that hazards to persons are precluded even when the drive is
moving unintentionally.
Danger
Do not dismount any necessary protective covers.
Do not wear gloves, lest they should get caught in the rotating shaft.
Never touch a rotating drive shaft.

1 Safety Instructions JetWeb
20 Jetter AG
1.3.2 Hazards after POWER has been turned
OFF
Danger
DANGER resulting from electric shock!
Up to 7 minutes after switching off the operating voltages, capacitors still carry
hazardous residual voltages.
As a precaution, measure the voltage in the DC link circuit (amplifier
terminal) and wait until it has fallen below DC 40 V.
Always wait at least 7 minutes after switching off the device, before
separating it from the mains or loosening the connections.
Always wait at least 10 minutes after switching off the device before taking
the following actions:
– Touching the screws of the terminals X1, X62 and X63;
– Disconnecting the terminals and touching the contacts.