Jetter JetWeb JetMove 203-230 User manual

Article # 60865160 / Edition 1.10 November 2006 / Printed in Germany
JetWeb
JetMove 203-230
Drive
User Manual

Introduction JetWeb
2 Jetter AG
Edition 1.10
Jetter AG reserves the right to make alterations to its products in the interest of
technical progress. These alterations need not 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 errors contained herein or for incidental or
consequential damage in connection with the furnishing, performance, or use of this
material.
The brand names and product names used in this manual are trade marks or
registered trade marks of the respective title owner.

JetMove 203-230 Introduction
Jetter AG 3
How to Contact Us
Jetter AG
Gräterstraße 2
D-71642 Ludwigsburg
Germany
Switchboard: 07141/2550-0
Sales: 07141/2550-433
Phone - Technical Hotline: [phone]
Fax - Sales: (+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 203-230:
To be entered by the customer:
© Copyright 2006 by Jetter AG. All rights reserved.
Type:
Serial No.:
Year of Manufacture:
Order No:
Inventory No:
Place of operation:

Introduction JetWeb
4 Jetter AG
Significance of this Operator's Manual
This operator's manual is an integral part of the digital servo amplifier
JetMove 203-230 and
• must be kept in a way that it is always at hand until the the digital servo amplifier
JetMove 203-230 will be disposed of.
• Pass this manual on if the digital servo amplifier JetMove 203-230 is sold or
loaned/leased out.
In any case you encounter difficulties to clearly understand the manual, please
contact the manufacturer.
We would appreciate any kind of suggestion and contributions on your part and
would ask you to inform us or to write us. This will help us to produce manuals that
are more user-friendly and to address your wishes and requirements.
This manual contains important information on how to transport, erect, install,
operate, maintain and repair the digital servo amplifier JetMove 203-230.
Therefore, the persons carrying out these jobs 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
Edition Comment
1.00 First edition
1.10 Revisions, see Appendix A: "Recent Revisions", page 81 of
edition 1.10

JetMove 203-230 Introduction
Jetter AG 5
Description of Symbols
Warning
This sign is to indicate a possible impending danger of serious physical damage
or death.
Caution
This sign is to indicate a possible impending danger of light injury. 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.
Important
This sign is to indicate a possible impending situation which might bring damage
to the product or to its surroundings.
This symbol also points to conditions, which must by all means be given heed to,
in order to guarantee faultless functioning.
Note
You will be informed of various possible applications and will receive further
useful suggestions.
Further, it points to tipps and advice for efficient use of the device and for
optimization of the corresponding software, in order to save you extra work.
· / - 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.

Introduction JetWeb
6 Jetter AG
PC and user interface keys.
This symbol refers to further information (data sheets, literature, etc.) on the
subject or product or the like that is being dealt with. Further, this text provides
helpful hints for your guidance through the manual.

JetMove 203-230 Table of Contents
Jetter AG 7
Table of Contents
1 Safety Instructions 9
1.1 General Information 9
1.1.1 Usage as agreed upon 9
1.1.2 Usage other than agreed upon 9
1.1.3 Who may operate the servo amplifier JetMove 203-230? 10
1.1.4 Modifications and alterations to the module 10
1.1.5 Repairs and servicing of the JetMove 203-230 10
1.1.6 Decommissioning and disposing of the JetMove 203-230 11
1.2 Ensure your Own Safety 12
1.2.1 Malfunctions 12
1.2.2 Information signs and labels 12
1.2.3 Earthing procedure 13
1.3 Residual Dangers 15
1.3.1 Hazards during operation 15
1.3.2 Hazards after POWER is turned OFF 17
1.4 Instructions on EMI 18
2 Installing the JetMove 203-230 21
2.1 Scope of Delivery 21
2.2 Mechanical Installation 22
2.3 Electrical Installation 24
2.4 Checking the Installation 25
2.5 Notes on Safety as regards the Installation 25
2.6 Safety Instructions for Commissioning 26
3 Operating Conditions 27
4 Physical Dimensions 33
5 Technical Data 35
5.1 Electrical Specification 35
5.2 Motor Protection 39
5.2.1 Thermal sensor integrated in the motor 39
5.2.2 I²t calculation 39
5.2.3 Motor overload calculation according to UL 41
6 Drive Controller Structure 43
7 Description of Connections 45
7.1 Power Supply 45
7.2 Motor Connection 47

Inhalt JetWeb
8 Jetter AG
7.2.1 General remarks 47
7.2.2 Assignment and specification 48
7.2.3 Motor power cable with mating connector SC 49
7.2.4 Connection assignment of terminal box 52
7.3 Connection of the Resolver 52
7.3.1 Specification 52
7.3.2 Resolver cable with mating connector 53
7.4 HIPERFACE Connection 55
7.4.1 Specification 55
7.4.2 HIPERFACE cable with mating connector 55
7.5 Digital Inputs, Logic Power Supply 58
7.6 Jetter System Bus 60
7.6.1 Specification of the Jetter system bus cable 60
8 Status Monitoring 63
9Diagnostics 65
9.1 Error Messages 65
9.2 WARNINGS 69
10 Wiring Diagrams 71
11 Analog Input (Option) 77
11.1 Function 77
11.2 Technical Data 77
11.3 Description of Connections 78
List of Appendices
Appendix A: Recent Revisions 81
Appendix B: Glossary 83
Appendix C: List of Illustrations 86
Appendix D: Index 87

JetMove 203-230 1.1 General Information
Jetter AG 9
Table of Contents 1Safety Instructions
1.1 General Information
The digital servo amplifier JetMove 203-230 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:
•relevant accident prevention regulations;
• accepted safety rules;
• EC guidelines and other country-specific regulations.
1.1.1 Usage as agreed upon
Usage as agreed upon includes operation in accordance with these operating
instructions.
The digital servo amplifier JetMove 203-230 may only be operated in the closed
control cabinet and within the range of the set values, see chapter 5 "Technical
Data", page 35.
Do not apply a voltage to the digital servo amplifier JetMove 203-230 that is
higher than the prescribed operating voltage.
The operating voltage of the digital servo amplifier JetMove 203-230 ranges between
AC 195 V and AC 265 V. Thus, the digital servo amplifier comes under the EC Low
Voltage Directive.
It is the explicitpurpose of the servo controller JetMove 203-230 to torque-,
speed- and/or position-control, and to drive brushless synchronous servo
motors. The winding isolation 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 203-230 is used to control machinery, such as
conveyors, production machines, and handling machines.
1.1.2 Usage other than agreed upon
The digital servo amplifier must not be used in technical systems which to a
high degree have to be fail-safe, e.g. ropeways and aeroplanes.
If the digital servo amplifier JetMove 203-230 is to be run under operating conditions,
which differ from the conditions mentioned in chapter 3 "Operating Conditions", page
27, the manufacturer is to be contacted beforehand.

1 Safety Instructions JetWeb
10 Jetter AG
1.1.3 Who may operate the servo amplifier
JetMove 203-230?
Only instructed, trained and authorised persons are permitted to operate the servo
amplifier JetMove 203-230.
1.1.4 Modifications and alterations to the
module
Due to safety reasons, no modifications and alterations to the digital servo
amplifier JetMove 203-230 and its functions are allowed.
Any modifications to the servo amplifier JetMove 203-230 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
203-230. Parts and equipment of 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 203-230.
From any damages resulting from usage other than agreed upon, e.g. the use of non-
original parts and equipment, any claims with respect to the liability of Jetter AG are
excluded.
1.1.5 Repairs and servicing of the JetMove
203-230
Repairs at the digital servo amplifier JetMove 203-230 must not be carried out by the
operator. The servo amplifier JetMove 203-230 does not contain any parts to be
repaired by the operator.
For being repaired, the servo amplifier JetMove 203 -230 must be sent to Jetter AG.
The digital servo amplifier JetMove 203-230 is maintenance-free. Therefore, no
inspection or maintenance is required for the operation of the module.
Transport: Only by personnel with knowledge in handling
electrostatically sensitive components.
Installation: Only by specialists with training in electrical
engineering.
Commissioning: Only by specialists with extensive knowledge of and
experience with electrical engineering / drive
technology.

JetMove 203-230 1.1 General Information
Jetter AG 11
1.1.6 Decommissioning and disposing of the
JetMove 203-230
The environmental regulations for the respective country apply to decommissioning
and disposing of the digital servo amplifier on the operating company’s premises.
You can disassemble the servo amplifier JetMove 203-230 into its main components
by unscrewing it (aluminium heat sink and side plate, steel casing cover, electronic
boards).

1 Safety Instructions JetWeb
12 Jetter AG
1.2 Ensure your Own Safety
1.2.1 Malfunctions
1.2.2 Information signs and labels
Warning
Isolate the digital servo amplifier JetMove 203-230 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 15.
Safety and protective devices, e.g. the barrier and cover of the terminal
box or the thermal motor circuit-breaker must not in any case 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 hazard
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 203-230 from the mains.
Please note chapter 1.3 "Residual Dangers", page 15.
Malfunctions or other damages are to be reported to an authorized person
immediately.
Secure the servo amplifier JetMove 203-230 against misuse or accidental
use.
Writings, information signs, and labels always have to be observed and
kept readable.
Damaged or unreadable information signs and labels are to be
exchanged.

JetMove 203-230 1.2 Ensure your Own Safety
Jetter AG 13
1.2.3 Earthing procedure
Screw the enclosure of the digital servo amplifier JetMove 203-230 onto a
highly conducting, earthed panel.
Do only use the servo amplifier JetMove 203-230 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 servo amplifier must not be operated when connected to unearthed
networks and to unsymmetrically earthed networks.
One-phase connection to this power supply is only possible via one mains
phase and the neutral conductor.
Der drei-phasige Anschluss darf nur über einen Tenn- oder
Spartransformator vorgenommen werden, (siehe auch chapter
"Connection type of the voltage supply", page 35 und chapter 10 "Wiring
Diagrams", page 71).
The digital servo amplifier JetMove 203-230 has got a leakage current
greater than 3.5 mA. In order to avoid electric shocks, a second
protective earth conductor will be required.
For this, the following measures must be taken:
• The PE must be connected to the bolt (1) located at the top side of the
rack, as well as to the PE terminal X1 (2); for this, please refer to 1.
The cross-sectional area of the two earthing conductors must be equal
to the cross-sectional area of the supply lines (1.5 mm2 min.):
• A durable connection with the power supply of the digital servo amplifier
JetMove 203-230 must be provided.
•Correct cabling of the PE bus according to the connection diagram (cf.
chapter 10 "Wiring Diagrams", page 71) must be carried out.

1 Safety Instructions JetWeb
14 Jetter AG
Fig.1: Double earthing
2
Motor
W2 V2 U2 PE
X62
U1 V1 W1 PE
3 x AC 230 V
X1
ENABLE
LIMIT +
LIMIT -
REF
INPUT
⊥
⊥
DC 24 V 0,6 A
BRAKE 1
BRAKE 2
X10
1
X
V
iew X
X71
X61
1
5
6
9
X18
X19
1
5
6
9
5
1
9
6
BUS-IN
BUS-OUT
ENCODER
Jetter
JetMove
203-230
Important!
Do not loop an earth-leakage current breaker into the mains power
supply.
Using an earth-leakage current breaker (FI) looped into in the mains power
supply is not possible.
If, in spite of this, an earth-leakage current breaker is installed, it will switch off
the digital servo amplifier JetMove 203-230, although there is no fault.
When a leakage current screen needs to be installed in the JetMove 203-230, an
isolating transformer must be used.

JetMove 203-230 1.3 Residual Dangers
Jetter AG 15
1.3 Residual Dangers
1.3.1 Hazards during operation
Warning
HAZARD caused by high operating voltage!
Extremely hazardous voltages of up to DC 480 V may
occur!
These voltages lead to muscle cramps, burns, unconsciousness, respiratory
standstill, and death.
During operation, all coverings and control cabinet doors must be kept
closed.
Do not open the device.
Do by no means disconnect the electric connections of the servo amplifier
JetMove 203-230 when it is live.
Warning
During operation, do not touch the screws of field wiring terminals X1
and X62.
In the given context, the terminals have the following meaning:
X1: AC 230 V supply voltage
X62: DC Motors voltage of up to 480 V
Caution
DANGER of hot surfaces!
During operation, the surfaces, respectively the heat sinks of the servo amplifier
JetMove 203-230 can heat up. The internal heat sink can reach temperatures of
up to 90 °C.
Do by no means touch the enclosure of the digital servo amplifier
JetMove 203-230 near the internal heat sink during operation and
during the cooling-off period after switching off the device.
Please make sure that no temperature-sensitive parts have been
connected or fastened to the servo amplifier JetMove 203-230.

1 Safety Instructions JetWeb
16 Jetter AG
Warning
DANGER in potentially explosive atmosphere!
Do not operate the digital servo amplifier JetMove 203-230 in a
potentially explosive atmosphere.
Caution
DANGER of injuries caused by mechanic force!
The digital servo amplifier JetMove 203-230 runs a servo motor. This servo
motor moves mechanic parts or sharp edges. Therefore, failure or malfunctioning
of the digital servo amplifier JetMove 203-230 can be dangerous for a person or
damage the manufacturing plant to an amount depending on the respective kind
of plant. This should be prevented by installing additional safety precautions.
• 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 to install a protection cover.
Make sure that hazards to persons are precluded even when the drive is
moving unintentionally.
Warning
Do not dismount any necessary protective covers.
Do not wear gloves, lest they should get caught in the rotating drive shaft.
Never touch a rotating drive shaft.

JetMove 203-230 1.3 Residual Dangers
Jetter AG 17
1.3.2 Hazards after POWER is turned OFF
Warning
DANGER resulting from electric shock!
Capacitors installed in the servo amplifier can still have dangerous voltages
present up to five minutes after switching off the supply voltages.
Always wait at least 5 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 and X62;
– Disconnecting the terminals and touching the contacts.

1 Safety Instructions JetWeb
18 Jetter AG
1.4 Instructions on EMI
The digital servo amplifier JetMove 203-230 is intended for use in industrial
surroundings. It can cause radio interferences in residential areas. It is operated at
the operator's own risk.
The noise immunity of a system corresponds to the weakest component of the
system. For this reason, correct wiring and shielding of the cables is important.
Important!
Measures for increasing immunity to interfering in electric plants:
Earth the device adequately according to chapter 1.2.3 "Earthing
procedure", page 13.
Connect all grounding terminals of the JetMove 203-230. A double
grounding terminal will be needed!
– Connect the protective earth terminal located on the enclosure
– Connect the protective earth (PE) conductor to terminal X1.
see Fig. 1 on page 14
Connect the motor lines. An optional mains filter must be as close to the
servo amplifier as possible. Both sides of the cable must be shielded.
If a motor power cable is used which includes cores for brake control, the
brake control cores must be separately shielded. Earth the shielding at
both ends. The shielding braid must be placed on both ends of the
applicable cables.
The distance between the optional line filters and the servo amplifier
JetMove 203-230 must be kept as short as possible.
Please follow the instructions given in Application Note 016 "EMC-
Compatible Installation of the Electric Cabinet" published by Jetter AG.
The following instructions are excerpts from Application Note 016:
Screw the enclosure of the digital servo amplifier JetMove 203-230 onto a
highly conducting, earthed panel.
On principle, physical separation should be maintained between signal
and power lines. We recommend spacings greater than 20 cm. Cables and
lines should cross each other at an angle of 90°.

JetMove 203-230 1.4 Instructions on EMI
Jetter AG 19
Fig.2: Shielding of SUB-D connectors in conformity with EMC standards.
Shielded cables must be used for the following lines:
Analog lines, data lines, motor cables coming from inverter drives (servo
output stage, frequency converter), lines between components and
interference suppressor filter, if the suppressor filter has not been placed
at the component directly .
Shield both sides of the cable.
Unshielded wire ends of shielded cables should be as short as possible.
The entire shield must be drawn behind the isolation, and then be
extensively clamped under a flat earthed strain relief.
If male connectors are used:
The shield (impedance shielding) must, in its entire perimeter, be drawn
behind the shielding clamp of the metallised connector housing,
respectively of the EMC gland bushing, its greatest possible surface area
being clamped under a strain relief.
Only use metallised connectors, e.g. SUB-D with metallised housing.
Make sure that the strain relief is directly connected with the housing here
as well (see Fig. 2).
What to do, if the shield cannot be fixed to the connector, e.g. if the signal
has been connected to terminal screws:
Shield and cable strap must be connected with low impedance to earthed
surfaces. Earthing must be done in a way that keeps the unshielded part of
the signal lines as short as possible (see Fig. 3).

1 Safety Instructions JetWeb
20 Jetter AG
Fig.3: EMC-conformous shielding for terminal screws
max. 1 mm
Mating Connector
Cable Strap
Motor Cable