Jetter JM-204-480 User manual

User Manual
JM-204-480 - Digital Servo Amplifier
60870618
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2Jetter AG
Item # 60870618
Rev. 2.10
September 2017 / Printed in Germany
Jetter AG reserve 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 user 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 incidental or consequential damage in connection with the furnishing,
performance, or use of this material.
The brand names and product names used in this document are trademarks or
registered trademarks of the respective title owner.

JetMove 204-480
Jetter AG 3
How to Contact us:
Jetter AG
Graeterstrasse 2
D-71642 Ludwigsburg
Germany
Phone - Switchboard: ++49 7141/2550-0
Phone - Sales: ++49 7141/2550-433
Phone - Technical Hotline:++49 7141/2550-444
Telefax:++49 7141/2550-484
E-Mail - Sales:sa[email protected]
E-Mail - Technical Hotline:[email protected]
Internet Address:http://www.jetter.de
This User Manual is an Integral Part of
the JetMove 204-480:
To be entered by the customer:
Model:
Serial number:
Year of construction:
Order number:
Inventory number:
Place of operation:

4Jetter AG
Significance of this User Manual
This user manual is an integral part of the digital servo amplifier JetMove 204-480.
• Therefore it must be kept in a way that it is always at hand until the digital servo
amplifier JetMove 204-480 will be disposed of.
• Pass this user manual on if the JetMove 204-480 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 204-480 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 204-480 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
Edition Meaning
1.00 First edition
1.01 Modifications, see Appendix A of user manual rev. 1.01
2.00 Modifications, see Appendix A of user manual rev. 2.00
2.01 Style and spelling have been revised
2.10 For revisions, please refer to Appendix A: "Recent revisions",
Seite 115 of the user manual, revision 2.10

JetMove 204-480
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 are asked 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.

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.
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 204-480 Table of Contents
Jetter AG 7
Table of Contents
1 Safety Instructions 11
1.1 General Information 11
1.1.1 Usage to the intended purpose 11
1.1.2 Non-intended use 11
1.1.3 Qualified personnel 12
1.1.4 Modifications and alterations to the module 12
1.1.5 Servicing and repairs 12
1.1.6 Disposal 13
1.2 Ensure Your Own Safety 14
1.2.1 Malfunctions 14
1.2.2 Information signs and labels 14
1.2.3 Earthing procedure 15
1.3 Residual Dangers 17
1.3.1 Hazards during operation 17
1.3.2 Hazards after POWER has been turned OFF 19
1.4 Instructions on EMI 20
2 Installing the JetMove 204-480 23
2.1 Scope of Delivery 23
2.2 Mechanical Installation 24
2.3 Electrical Installation 26
2.4 Checking the Installation 27
2.5 Notes on Safety as regards the Installation 27
2.6 Notes on Safety as regards Commissioning 28
2.7 Notes on decommissioning 28
3 Operating Conditions 29
4 Physical Dimensions 33
5 Technical Data 35
5.1 Electrical Specification 35
5.2 Motor Protection 39
5.2.1 Built-in temperature sensor 39
5.2.2 I²t calculation 39
5.2.3 Motor overload protection according to UL 40
6 Drive Controller Structure 43
7 Description of Connections 45
7.1 Power Supply Connection 45

Table of Contents
8Jetter AG
7.2 Motor Connection 46
7.2.1 General remarks 46
7.2.2 Assignment and specification 47
7.2.3 Motor power cable with mating connector SC 48
7.2.4 Motor power cable with mating connector SM 51
7.2.5 Connection assignment of terminal box 54
7.3 Resolver Connection 55
7.3.1 Specification 55
7.3.2 Resolver cable with mating connector 55
7.4 HIPERFACE Connection 57
7.4.1 Specification 57
7.4.2 HIPERFACE cable with mating connector 57
7.5 Sin-Cos Encoder Connection 60
7.5.1 Adapter 60
7.5.2 Specification 60
7.5.3 Connection diagram 61
7.6 External Ballast Resistor and DC Link Connection 64
7.7 Digital Inputs, Logic Power Supply 70
7.8 Connection Details for Digital Outputs 72
7.9 Jetter System Bus 73
7.9.1 Specifications of the Jetter system bus cable 73
8 Status Monitoring 75
9 Diagnostics 77
9.1 Error Messages 77
9.2 Alarms 81
10 Connection Diagrams 83
11 Analog Input (Option) 87
11.1 Function 87
11.2 Technical Data 87
11.3 Description of Connections 88
12 Ethernet Interface (Option) 89
12.1 Function 89
12.2 Description of Connections 89
12.2.1 Connection JetMove 204-480...-OEM - PC or JetControl 90
12.2.2 Connection JetMove 204-480...-OEM - PC or JetControl via a
switch 90
12.3 Logic Circuit LEDs, Mode Selector 91

JetMove 204-480 Table of Contents
Jetter AG 9
12.3.1 LEDs 91
12.3.2 The DIP switches 92
12.4 Setting the IP Address 92
12.4.1 Fixed IP address 92
12.4.2 IP address taken out of the configuration store 92
12.4.3 IP address taken out of the switch position 94
13 Safe Standstill (Option) 95
13.1 Introduction 95
13.2 Motion System JetMove 204-480 96
13.3 Safety Instructions 97
13.4 Performance Test 97
13.5 Demands on the Safety System 97
13.5.1 Control variants for "Safe Standstill" 99
13.5.2 Application 1 100
13.5.3 Application 2 101
13.5.4 Application 3 102
13.5.5 Application 4 103
13.6 Block Diagram JM-204-480 with the "Safe Standstill"
Function 104
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 Voltage supply 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 Document Survey 115
15.2 Options 115
Appendix

Table of Contents
10 Jetter AG
Appendix A: Recent Revisions 119
Appendix B: Glossary 120
Appendix C: List of Abbreviations 122
Appendix D: List of Illustrations 123
Appendix E: Index 124

JetMove 204-480 1.1 General Information
Jetter AG 11
TableofContents 1 Safety Instructions
1.1 General Information
The digital servo amplifier JetMove 204-480 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 Usage to the intended purpose
Usage to the intended purpose includes operation in accordance with this user
manual.
The digital servo amplifier JetMove 204-480 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 204-480 that is
higher than the prescribed operating voltage.
Each of the three phases of the digital servo amplifier JetMove 204-480 has got an
operating voltage ranging between AC 340 V and AC 530 V. Thus, the digital servo
amplifier JetMove 204-480 comes under the EG Low Voltage Directive.
It is the explicit purpose of the digital servo controller JetMove 204-480 to
torque-, speed- and/or position-control, and to drive brushless synchronous
servo motors, asynchronous motors and three-phase stepper 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 204-480 is used to control machinery, such as
conveyors, production machines, and handling machines.
1.1.2 Non-intended use
The digital servo amplifier JetMove 204-480 must not be used in technical
systems which to a high degree have to be fail-save, e. g. ropeways and
aeroplanes.
Please do not use the integrated braking circuit in applications, where safety
hazards can occur.
The digital servo amplifier JetMove 204-480 is not a safety-relevant device
according to the machinery directive 2006/42/EG. Therefore, using this servo
amplifier for safety-relevant applications as regards safety of persons is
neither adequate nor permitted.

1 Safety Instructions
12 Jetter AG
1.1.3 Qualified personnel
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 204-480 at each phase of the product life cycle.
1.1.4 Modifications and alterations to the
module
Due to safety reasons, neither opening the digital servo amplifier
JetMove 204-480, nor carrying out any modifications or alterations to the
device and its functions is allowed.
Any modifications to the servo amplifier JetMove 204-480 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
204-480. 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 204-480.
Any liability on the part of Jetter AG for any damages resulting from the use of non
original parts and equipment is excluded.
1.1.5 Servicing and repairs
Repairs at the digital servo amplifier JetMove 204-480 must not be carried out by the
operator. The digital servo amplifier JetMove 204-480 does not contain any parts to
be repaired by the operator.
For being repaired, the servo amplifier JetMove 204 -480 must be sent to Jetter AG.
Phase of the Product
Life Cycle
Minimum Demands on the Personnel
Transport / Storage: Only properly trained and instructed personnel with
knowledge of correctly handling electrostatically
sensitive components.
Mounting /
Installation:
Trained personnel specified in electrical automotive
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.
:Trained personnel specified in electrical automotive
engineering, such as industrial electronics engineers.

JetMove 204-480 1.1 General Information
Jetter AG 13
The digital servo amplifier JetMove 204-480 is maintenance-free. Therefore,
absolutely no inspection or maintenance works are required for the operation of the
module.
1.1.6 Disposal
In case of obvious damage or erratic behavior, the servo amplifier must not be used
any more.
The environmental regulations for the respective country apply to disposing of the
digital servo JetMove 204-480 amplifier on the operating company’s premises.
You can disassemble the digital servo amplifier JetMove 204-480 into its main
components by unscrewing it (aluminium heat sink and side plate, steel casing cover,
electronic boards).

1 Safety Instructions
14 Jetter AG
1.2 Ensure Your Own Safety
1.2.1 Malfunctions
1.2.2 Information signs and labels
Danger
Isolate the digital servo amplifier JetMove 204-480 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 follow the information given in chapter 1.3 "Residual Dangers",
page 17.
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 204-480 from the mains.
Please follow the information given in chapter 1.3 "Residual Dangers",
page 17.
Malfunctions or other damages are to be reported to an authorised person
at once.
Secure the digital servo amplifier JetMove 204-480 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 have to be
exchanged.

JetMove 204-480 1.2 Ensure Your Own Safety
Jetter AG 15
1.2.3 Earthing procedure
Screw the enclosure of the digital servo amplifier JetMove 204-480 onto a
highly conducting, earthed panel.
Do only use the digital servo amplifier JetMove 204-480 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 asymmetrically earthed networks.
The digital servo amplifier JetMove 204-480 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 protective earth bus must 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 must be equal to the
diameter of the supply lines (1.5 mm²min. / AWG 16).
• A durable connection with the power supply of the digital servo amplifier
JetMove 204-480 must be provided.
• Correct cabling of the PE (GND) bus according to the connection
diagram (cf. chapter 10 "Connection Diagrams", page 83) must be
carried out.

1 Safety Instructions
16 Jetter AG
Fig. 1: Double earthing
12
Important!
Do not loop an earth-leakage current breaker into the mains power
supply.
Do not install a leakage current protection switch in the supply line.
If, in spite of this, a leakage current protection switch is installed, same will switch
off the digital servo amplifier JetMove 204-480, although there is no fault.
When an earth-leakage current breaker needs to be installed in the
JetMove 204-480, an isolating transformer must be used.

JetMove 204-480 1.3 Residual Dangers
Jetter AG 17
1.3 Residual Dangers
1.3.1 Hazards during operation
Warning
HAZARD caused by high operating voltage!
Extremely hazardous voltages of up to 850 V may occur!
Such voltages may result in muscle cramps, burns, unconsciousness, respiratory
standstill, or death.
During operation, keep all cover plates and control cabinet doors closed.
Do not remove the cover.
Do by no means disconnect the electric connections of the digital servo
amplifier JetMove 204-480 when it is live.
Warning
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
Warning
CAUTION! Hot surfaces!
During operation, the surfaces, respectively the heat sinks of the digital servo
amplifier JetMove 204-480 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 204-480 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 204-480.

1 Safety Instructions
18 Jetter AG
Warning
DANGER in potentially explosive atmosphere!
Do not operate the digital servo amplifier JetMove 204-480 in a
potentially explosive atmosphere.
Caution
DANGER of injuries caused by mechanic force!
The digital servo amplifier JetMove 204-480 runs a servo motor. This servo
motor moves mechanic parts or sharp edges. Therefore, failure or malfunctioning
of the digital servo amplifier JetMove 204-480 can be dangerous for persons 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 is to install a guard.
Make sure that hazards to persons are precluded even when the drive is
rotating unintentionally.
Warning
Do not remove any guards.
Do not wear gloves, lest they should inadvertently get caught in the
rotating shaft.
Never touch a rotating drive shaft.

JetMove 204-480 1.3 Residual Dangers
Jetter AG 19
1.3.2 Hazards after POWER has been turned
OFF
Warning
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.

1 Safety Instructions
20 Jetter AG
1.4 Instructions on EMI
The digital servo amplifier JetMove 204-480 is intended for use in industrial
surroundings. This module can cause radio interferences in residential areas. This
module 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 cables is of paramount
importance.
Important!
Measures for increasing immunity to interference:
Earth the device adequately according to chapter 1.2.3 "Earthing
procedure", page 15.
Connect all grounding terminals of the JetMove 204-480. A double
grounding terminal will be needed!
– Connect the earth to the cover. For this, please refer to fig. 1 on
page 16.
– Connect protective earth (PE / GND) at terminal X1
The distance between the optional line filters and the digital servo amplifier
JetMove 204-480 must be as short as possible.
When of a motor cable with included brake lines is used, these brake lines
must be shielded separately.
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:
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°.
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 cables at both ends.
Unshielded wire ends of shielded cables should be as short as possible.