Keba ServoOne Series User manual

ServoOne
Multi-Axis System
Operation Manual
Supply Unit
Multi-axis system
with sinusoidal regeneration

Size (BG) BG5 BG6a BG7
Device SO84.040.S
SO84.076.S
SO84.115.S
SO84.170.S
SO84.375.S
SO84.540.S
Figure
ServoOne Multi-Axis System
Operation Manual Supply Unit
ID no.: 1101.21B.6-00
Date: 04/2020
Applicable as from rmware version: V220.13-01
The German version is the original of this operation manual.
ServoOne high-performance drives
The modularity of the ServoOne guarantees optimum integration into the machine
process. Whether in high-speed eld bus communication with the central multi-axis
machine controller or with distributed programmable Motion Control intelligence in the
drive controller, the ServoOne is a master of both.
Subject to technical change without notice
The content of our documentation was compiled with the greatest care and attention,
and based on the latest information available to us.
We should nevertheless point out that this document cannot always be updated
simultaneously with the on-going technical development of our products.
Information and specications may be subject to change at any time. For information on
the latest version please visit www.keba-lti.com.
Operation Manual ServoOne Supply Unit 2
ID no.: 1101.21B.6-00 Date:04/2020

Operation Manual ServoOne Supply Unit 3
ID no.: 1101.21B.6-00 Date:04/2020
3 Mechanical installation.................................................................. 15
3.1 Notes for mechanical installation...............................................................................15
3.1.1 Arrangement and mounting .....................................................................15
3.2 Switch cabinet layout ................................................................................................16
3.3 Mounting supply unit, wall mounting housing variant...............................................18
3.3.1 Dimensions, wall mounting housing variant...............................................19
3.4 Mounting supply unit, liquid cooling housing variant ................................................20
3.4.1 Dimensions, liquid cooling housing variant ................................................22
3.5 Cooling circuit connection.........................................................................................24
3.6 Mounting step-up choke...........................................................................................24
3.6.1 Dimensions ................................................................................................24
3.6.2 Cooling the step-up choke.........................................................................25
3.7 Mounting input choke with film capacitor.................................................................26
3.7.1 Dimensions ................................................................................................26
3.8 Mounting mains filter................................................................................................27
3.8.1 Dimensions ................................................................................................27
4 Electrical installation .....................................................................29
4.1 Before you start ........................................................................................................29
4.2 Effective EMC installation..........................................................................................30
4.2.1 Cable type .................................................................................................30
4.2.2 Routing of cables.......................................................................................30
4.2.3 Earthing measures .....................................................................................30
4.2.4 Shielding measures ....................................................................................31
Table of contents
1 General ..........................................................................................7
1.1 Target group ...............................................................................................................7
1.2 Prerequisites................................................................................................................7
1.3 Reference documents..................................................................................................7
1.4 Order code..................................................................................................................8
1.5 Data on manufacture ..................................................................................................8
1.6 Scope of supply...........................................................................................................8
1.7 Pictograms ..................................................................................................................9
1.8 Disclaimer ...................................................................................................................9
1.9 Disposal .....................................................................................................................9
1.10 Service & Helpline .......................................................................................................9
2 Safety........................................................................................... 11
2.1 Overview................................................................................................................... 11
2.2 Measures for your safety........................................................................................... 11
2.3 General safety instructions and warnings..................................................................12
2.4 Intended use ............................................................................................................. 12
2.4.1 The ServoOne multi-axis system ................................................................13
2.4.2 Repair ........................................................................................................ 13
2.5 Misuse ......................................................................................................................13
2.6 Responsibility ............................................................................................................ 13
2.7 Relevant laws, standards and directives applied ........................................................13
2.8 Declaration of conformity .........................................................................................14
Table of contents

Operation Manual ServoOne Supply Unit 4
ID no.: 1101.21B.6-00 Date:04/2020
4.9 Control connections (X4)...........................................................................................50
4.9.1 Specification, control connections .............................................................50
4.9.2 Standard terminal assignment.................................................................... 51
4.10 Functions of the digital inputs...................................................................................52
4.11 Functions of the digital outputs ................................................................................52
4.12 Specification, USB interface (X2) ...............................................................................53
4.13 Specification, Ethernet interface (X3) ........................................................................53
4.14 Option 1 ...................................................................................................................53
4.15 Braking resistor (X12/RB) ...........................................................................................53
4.15.1 Connection of the external braking resistor ...............................................53
4.16 Overview of the step-up choke connections .............................................................54
4.17 Overview of the input choke connections .................................................................55
4.18 Overview of the mains filter connections...................................................................57
5 Commissioning.............................................................................59
5.1 Notes for operation...................................................................................................59
5.2 Initial commissioning (operation via terminals)...........................................................59
5.2.1 System requirements .................................................................................60
5.2.2 Wiring the components .............................................................................60
5.2.3 Switching on control voltage (24VDC) ...................................................... 61
5.2.4 Communication with DriveManager 5 .......................................................61
5.2.5 Setting mains voltage and mains frequency of the supply system ..............62
5.2.6 Automatic identification of the DC link capacitance and
the equivalent time constant for the current regulation .............................63
5.2.7 Setting DC link capacitance .......................................................................63
5.2.8 Setting DC link voltage ..............................................................................64
5.2.9 Setting monitoring of the braking resistor..................................................64
4.3 Overview of the connections.....................................................................................32
4.3.1 Layout, BG5 (SO84.040.S and SO84.076.S) ...............................................32
4.3.2 Layout, BG6a (SO84.115.S and SO84.170.S) ..............................................32
4.3.3 Overview of connections, BG5 and BG6a ..................................................33
4.3.4 Connection diagram, BG5..........................................................................34
4.3.5 Connection diagram, BG6a........................................................................35
4.3.6 Layout, BG7 (SO84.375.S and SO84.540.S) ...............................................36
4.3.7 Overview of connections, BG7...................................................................37
4.3.8 Connection diagram and precharging, BG7 ...............................................38
4.4 Mains On/Off control process ...................................................................................39
4.5 Connection of the protective earth conductor ..........................................................39
4.5.1 Protective earth conductor (X11)supply unit BG5 ......................................39
4.5.2 Protective earth conductor (X11),supply unit BG6a....................................40
4.5.3 Protective earth conductor (X11)supply unit BG7 ......................................41
4.5.4 Protective earth conductor connection other components......................... 41
4.6 Electrical isolation concept ........................................................................................42
4.7 Connection of the supply voltages ............................................................................43
4.7.1 Control supply 24VDC (X9, X10) for BG5 and BG6a.................................43
4.7.2 Control supply 24VDC (X44) for BG7.......................................................44
4.7.3 Precharging and mains synchronisation (X21) for BG5 and BG6a ...............44
4.7.4 Precharging (X44) and mains synchronisation (X45) for BG7......................45
4.7.5 Connection, mains 400/480VAC (X12) ....................................................45
4.8 Connection of the DC power supply .........................................................................47
4.8.1 Connection, DC power supply (X11) BG5...................................................47
4.8.2 Connection, DC power supply BG6a and BG7 ...........................................48
Table of contents

Operation Manual ServoOne Supply Unit 5
ID no.: 1101.21B.6-00 Date:04/2020
Glossary...............................................................................................87
5.2.10 Switching on mains supply voltage ............................................................65
5.2.11 Switching on regulation .............................................................................65
5.3 Diagnostics ...............................................................................................................65
5.3.1 Malfunctions and warnings in DriveManager 5..........................................65
5.4 Integrated control unit ..............................................................................................66
5.4.1 Function of buttons T1 and T2...................................................................67
5.4.2 Display.......................................................................................................67
5.4.3 Parameter menu (PA) .................................................................................68
5.4.4 Ethernet IP address menu (IP).....................................................................68
5.4.5 Field bus address menu (Fb) .......................................................................69
6 Diagnostics...................................................................................71
6.1 Device states .............................................................................................................71
6.1.1 Errors .........................................................................................................71
6.2 Error list ....................................................................................................................72
A Appendix......................................................................................75
A.1 Technical data, supply unit ........................................................................................75
A.2 Current required for the control supply .....................................................................79
A.3 Pre-assembled connection cables..............................................................................79
A.4 Hydrological data for the liquid cooling.....................................................................80
A.5 Dynamic temperature monitoring .............................................................................80
A.6 Ambient conditions...................................................................................................81
A.7 Technical data, step-up choke...................................................................................82
A.8 Technical data, input choke.......................................................................................83
A.9 Technical data, mains filter........................................................................................84
A.10 Technical data, mains fuse.........................................................................................84
A.11 Technical data, mains contactor ................................................................................85
A.12 Technical data, circuit breaker ...................................................................................85
A.13 UL certification..........................................................................................................86
Table of contents

Operation Manual ServoOne Supply Unit 6
ID no.: 1101.21B.6-00 Date:04/2020
Table of contents

Operation Manual ServoOne Supply Unit 7
ID no.: 1101.21B.6-00 Date:04/2020
General
1 General
The product DVD from KEBA Industrial Automation Germany GmbH contains the
complete documentation for the related product series. The documentation for a product
series includes the operation manual (hardware description), device help (software
description) as well as further user manuals (e.g. eld bus description and specications).
The documents are available in the formats PDF or HTML.
1.1 Target group
Dear user,
the documentation forms part of the device and contains important information on
operation and service. It is aimed at all persons who undertake mounting, installation,
commissioning and servicing work on the product.
1.2 Prerequisites
Prerequisites for the usage of devices from KEBA:
yThe documentation on the devices is to be stored so it legible, accessible at all times and for the
entire life of the product.
yRead and ensure you understand the documentation on your device.
yQualication: to prevent injury or damage, personnel may only work on the device if they have
electrical engineering qualications.
yKnowledge required:
− National health and safety regulations (e.g. BGV A3 in Germany)
− Mounting, installation, commissioning and operation of the device
Work in other areas, for example transport, storage and disposal is only allowed to be
undertaken by trained personnel.
NOTE
This operation manual only applies to the supply unit for the ServoOne multi-
axis system (referred to in the following as the supply unit or SOVE for short).
1.3 Reference documents
Document Contents ID no.
Format
ServoOne junior -
Operation Manual
Safety, mechanical installation, electrical installation, commissioning,
diagnostics, specications, certication and applicable standards,
technical data
1300.20B.x
PDF
ServoOne Single-Axis
System -
Operation Manual
Safety, mechanical installation, electrical installation,
commissioning, diagnostics, specications, certication and
applicable standards, technical data
1100.20B.x
PDF
ServoOne Multi-Axis System -
Operation Manual
Safety, mechanical installation, electrical installation, commissioning,
diagnostics, STO, operation with servocontroller as supply, planning,
application example, specications, certication and
applicable standards, technical data
1101.20B.x
PDF
ServoOne Multi-Axis System
Supply Unit -
Operation Manual
Safety, mechanical installation, electrical installation, commissioning,
diagnostics, specication, certication and applicable standards,
technical data
1101.21B.x
PDF
ServoOne Sercos II -
User Manual
Safety, commissioning, communication phases, parameter interface,
error, warning and status messages, operation modes, weighting,
referencing, touchprobe, parameter lists
1100.29B.x
PDF
ServoOne Sercos III -
User Manual
Safety, installation and connection, commissioning and conguration,
setting parameters, data transmission, scaling and weighting,
functionality, error message and diagnostics, parameter lists
1108.26B.x
PDF
CANopen/EtherCAT -
User Manual
Safety, commissioning, data transmission, operation modes,
referencing, parameters, technical data 1108.28B.x
PROFIBUS-DPV
User Manual
Description and conguration of the parameters for the ServoOne
on the PROFIBUS-DPV eld bus system
1108.27B.x
PDF
ServoOne System -
System Catalogue
Information, notes on ordering, specications and
technical data on:
ServoOne junior, ServoOne single-axis system, ServoOne multi-axis
system, safety technology, communication, technology, function
packages, accessories and motors
1100.24B.x
PDF
ServoOne - device help
Description of the software functionality ServoOne,
rmware versions:
- SO junior from V1.30-xx
- SO single-axis system from V3.25-xx
- SO multi-axis system from V3.25-xx
0842.26B.x
PDF and HTML
Program help DriveManager 5
PC user software
Context-sensitive help for DriveManager version 5.x graphic PC
user software for initial commissioning and serial commissioning,
operation, diagnostics and project management
0842.25B.x
PDF and HTML
UL-Certication Notes on UL-compliant mounting and usage 0927.21B.x
PDF

Operation Manual ServoOne Supply Unit 8
ID no.: 1101.21B.6-00 Date:04/2020
General
1.4 Order code
The supply unit (SOVE) has the article designation SO84.xxx.S0xx.xxxx.x. This provides
information on the related variant of the SOVE supplied. The signicance of the individual
characters of the article designation is given in the following order code.
Article
designation SO8 4 . 040 . S 0 0 0 . 0 0 0 0 . X
ServoOne
Supply voltage: 3 x 400V 4
Rated current BG5 40A
76A
040
076
BG6a 115A
170A
115
170
BG7 375A
540A
375
540
DC supply unit regenerative S
Option 1 Communication Not included
SercosII
PROFIBUS
EtherCAT
CANopen
CANopen + 2AO
PROFINET IRT
SercosIII
Powerlink1)
0
1
2
3
4
5
7
8
9
Option 2 Technology Not included 0
Housing/cooling method Air-cooled
Liquid-cooled with internal braking resistor
Liquid-cooled
0
7
8
Function package Basic (without additional function package)
iPlc
1
Special design None 0
Protection PCBs with protective varnish 1
Hardware version (May be multi-digit) X
1) in preparation
1.5 Data on manufacture
On the rating plate for the SOVE you will nd the serial number, from which you can
identify the date of manufacture based on the following key. For the location of the rating
plate on the SOVE refer to chap. 4.3 FF.
SN.: JJWWxxxxxSN.: JJWWxxxxx
Year of production
Week of production
Figure 1.1 ServoOne hardware rating plate
1.6 Scope of supply
The scope of supply includes:
yServoOne supply unit
yPre-assembled DC link cables up to BG5
yProduct DVD with booklet (safety and application instructions for electrical equipment in
25languages)
Mains connection set required
The mains connection set is required for the intended use of the ServoOne supply unit.
The scope of supply includes:
yMains lter
yInput choke with lm capacitor
yStep-up choke
yShield plates and clamps (only for the sizes BG5 and BG6a)

Operation Manual ServoOne Supply Unit 9
ID no.: 1101.21B.6-00 Date:04/2020
General
1.10 Service & Helpline
Address: KEBA Industrial Automation Germany GmbH
Gewerbestrasse 5-9
35633 Lahnau
If you have any questions about the project planning for your machine or the
commissioning of your device, our Helpline will provide you with quick, specic
assistance.
The Helpline is available by e-mail or telephone:
Service hours: Mo.-Fr.: 8a.m. - 5p.m. (CET)
E-mail: [email protected]
Telephone: +496441966-180
Internet: www.keba-lti.com
NOTE
You will nd detailed information about our services on our web site www.keba-lti.com 
Service
1.7 Pictograms
The pictograms used in this operation manual signify the following for the user:
NOTE
Useful information or reference to other documents.
1.(digit) ACTION TO BE TAKEN
Action undertaken by the user or the system.
You will nd the pictograms used in this operation manual for "safety instructions and
warnings" in chapter 2 Safety.
1.8 Disclaimer
Following the documentation on the devices from KEBA is a prerequisite:
yFor safe operation.
yTo achieve stated performance features and product characteristics.
KEBA does not accept any liability for injuries, damage or nancial losses that result from
the failure to follow the documentation.
1.9 Disposal
Follow the applicable national regulations! If necessary, dispose of individual parts,
depending on their characteristics and existing national regulations, e.g. as:
yElectrical waste
yPlastic
yMetal
Or engage a certied disposal organisation with scrapping

Operation Manual ServoOne Supply Unit 10
ID no.: 1101.21B.6-00 Date:04/2020

Operation Manual ServoOne Supply Unit 11
ID no.: 1101.21B.6-00 Date:04/2020
Safety
2 Safety
2.1 Overview
Our devices are state-of-the-art and comply with recognised safety regulations,
nevertheless hazards can arise. In this chapter:
yWe provide information on residual risks and hazards that can emanate from
our devices on usage as intended.
yWe warn about the foreseeable misuse of our devices.
yWe refer to the necessary care and measures to be taken to prevent risks.
2.2 Measures for your safety
NOTE
Please only install and place in operation your device taking into account the
documentation for the related device family!
Our devices are quick and safe to operate. For your own safety and for the safe function
of your device, please be sure to observe the following points:
1. Follow safety instructions for the devices:
Follow all safety instructions and warnings in the entire documentation related to the device series.
2. Electric drives are dangerous:
• Due to electrical voltages up to 480V AC and up to 900 V DC
• Even 10min. after switching off the mains supply, dangerously high voltages of ≥50V may
still be present (capacitor charge). So check that electrical power is not present! See also the
warning label on the front panel on the device.
• Rotating parts
• Automatically starting drives.
• Hot components and surfaces
3. Protection against magnetic and/or electromagnetic elds during
installation and operation.
Persons tted with heart pacemakers, metallic implants and hearing aids etc. must not be allowed
access to the following areas:
• Areas in the immediate vicinity of electrical equipment!
• Areas in which electronics components and drive controllers are installed,
repaired and operated!
• Areas where motors are installed, repaired and operated!
Motors with permanent magnets pose particular hazards.
4. During installation observe the following:
• Comply with connection conditions and technical data as per the documentation and the rating
plate!
• Comply with standards and directives on electrical installation, such as cable cross-section,
shielding, etc.!
• Do not touch electronic components and contacts!
Electrostatic discharge can harm people and destroy components!
• Take protection measures and use protective devices as per the applicable regulations
(e.g. EN 60204 or EN 61800-5-1)!
• Take "device earthing" protection measure!
5. Ambient conditions
• Follow the instructions on the transport, storage and correct operation of the devices stated in
the operation manual in "A Appendix".

Operation Manual ServoOne Supply Unit 12
ID no.: 1101.21B.6-00 Date:04/2020
Safety
2.3 General safety instructions and warnings
Hazards may emanate from our devices. For this reason it is imperative you follow the
safety instructions and warnings in this document.
DANGER! Risk of injury due to electrical power!
• Carelessness will result in serious injuries or death.
Follow safety instructions and warnings in this document and on the device.
WARNING! Risk of injury due to electrical power!
• Carelessness may result in serious injuries or death.
Follow safety instructions and warnings in this document and on the device.
CAUTION! Risk of injury or damage to the device due to incorrect operation!
• Carelessness may result in minor injuries or damage.
Follow safety instructions and warnings in this document and on the device.
WARNING! Risk of injury due to hot surfaces and components!
• Carelessness may result in serious burns.
Electronic components may become hot during operation!
Follow safety instructions and warnings in this document and on the device!
Caution! Damage due to electrostatic discharge!
• Electrostatic discharge can destroy components.
Do not touch electronic components and contacts!
Follow safety instructions and warnings in this document and on the device!
DANGER! Risk of injury due to rotating parts on the motor!
• Carelessness will result in serious injuries or death.
Follow safety instructions and warnings in this document.
Pay attention to special safety instructions and warnings that are given here in the document before a
specic action and that warn the user about a specic hazard!
NOTE:
The pictograms may also be used on their own with the signal word, e.g.
in the connection diagrams, however they have the same function as in the
complete warning.
DANGER WARNING CAUTION
2.4 Intended use
Our devices are components intended for stationary electrical systems and machines in
the industrial and commercial sector.
The supply unit for the ServoOne multi-axis system conforms to the
Low Voltage Directive 2014/35/EU
Tested and certied according to applicable standards (see declaration of conformity in
chap. 2.8).
This supply unit is only allowed to be combined with the axis controllers in the ServoOne
multi-axis system.
When installed in machines it is prohibited to start up intended operation until it has
been ascertained that the completed machine fully complies with the provisions of the
Machinery Directive (2006/42/EC); compliance with EN 60204 is mandatory.
Starting up intended operation is only permitted on compliance with the EMC Directive
2014/30/EU
The devices meet the requirements of the harmonised product standard EN 61800-5-1.

Operation Manual ServoOne Supply Unit 13
ID no.: 1101.21B.6-00 Date:04/2020
Safety
2.6 Responsibility
Electronic devices are not fail-safe. The installer and/or operator of a complete machine
or system is responsible:
yFor ensuring the drive is rendered safe if the device fails
yFor ensuring the safety of personnel and machinery
yFor ensuring the complete machine is in correct working order
yFor the risk assessment on the complete machine or system according to
EN ISO 12100 (formerly DIN EN 1050) and EN ISO 13849-1
(formerly DIN EN 954-1)
Pay attention to the topic of “Electrical equipment of machines” in EN60204-1:2006
“Safety of machinery”. The safety requirements on electrical machines dened there are
intended to protect personnel and machinery or systems.
The emergency stop function (as per EN 60204) shuts down the supply of power to a
machine, which results in the drives coasting down in an uncontrolled manner. To avert
hazards, check whether it is appropriate:
− To keep individual drives in operation
− To initiate specic safety procedures
− To incorporate a Safe Torque Off function (Safe Torque Off: movement stop
by "switching off the electrical supply" - STO)
2.4.1 The ServoOne multi-axis system
The ServoOne supply unit is intended for use in a ServoOne multi-axis system.
The multi-axis system comprises at least one ServoOne CMP supply unit with the mains
connection set and several ServoOne DC axis controllers connected to it. In motor
operation the supply unit draws energy from the supply system and makes it available to
the DC axis controllers connected via the DC link. In regenerative operation the energy
is stored in the DC link. Temporarily surplus energy is fed back to the supply system in
sinusoidal form by the supply unit.
2.4.2 Repair
Only have repairs undertaken by authorised repair shops. Unauthorised opening and
incorrect intervention could lead to death, injury or damage. The warranty provided by
KEBA will be rendered void.
2.5 Misuse
Our devices are:
yNot intended for installation in vehicles. Deployment of the device in mobile
equipment is classed as non-standard ambient conditions, and is permissible
only by special agreement.
yNot intended for installation in environments with harmful oils, acids, gases,
vapours, dusts, radiation etc.
yNot approved for usage in special applications (e.g. in potentially explosive
atmospheres or areas in which there is a risk of re).
yNot approved for usage outside a switch cabinet
yNot approved for the generation of high-frequency onboard networks for which
the device is not designed

Operation Manual ServoOne Supply Unit 14
ID no.: 1101.21B.6-00 Date:04/2020
Safety
2.7 Relevant laws, standards and directives
applied
For information on the laws, standards and directives applied by KEBA, refer to the
declaration of conformity.
NOTE:
Depending on the specic application for the devices, other laws, standards
and directives with provisions on "Safety" may apply. If necessary, contact the
machine or system manufacturer.
NOTE:
Due to possible output frequencies >600Hz, the drive controllers fall under
Dual Use Regulation (EU) no. 1382/2014 dated 22 October 2014 item 3A225.
Export authorisation is therefore required for non-EU countries. Please note
the information in the delivery documents.
2.8 Declaration of conformity

Operation Manual ServoOne Supply Unit 15
ID no.: 1101.21B.6-00 Date:04/2020
3 Mechanical installation
The device is designed only for installation in a stationary switch cabinet. The switch
cabinet must as a minimum provide IP4x protection.
3.1 Notes for mechanical installation
WARNING! Risk of injury due to hot surfaces on the device!
• Carelessness may result in serious burns.
Thedeviceandespeciallytheheatsinkheatupsignicantlyduringoperationandcanreach
temperaturesofupto100°C.Thechokesconnectedalsoheatupduringoperationandcan
reachtemperaturesofupto145°C.Priortostartingwork,makesurethedevicehascooled
down.
Ontouchingthereisariskofburnstotheskin.Forthisreasonprovideprotectionagainst
touching.
Duringmountingmaintainanappropriatedistancetoneighbouringassemblies.
CAUTION! Damage to the device due to incorrect installation conditions!
The device may suffer irreparable damage.
Forthisreason
• Moisturemustnotbeallowedtoenterthedevice
• Theremustnotbeanyaggressiveorconductivesubstancesintheambientair
• Foreignbodiessuchasdrillingchips,screws,washersetc.mustnotbeallowedtofallinto
thedevice
• Theventilationopeningsmustnotcovered
NOTE:
The supply unit must not be installed in areas where it would be permanently
exposed to vibration. You will nd further information in Table A.17 in the
appendix.
NOTE:
On installing the supply unit in a ServoOne multi-axis system, it is also
imperative the operation manual for the DC axis controllers is followed.
3.1.1 Arrangement and mounting
The following guidelines apply in principle to the supply unit and DC axis controller:
yThe backing plate must be well-earthed.
yTo attain the best result for effective EMC installation you should use a
chromated or galvanised backing plate. If backing plates are varnished, remove
the coating from the contact area! The devices have a galvanised sheet steel
back panel.
yMaximum pollution degree2 according to EN60664-1. You will nd further
information on ambient conditions in Table A.15 in the appendix.
yCooling air must be able to ow through the device without restriction.
yOn installation in cabinets with convection (= heat loss is dissipated to the
outside via the switch cabinet walls), always t an internal air circulation fan.
yDevices with different housing variants (wall mounting and liquid cooling) can be
mounted side-by-side in any combination.
yDevices with the liquid cooling housing variant have a spacer on the rear in
place of the heat sink. As a consequence it is possible to connect devices with
the wall mounting housing variant using pre-assembled DC link cables without
additional compensation measures in relation to the device depth.
yBetween the devices, minimum distances as per Table 3.1 and Table 3.2 are to
be met.
yThe maximum distance between the devices up to size BG5 is dened by the
pre-assembled connection cables supplied and is 2mm (for exceptions see
Table 3.1 and Table 3.2).
Mechanical installation

Operation Manual ServoOne Supply Unit 16
ID no.: 1101.21B.6-00 Date:04/2020
1
ON
0
OFF
0
PWR
LOCK
CF
Power
Reset
RJ-45/Line
RS232
COM
Data
Status
< 200 mm
< 20
1
7
8
6
5
4
3
2
12 9
10
10
10
10
11
14
13
Key
1) Mains cable
2) Main switch
3) Fuses
4) Mains lter
Cables without interference suppression must be laid at
a distance of at least 200mm from the mains input side
of the lter so that no interference can be coupled into
the cables.
5) Circuit breaker
6) Mains contactor
7) Input choke with capacitor connected
8) Step-up choke
9) ServoOne supply unit
10) ServoOne DC axis controller
11) DC power supply via DC link cable
12) Braking resistor
13) Motor cables
14) Controller
Figure 3.1 Example: arrangement in the switch cabinet
3.2 Switch cabinet layout
The positioning of the components in the switch cabinet has a signicant effect on the
trouble-free system and machine function. You should take into account the following
points in your planning:
yEvaluate the assemblies used in relation to EMC.
yDivide the switch cabinet into zones with different power and interference levels.
yFor devices susceptible to interference, maintain a distance of at least 200mm
from the following components:
− Drive controller
− Input and output chokes, transformers
− Mains, motor, DC power supply and braking resistor cables (even if shielded)
− Relay and contactors (even if interference-suppressed)
yFor small distances use separators for shielding; fasten the separators directly
and conductively to the backing plate.
yIf a motor contactor or motor choke is used, the component should be
positioned directly at the drive controller.
yDo not use uorescent lamps in switch cabinets, as they emit high-frequency
interference.
yFit contactors, relays, solenoid valves, switched inductors and capacitors with
suppressors.
yThe mains lter must be mounted on the backing plate as close as possible to
the feed point and with large surface area contact. The backing plate must be
connected to the central earthing point with a low-impedance connection.
No unltered cables are allowed to be laid on the mains input side of the lter so
that no interference can be coupled into the cables.
Mechanical installation

Operation Manual ServoOne Supply Unit 17
ID no.: 1101.21B.6-00 Date:04/2020
NOTE:
Arrange the controller separated from the power area to prevent EMC
coupling mechanisms.
Control cables, signal cables and cable shields have been omitted for clarity.
yUse bare metal backing plates.
yThe rear of the drive controller must have good contact to the switch cabinet
ground. The contact area must be bare metal to establish a good ground
connection to the switch cabinet ground. There must not be an air gap between
the rear wall of the drive controller and the wall of the switch cabinet.
yThe bases of the chokes must have good contact to the switch cabinet ground.
The contact area must be bare metal to establish a good ground connection to
the switch cabinet ground.
= 0 mm
1
2
> 0 mm
1
2
1) Bare metal backing plate
2) Large area contact
1) Paint
2) Air gap
Figure 3.2 CORRECT mounting of drive
controller
Figure 3.3 INCORRECT mounting of drive
controller
Mechanical installation

Operation Manual ServoOne Supply Unit 18
ID no.: 1101.21B.6-00 Date:04/2020
ServoOne DC BG1 ServoOne DC BG2 ServoOne DC BG3 ServoOne DC BG4
ServoOne
Supply unit BG5
B
A
Figure 3.4 Butt mounting axis group, wall mounting with supply unit BG5
ServoOne DC BG1 ServoOne DC BG2 ServoOne DC BG3
ServoOne DC BG4
ServoOne DC BG5
20 mm
ServoOne DC BG6a wall mounting
ServoOne
Supply unit BG6a
wall mounting
B
A
Figure 3.5 Butt mounting axis group, wall mounting with supply unit BG6a
3.3 Mounting supply unit,
wall mounting housing variant
1.
Arrange the devices starting from the supply unit to the right or left sorted in
descending order by power rating to minimise thermal interaction. Pay attention
to the notes on effective EMC installation prior to mounting the devices and
components in the switch cabinet.
• Align the supply unit BG5 and all ServoOne DC axis controllers in a line along the
top edge of the devices (see line A in Figure 3.4).This action is necessary to be
able to make the DC link connections.
• Align the supply unit BG6a and all ServoOne DC axis controllers in a line along
the top edge of the devices (see line A in Figure 3.5). This action is necessary to
be able to make the DC link connections. Move down the mounting bores for
the supply unit BG6a and the ServoOne DC BG6a by approx. 20 mm
(see red line B in Figure 3.5). It is imperative you pay attention to the information
in Table 3.1 on the mounting distances.
2.
Mark out the position of the tapped holes on the backing plate.
Cut a thread for each xing screw in the backing plate.
Note the mounting distances. Also pay attention to the bending radius of the
connection cables. For dimensional drawings/hole spacing see Figure 3.6 and
Table 3.1.
3.
Mount the supply unit vertically and butt-mounted in a row on the backing plate.
The contact area must be bare metal.
Mechanical installation

Operation Manual ServoOne Supply Unit 19
ID no.: 1101.21B.6-00 Date:04/2020
A
B
C1
H1
H3
H
H2
C
T
D D
Figure 3.6 Dimensional drawing wall mounting housing variant BG5 + BG6a (symbolic depic-
tion)
EG F
F
Figure 3.7 Mounting distance wall mounting housing variant BG5 + BG6a (symbolic depiction)
3.3.1 Dimensions, wall mounting housing variant
Size BG5 BG6a
Device SO84.040.Sxxx.0
SO84.076.Sxxx.0
SO84.115.Sxxx.0
SO84.170.Sxxx.0
Weight [kg] 13 32
B (width) 190 280
H (height) 1) 345 540
T (depth) 1) 238 322
A 150 200
C 406.5 581
C1 6 10
H1 418.5 600
H2 15 20
H3 64 166
D 5.6 10
Fastening screws 4xM5 4xM8
EDirect butt mounting, max.
2mm
Direct butt mounting, max. 2mm
/ 40 2)
F 3) ≥180
G 3) ≥300 ≥500
All dimensions in mm,
1) Without terminals, connectors
2) Mounting distance BG6a to other BG6a
3) Also pay attention to the bending radius of the connection cables
Table 3.1 Dimensions, wall mounting housing variant
NOTE:
On butt mounting devices with different drive powers you should arrange the
devices in descending order by power rating (e.g., viewed from the left, BG4-
BG3-BG2-BG1). This arrangement will minimise the thermal interaction. The
supply unit must always be tted beside the axis controller with the highest
power.
Mechanical installation

Operation Manual ServoOne Supply Unit 20
ID no.: 1101.21B.6-00 Date:04/2020
ServoOne DC BG1 ServoOne DC BG2 ServoOne DC BG3 ServoOne DC BG4
ServoOne
Supply unit BG5
B
A
Figure 3.8 Butt mounting axis group with liquid cooling and supply unit BG5
ServoOne DC BG1 ServoOne DC BG2
ServoOne DC BG3 ServoOne DC BG4
ServoOne DC BG5
20 mm
ServoOne DC BG6a
with liquid cooling
ServoOne
Supply unit BG6a
with liquid cooling
B
A
Figure 3.9 Butt mounting axis group with liquid cooling and supply unit BG6a
3.4 Mounting supply unit,
liquid cooling housing variant
1.
Arrange the devices starting from the supply unit to the right (up to ServoOne
DC BG5) or left (from ServoOne DC BG6a) sorted in descending order by power
rating to minimise thermal interaction. Pay attention to the notes on effective EMC
installation prior to mounting the devices and components in the switch cabinet.
• AlignthesupplyunitBG5andallServoOneDCaxiscontrollersinalinealongthetopedge
ofthedevices(seelineAinFigure3.8).ThisactionisnecessarytobeabletosupplytheDC
powerusingthepre-assembledcables.
• AlignallServoOneDCaxiscontrollersandthesupplyunitBG6ainalinealongthetopedge
ofthedevices(seelineAinFigure3.9).MovedownthemountingboresforDCaxiscontroller
BG6aandthesupplyunitBG6byapprox.20mm(seeredlineBinFigure3.9).Thisactionis
necessarytobeabletomaketheDClinkconnections.
• AlignallServoOneDCaxiscontrollersandthesupplyunitBG7inalinealongthetopedge
ofthedevices(seelineAinFigure3.10).Movedownthemountingboresforthesupplyunit
BG7byapprox.28mmandfortheDCaxiscontrollerBG6abyapprox.20mm(seeredline
BinFigure3.10).Inaddition,adistanceof≥40mmmustbemaintainedattheside(inthe
guretotherightofthesupplyunitBG7).ThisactionisnecessarytobeabletomaketheDC
linkconnection.
2.
Mark out the position of the tapped holes and the pipe ttings on the backing plate.
Drill holes and cut a thread for each xing screw in the backing plate.
Note the mounting distances. Also pay attention to the bending radius of the
connection cables. For dimensional drawings/hole spacings see Figure 3.8 to
Figure 3.10 and Table 3.2.
3.
Mount the supply unit vertically and butt-mounted in a row on the backing plate.
The contact area must be bare metal.
4.
On screwing the hose connections (not included in the scope of supply) into the
pipe ttings, lock the pipe ttings using a 22mmopen-ended wrench to prevent
damage due to the application of torque to the device.
Pay attention to a perfectly sealed connection without leaks (e.g. using Teon
sealing tape).
You will nd further notes on the liquid cooling in chap.A.4, p.80.
Mechanical installation