Kollmorgen Seidel 60WKS Series User manual

Analog Servo Amplifier
Series 60WKS
Assembly / Installation / Commissioning
Edition 12/99

Technical changes to improve the performance of the equipment
may be made without prior notice !
Printed in the Federal Republic of Germany 12/99
Mat.No. 67769
All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, mi-
crofilm or any other method) or stored, processed, copied or distributed by electronic means, without the
written permission of Seidel Corporation.
Previous editions
Edition Comments
10 / 87 First edition
12 / 87 Corrections
03 / 89 Corrections
08 / 89 New layout, completely produced with DTP, significant additions for Installation etc.
11 / 90 New layout, corrections, transformer specification added
04 / 92 Corrections
01 / 93 Improvements
06 / 94 Corrections
11/96 Corrections, CE-conform wiring diagrams, glossary, index, fault-finding, layout, new arrangement,
valid for 60WKS amplifiers from serial number 0600270000
10 / 97 Seidel Servo Drives GmbH
12 / 99 KMS, Layout

Contents
Contents Page - A -
Kollmorgen 12.99 Series 60WKS
I General
I.1 Preface ......................................................................I-1
I.2 Prescribed usage of the servo amplifiers ............................................I-1
I.3 Abbreviations used in this manual..................................................I-2
I.4 Nameplate ....................................................................I-2
- A.4.028.6/10
I.5 Equipment description 60WKS ....................................................I-3
I.5.1 Function groups 60WKS ......................................................I-4
I.6 Block diagram .................................................................I-5
- E.4.927.1/5
I.7 Frontal view 60WKS ............................................................I-6
- E.4.927.4/18
I.8 Technical Data ................................................................I-7
I.8.1 Technical data for 60WKS-M240/xx-PB...........................................I-7
I.8.2 Permissible ambient conditions, ventilation, mounting position .........................I-8
I.8.3 Cable cross-sections .........................................................I-8
I.8.4 Fuse protection .............................................................I-8
I.9 Interference suppression.........................................................I-9
I.10 Ballast circuit ..................................................................I-9
II Installation and Commissioning
II.1 Important instructions ...........................................................II-1
II.2 Installation ...................................................................II-2
II.2.1 - correct wiring for 60WKS, general diagram ...................................II-4
- E.4.927.1/27
II.2.2 Module backplanes F60WKSMB and R60WKSMB .................................II-5
II.2.2.1 Connector assignments for R60WKSMB ....................................II-5
II.2.2.2 Connector assignments for F60WKSMB ....................................II-6
II.3 Wiring diagrams ...............................................................II-7
II.3.1 Recommended wiring (power) for more than one compact housing ....................II-7
- E.4.927.1/8
II.3.2 Motor connection............................................................II-8
- E.4.927.1/14
II.3.3 Wiring diagram for 60WKS ....................................................II-9
- E.4.927.1/15
II.3.4 Recommended wiring for 2x60WKS with SM56 ... SM100 ..........................II-10
- E.4.927.1/4
II.3.5 Recommended wiring for soft start and brake ....................................II-11
- E.4.916.1/a
II.3.6 Schematic representation of the GND and PE connections ..........................II-12
- A.4.029.1/5
II.4 Commissioning...............................................................II-13
II.4.1 Important notes ............................................................II-13
II.4.2 Notes on commissioning.....................................................II-14
Contents Diagram Page
Contents ...............................................A
Safety instructions ........................................D
Directives and standards ....................................E
- conformance .........................................E

Contents
Page - B - Contents
Series 60WKS 12.99 Kollmorgen
III Functions and Options
III.1 Important notes ...............................................................III-1
III.2 Description of the functions ......................................................III-1
III.2.1 Input functions .............................................................III-1
III.2.1.1 Setpoint inputs SW1, SW2...............................................III-1
III.2.1.2 Tachometer input Ta ...................................................III-1
III.2.1.3 Digital control inputs....................................................III-2
III.2.2 Output functions ............................................................III-3
III.2.2.1 Armature current monitor output IDC, terminal 19 .............................III-3
III.2.2.2 Tachometer monitor output VTA, terminal 23 ................................III-3
III.2.2.3 Ready/standby contact BTB .............................................III-3
III.2.2.4 Measurement points ...................................................III-3
III.2.3 Setting functions............................................................III-4
III.2.3.1 Ramp potentiometer P301 ...............................................III-4
III.2.3.2 Setpoint potentiometer P302 .............................................III-4
III.2.3.3 Offset potentiometer P303 ...............................................III-4
III.2.3.4 Tacho potentiometer P304, tacho adjustment R310 ...........................III-4
III.2.3.5 AC-gain potentiometer P305 .............................................III-5
III.2.3.6 Peak current IPEAK, P306................................................III-5
- E.4.927.4/7
III.2.3.7 Effective current IRMS, I²t limit, P307 .......................................III-6
III.2.4 Other functions .............................................................III-6
III.2.4.1 Frequency response of the servo amplifier ..................................III-6
III.2.4.2 I²t monitoring .........................................................III-6
III.2.4.3 Displays .............................................................III-7
- E.4.927.3/1
III.3 Options .....................................................................III-8
III.3.1 Option board -01- ...........................................................III-8
III.3.1.1 Ramp generator, RAMP.................................................III-8
III.3.1.2 1:1 control ...........................................................III-8
III.3.1.3 Limit switch PSTOP, NSTOP .............................................III-8
III.3.1.4 Option board -01- , mounting position and component layout ...................III-9
- E.4.927.2/12
III.3.2 Option -24V-, external 24 V auxiliary voltage ....................................III-10
III.4 Solder links .................................................................III-10
III.4.1 Digital-GND, Analog-GND, LB2 ...............................................III-10
III.4.2 Option board -01-, LB3......................................................III-10
III.4.3 DC tacho [LB10, 11, 12, 13]..................................................III-10
III.4.4 Other solder links ..........................................................III-11
III.4.5 Layout of the solder links, motherboard 60WKS ..................................III-11
-E.4.927.4/19
Contents Diagram Page

Contents
Contents Page - C -
Kollmorgen 12.99 Series 60WKS
IV Peripheral equipment
IV.1 Isolation transformers ..........................................................IV-1
IV.1.1 Dimensions and connections of the isolation transformers ...........................IV-2
- E.4.927.4/1
IV.2 Mains filter...................................................................IV-3
IV.2.1 Dimensions and connections of the mains filter ...................................IV-3
- A.4.011.4/26
IV.3 Power supply unit 56WK-P240/80-B...............................................IV-4
IV.3.1 PSU description 56WK-P.....................................................IV-4
IV.3.2 Technical Data 56WK-P .....................................................IV-5
IV.3.3 Power supply backplane N56WKMB/RN56WKMB .................................IV-6
IV.3.4 Ballast resistor BAR375 ......................................................IV-6
- E.4.906.4/3
IV.3.5 Component layout diagram 56WK-P ............................................IV-7
- E.4.906.2/1
V Drawings
V.1 Wiring example: multi-axis system with power supply ..................................V-1
- A.4.029.1/11
V.2 Speed control loop 60WS .......................................................V-2
- E.4.927.1/7
V.3 RLG-/TA input circuits for 60WKS ................................................V-3
- E.4.927.1/6
V.4 Illustration of K1.1-L with 60WKS .................................................V-4
- E.4.925.4/26
V.5 Frontal view and pin assignments for K1.1-L with 60WKS ..............................V-5
- E.4.927.4/3
V.6 19"-rack module 84TE with 9x60WKS..............................................V-6
- E.4.925.4/23
V.7 Backplanes F/R60WKSMB, N/RN56WKMB .........................................V-7
- E.4.927.4/20
V.8 Custom p.c.b. 60WKS, form .....................................................V-8
- E.4.930.2/0
VI Appendix
VI.1 Delivery package, transport, storage, maintenance, disposal ...........................VI-1
VI.2 Fault-finding .................................................................VI-2
VI.3 Glossary ....................................................................VI-3
VI.4 Index ......................................................................VI-4
Contents Diagram Page

Safety instructions
Page - D - Safety instructions
Series 60WKS 12.99 Kollmorgen
Safety instructions
Warning signs : you must observe the important instructions in the text,
which are indicated by the following symbols :
hazard from electricity general warning
and its effects general instructions
uOnly properly qualified personnel are permitted to perform activities such
as transport, installation, commissioning and maintenance. Properly
qualified persons are those who are familiar with the transport, assembly,
installation, commissioning and operation of the product and who have the
appropriate qualifications for their job. The qualified personnel must know
and observe the following standards and directives:
IEC 364 and CENELEC HD 384 or DIN VDE 0100
IEC-Report 664 or DIN VDE 0110
national accident prevention regulations or VBG 4
uRead the available documentation before carrying out installation and
commissioning. Incorrect handling of the servo amplifier can lead to injury
to persons or material damage.
It is vital that you keep to the technical data and information on installation
requirements (nameplate and documentation).
uThe servo amplifiers contain electrostatically sensitive components which
can be damaged by incorrect handling. Discharge yourself before touching
the servo amplifier. Avoid contact with highly insulating materials (artificial
fabrics, plastic film etc.). Place the servo amplifier on a conductive surface.
uDuring operation, keep all covers and cabinet doors shut. Otherwise there
are deadly hazards with the possibility of severe danger to health or
material damage.
uIn operation, depending on the degree of enclosure protection, servo
amplifiers can have bare components which are live, and hot surfaces.
Control and power cables can carry a high voltage even when the motor is
not rotating.
uNever pull out or plug in the servo amplifier while the system is live. There
is a danger of electric arcing and danger to persons and contacts.
uAfter disconnecting the servo amplifier, wait at least two minutes before
touching live sections of the equipment or undoing connections (e.g.
contacts, screwed connections). Capacitors can still carry dangerous
voltages after the supply voltage has been switched off. To be safe,
measure the DC-link voltage, and wait until it has fallen below 40 V.

Directives and standards / CE-conformance
Directives and standards / CE-conformance Page - E -
Kollmorgen 12.99 Series 60WKS
Directives and standards
Servo amplifiers are components which are intended to be incorporated into electrical machines
and plant.
When the servo amplifiers are built into machines or plant, the intended operation is forbidden
until it has been shown that the machine or plant fulfills the requirements of the EC Directive on
Machines (89/392/EEC), the EC Directive on EMC (89/336/EEC) and the EC Low-Voltage
Directive (73/23/EEC). EN 60204 and EN 292 must also be observed.
In connection with the Low-Voltage Directive 73/23/EEC, the harmonized standards of the
EN 50178 series are applied to the servo amplifiers, together with EN 60439-1, EN 60146 and
EN 60204.
The manufacturer of the plant or machine is responsible for ensuring that the plant or machine
meets the limits which are laid down in the EMC regulations. Advice on the correct installation for
EMC – such as shielding, grounding, filter arrangement, treatment of connectors and cable layout
– can be found in this documentation.
- Conformance
Conformance to the following directives is mandatory for the supply of servo amplifiers within the
European Community:
since 1 January 1996 : EC EMC Directive 89/336/EEC
since 1 January 1997 : EC Low-Voltage Directive 73/23/EEC
The servo amplifiers have been tested in an authorised testing laboratory, in a defined
configuration with the components shown in Chapter II.
Any divergence from the assembly and installation described in the documentation means that
you will be responsible for the performance of new measurements to ensure that the regulatory
requirements are met.

This page has been deliberately left blank.
Page - F - Directives and standards / CE-conformance
Series 60WKS 12.99 Kollmorgen

I General
I.1 Preface
This manual describes the installation, commissioning, adjustment and adaptation of the
60WKS-M240/xx-PB (abbeviated 60WKS) servo amplifiers.
The manual is divided into 6 chapters :
Chapter 1: General Information
Chapter 2: Installation and Commissioning
Chapter 3: Functions and Options
Chapter 4: Peripheral Equipment
Chapter 5: Drawings
Chapter 6: Appendix with Glossary, Index and Fault-Finding
We offer training and familiarisation courses on request.
I.2 Prescribed usage of the servo amplifiers
The servo amplifiers are exclusively intended for driving brushless synchronous servo motors
from the SM series under speed or torque control. The servo amplifiers are installed as compo-
nents in electrical equipment or machines, and may only be operated as integral components of
such equipment.
The 60WKS-M240/xx-PB series of servo amplifiers are supplied from the industrial 3-phase
mains supply, via an isolating transformer. This isolating transformer must meet the specifica-
tion in Chapter IV.1.
The servo amplifiers may only be operated in a closed steel switchgear cabinet, observing the
ambient conditions defined in Chapter I.8.2. The notes on the ventilation of the servo amplifers
are especially important.
The equipment must be plugged into a standard industrial 19"-casing (rack module) or into one
of our compact housings, and connections must only be made via on of our module backplanes.
In accordance with the EC Directives on machines and the safety regulations, you must prepare
a hazard analysis of the machine.
Chapter I General Page I - 1
Kollmorgen 12.99 Series 60WKS
Transport : only by personnel with knowledge of the handling of
electrostatically-sensitive components
Installation : only by electrically qualified personnel
Commissioning : only by qualified personnel with extensive knowledge of
electrical engineering and drive technology
We can only guarantee the functionality of the servo amplifier and servo motor if
SM-series motors and our isolating transformers and accessories are used.
Only if the system components which are described in Chapter II are used, and the rules
for installation in this documentation are followed, can we guarantee the conformance of
the servo amplifiers with the following standards for industrial areas:
EC EMC Directive 89/336/EWG
EC Low-Voltage Directive 73/23/EWG

I.3 Abbreviations used in this manual
The abbreviations used in this manual are explained in the table below.
Abbrev. Meaning Abbrev. Meaning
AGND analog ground PELV protected low voltage
EMC electromagnetic compatibility PLC programmable logic controller
BTB system ready to operate PSTOP limit switch for CW rotation
PSU Power supply unit
CE European Community PWM pulse-width modulation
DIN Deutsches Institut für Normung RBallast ballast resistor
DGND digital ground RLG rotor position sensor
EN European standard SW setpoint
ESD electrostatic discharge V AC AC voltage
IDC analog current monitor V DC DC voltage
LED light-emitting diode VDE Verein deutscher Elektrotechniker
NSTOP limit switch for CCW rotation VTA analog speed monitor
I.4 Nameplate
The nameplate depicted below is mounted on the servo amplifier. The information shown below
is printed in the individual fields. - A.4.028.6/10
Page I - 2 General Chapter I
Series 60WKS 12.99 - A.4.028.6/10 Kollmorgen
Custom p.c.b. and
options
Serial numberServo amplifier type
Mains power supply
installed load Nominal current Protection class

I.5 Equipment description 60WKS
Design
Plug-in modules with an aluminium front panel, 19"-system, connections via module backplane
Unit size
Unit Format Height Width
60WKS (servo amp.) double Eurocard 6HE (233.4 mm) 9 TE (approx. 61 mm)
Options
-24V- electronics supply from external 24 V supply
-01- limit-switch logic, 1:1-control and ramp generator
Function
The 60WKS series of servo amplifiers in 240 V technology are set up for driving the SM series of
synchronous servo motors with RLG/tacho-feedback and trapezoidal commutation. The power
section is implemented as a 3-phase, pulse-width modulated transistor stage.
The motor speed and the trapezoidal output currents are controlled by PI-controllers. The pha-
se-switching of the motor and tacho windings are controlled by the electronic rotor-position sensor
(RLG) of the motor.
Custom p.c.b.
All the adjustment and parameters which can be altered by the user are put onto a plug-in custom
p.c.b. and are accessible from the front.
The potentiometers which are provided as standard can be replaced by fixed resistors for series
production.
Variants
Amplifier 60WKS-CE240/xx-PB: - power feed via 3-phase isolating transformer
- PSU, ballast circuit and ballast resistor are integrated.
Accessories
Isolating transformers : Type 3TxxK-240 (see Chapter IV)
F-backplanes : Unit connections on the rear face: via plug-in terminals for the
control signals and terminals/studs for the power connections
R-backplanes : Unit connections: plug-in terminals, accessible from the front, for
control signals and terminals/studs for the power connections
19"-rack modules : 19"-base units in various widths, with assembled F- or
R-backplanes (example 84TE, see Chapter V.6)
Compact housing : Type K1.1-L with fan and R-backplane (see Chapter V.4/5)
Chapter I General Page I - 3
Kollmorgen 12.99 Series 60WKS
The following servo amplifiers must be operated with forced ventilation :
— all 60WKS servo amplifiers with a rated output current of 12 A and above
— all 60WKS servo amplifiers with Option -24V-
— all 60WKS servo amplifiers in an ambient temperature > 40 °C
The ventilation is necessary as soon as the DC-link voltage, or even just the 24 V
auxiliary supply, is switched on, i.e. even if the servo amplifier is unloaded or
disabled.

I.5.1 Function groups 60WKS
n3-phase power supply unit with smoothing capacitors
nBallast circuit with -w- characteristic
nAuxiliary supply, to generate the auxiliary voltages from the DC-link voltage
(alternatively, an external 24V-supply, Option -24V-)
n3-phase output stage for 4-Q operation
n2 differential inputs for setpoints, setpoint 2 is adjustable
nEnable-input
nLimit-switch inputs (Option -01-)
nPI / current / speed controller
nTrimmer potentiometer and fixed components for all the important operating parameters
– on the plug-in custom p.c.b.
nExpansion slot for Option p.c.b. -01- with limit-switch logic and ramp generator
nInput for 3-phase, brushless or DC-tacho
nInput for rotor position sensor (RLG)
nReady/standby relay with isolated contact for fault signalling
n24 V logic with isolated optocouplers for control signals, PLC-compatible
nLEDs for all important operating states
n±15 V auxiliary voltage outputs
Protection and monitoring functions
nFuses for the DC-link and auxiliary power supply
nShort-circuit / earth-fault protection at the motor connection terminals
nShort-circuit protection of the 15 V auxiliary supply
nUndervoltage monitoring
nOvervoltage monitoring
nI²t effective current monitoring
nTemperature monitoring of the power output transistors
nRLG- and Tacho monitoring (cable break)
Page I - 4 General Chapter I
Series 60WKS 12.99 Kollmorgen

I.6 Block diagram - E.4.927.1/5
Chapter I General Page I - 5
Kollmorgen 12.99 - E.4.927.1/5 Series 60WKS

I.7 Frontal view 60WKS - E.4.927.4/18
Page I - 6 General Chapter I
Series 60WKS 12.99 - E.4.927.4/18 Kollmorgen

I.8 Technical Data
I.8.1 Technical data for 60WKS-M240/xx-PB
Transistorized inverter 60WKS-M240/
Rated data DIM 3-PB 6-PB 12-PB 22-PB 26-PB
Rated supply voltage V~ 3 x 60—172 / 50 ... 60Hz +max. 10%
Installed load at rated current * kVA 0.5 1 2 3.7 4.4
rated DC-link voltage V= 240
Rated output current for 4-Q operation,
peak value at standstill A36122226
Peak output current (max. approx. 5 s) A 7.5 15 30 50 50
AC fusing, maximum AM 3 x 20
Switch-on threshold of the ballast circuit V 300
Switch-off threshold of the ballast circuit V 285
Pulse power of the ballast circuit kW 5.4
Continuous power of the ballast circuit W 135
Overvoltage switch-off threshold V 325
Form-factor of the output current
(rated conditions, with min. load inductance) — 1.01
Minimum motor inductance mH 5 2.5 1.2 0.7 0.6
Bandwidth of the subordinate current control loop kHz 1
Clock frequency of the output stage kHz (2x) 8.5
Voltage drop at rated current V 5
Quiescent dissipation, output stage disabled W 12
Dissipation at rated current (incl. PSU losses,
without ballast dissipation) W 30 45 85 140 170
Aux. voltage outputs (Ri=330 W)V ±15
mA ±20
Aux. voltage outputs for RLG/Tacho V ±15
mA ±30
Inputs
Setpoint 1, fixed setting V ±10
Setpoint 2, adjustable 0 — 100 % V ±10
Common-mode voltage max. V ±10
Input resistance kW150
Input drift max. mV/K ±15
24 V auxiliary supply(Option-24V-) V 24 (20 ... 30)
referred to 0V/GND A 0.5
Connections
Servo amplifier control signals DIN 41612—C64 (plug connector)
power signals DIN 41612—D32 (plug connector)
Backplane board RLG/tacho SubD 9-pin (socket)
control signals Combicon 5.08/20-pin (or 2x12-pin)
power signals 4 mm² terminals
Mechanical
Weight kg 1.4
Dimensions (double Eurocard, 9 TE-units) mm 220 x 233.4 x 45
* maximum value in operation with SM-series motors
Chapter I General Page I - 7
Kollmorgen 12.99 Series 60WKS

I.8.2 Permissible ambient conditions, ventilation, mounting position
Transport temperature/humidity see Chapter VI.1
Storage temp./humidity/time see Chapter VI.1
Supply voltage tolerances
mains power
aux. supply (Option -24V-)
min.3x60VAC/max.3x172VAC+10%
min. 20 V DC / max. 30 V DC referred to 0V/GND
Ambient temperature TAMB.
in operation
0 ... +45 °C at rated data
+45 ... +55 °C with power derating 2,5% / °C (forced ventilation)
Humidity in operation 5...85 % rel. Feuchte, nicht kondensierend
Site altitude up to 1000 m above mean sea level without restriction
1000 ... 2500 m a.m.s.l. with derating 1.5 % / 100m
Pollution level pollution level 2 to EN60204 / EN50178
Protection class IP 00 (protected against touching in the power connections area)
Mounting / position in a closed switchgear cabinet / normally vertical
Ventilation cont. current < 12A
and no Option -24V-
and TAMB. < 40°C
cont. current ³12A
or with Option -24V-
or TAMB. > 40°C
natural convection with uninterrupted air flow (we always
recommend forced ventilation at higher current or with cramped
mounting conditions.
forced ventilation
Ensure that there is an adequate volume of cooling air entering
the switching cabinet, and that it is as dust-free as possible.
I.8.3 Cable cross-sections
In accordance with EN 60204 and taking account of the operating conditions for multi-axis systems,
we recommend the following cable cross-sections:
Amplifier type 60WKS
Peak value Irated
Dimension
3/6A
[mm²]
12 A
[mm²]
22/26 A
[mm²]
AC supply 4i x 1.5 4i x 2.5 4i x 4
DC-link 3i x 1.5 3i x 2.5 3i x 4
Motor leads 4i x 1.5 4i x 2.5 4i x 4
RLG/tacho 6x2x0.25 (twisted pairs, shielded)
Setpoints 2 x 0.14 (stranded, shielded)
Control signals, BTB 0.5
Brake (motor) 2 x 1.0
Thermal cutout (motor) 2 x 0.5
+24 V / GND 1.0 (Option -24V-)
I.8.4 Fuse protection
60WKS 3 A 6 A 12 A 22 A 26 A
AC supply external power contactor for system protection, motor or transformer
characteristic, set to 0.5 X rated amplifier current
DC-link (F1) internal 10 AT 10 AT 15 AT 30 AT 30 AT
Aux. supply (F2) internal 1 AT (2AT with Option -24V-)
Ballast board (F3) internal 3.15 AT
Fan (V3,W3) compact housing - - 1 AT 1 AT 1 AT
Page I - 8 General Chapter I
Series 60WKS 12.99 Kollmorgen

I.9 Interference suppression
If interference occurs in the CNC or the analog or digital path measuring systems, the additional
measured listed here may be applied:
nadditional ferrite rings around the motor cables
ninstallation of armature chokes (please use the types supplied by us)
nHF filter in the setpoint output of the CNC (RC of 1 kW/10nF)
In each case, you will have to try out which measures suffice to eliminate the interference.
I.10 Ballast circuit
When the motor is braked, energy is fed back into the servo amplifier. This energy is dissipated
as heat in the ballast resistor. The ballast resistor is switched into action by the ballast circuit.
The response of the circuit begins at a DC-link voltage of 285 V, and is indicated by a blinking of
the internal yellow LED D83.
As the loading is repeated, the built-in -w- characteristic causes the threshold to rise to 300 V,
so that there is power-sharing between more than one module, if they are parallel-connected
on the same DC-bus.
You should make an estimate of the ballast power which is to be expected
– especially for single axes – from the known drive data.
For normal servo applications, the following method has proved to be good:
peak ballast circuit power peak power of all the amplif>×
1
3iers
å
continuous ballast circuit power . continuo>×003 us power of all motors
å
You can receive further help on calculating the required ballast power for your system from our
in-house applications department.
Chapter I General Page I - 9
Kollmorgen 12.99 Series 60WKS
The ventilation is necessary as soon as the DC-link voltage, or even just the 24 V auxi-
liary supply, is switched on, i.e. even if the servo amplifier is unloaded or disabled.
Permitted combinations of amplifier motherboarde / ballast board
Before swapping a ballast board, check the labelling on the board !
Amplifiers up to serial no. 0600269999 :
motherboard 60 PC 8802-010
ballast board 60 WK-BAL
Amplifiers from serial no. 0600270000 (with CE sign) :
motherboard E.F.927.5/2
ballast board E.F.927.5/3

This page has been deliberately left blank.
Page I - 10 General Chapter I
Series 60WKS 12.99 Kollmorgen

II Installation and Commissioning
II.1 Important instructions
nCheck the conformance of the servo amplifier and the motor. Compare the rated voltage
and current of the equipment. Implement the wiring according to the wiring diagram in
Chapter II.2.3 ff. For correct EMC wiring follow the connection diagrams in Chapter II.2.1.
nLay out all cables which carry a high current with an adequate cross-section in accordance
with EN 60204. A tabular summary of the recommended cross-sections can be
found in Chapter I.8.3.
nMake sure that, even under worst-case conditions, the rated voltage on the terminals U1,
V1, W1 resp. Ucc, 0V/GND is not exceeded by more than 10 %. An excessive voltage on
these terminals can cause destruction of the ballast circuit. We recommend using the upper
transformer tap.
nMake sure that the supply voltages and the ballast resistor are adequately protected by
fusing. Use the values recommended in Chapter I.8.4 as a guide.
nConnect all shielding with large areas (low impedance), using metallized connector hou-
sings where possible (see Chapter II.2.1).
nLoop the BTB contact into the safety circuit of the system. Only so can the monitoring of the
servo amplifier be assured.
nLoop the temperature monitoring of the motors into the safety circuit of the system.
Overheating of the motors can lead to their destruction.
nThe ±15V auxiliary voltages must not be brought out of the switchgear cabinet.
This is to prevent capacitively and/or inductively induced interference.
nEnsure that there is an adequate supply of filtered cooling air in the switchgear cabinet, fed
from below. Observe the rules for ventilation in Chapter I.8.2.
nAt the front of the modules, protection against contact is only assured if the modules are in-
serted into a 19"-rack unit and secured with the screws which are provided.
After inserting the modules, fix the front panel with the fixing screws. This is vital to ensure
good contact in the plug connectors. Poor contact can burn out the connector contacts.
Chapter II Installation and Commissioning Page II - 1
Kollmorgen 12.99 Series 60WKS
Caution
Never connect or remove the servo amplifier while it is live.
In unfavourable cases this could result in destruction of the electronics.
Residual charge in the capacitors can still have a dangerous level up to 120 seconds
after switching off. Measure the voltage in the DC-link circuit, and wait until the voltage
has dropped below 40 V.
Even when the motor is at standstill, control and power leads can still be live.

II.2 Installation
Only electrically qualified personnel are allowed to install the servo amplifier.
The installation procedure is described as an example. Depending on the application of the
equipment, a different procedure may be appropriate or necessary.
More detailed knowledge can be acquired through our training courses (on request).
Page II - 2 Installation and Commissioning Chapter II
Series 60WKS 12.99 Kollmorgen
Warning !
Protect the servo amplifier from inadmissable loading.
In particular, components must not be bent or isolation clearances altered
during transport and handling.
Avoid touching electronic components and contacts.
Caution !
Only install and wire up the equipment in a de-energized state,
i.e. neither the mains supply not the operating voltages of any other
connected equipment may be switched on.
Make sure that the switchgear cabinet is safely disconnected (safety
lock-out, warning signs etc.).
The individual voltages will only be switched on during commissioning.
Ground and PE-symbol
The ground symbol , which is found in all the wiring diagrams,
indicates that you must provide an electrically conductive connection
with as large an area as possible between the designated unit and the
mounting plate in your switchgear cabinet.
This connection is for the suppression of HF interference, and must not
be confused with the PE-symbol (which is a safety measure to EN 60204).
Grounding system and protective earth
Power and signal electronics have safely separate routing to EN 50178.
The DC-link circuit is grounded on one side, and supplied from the mains
via an isolation transformer with a screen winding.
The reference potentials 0V/GND/PE (DC-link) and AGND (control electro-
nics) are connected on the unit for functional reasons.
The central connection to the protective earth (PE) is made on the back-
plane.
The most favourable way of connecting the reference potentials for inter-
ference suppression is shown in Chapter II.3.6.