Kollmorgen SILVERLINE S/O Series User manual

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Kollmorgen SILVERLINE®
S/O Manual
Kollmorgen SILVERLINE®Product Series
S/O Installation Manual
Old Number M-SL-000-H
New Number MSO000H
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Record of Manual Revisions
ISSUE NO.
DATE BRIEF DESCRIPTION OF REVISION
1 8/96 M96104 - Initial Product Launch
2 5/97 M96104 - Update of previous Issue
3 11/98 MSL000H - Model Number change and rearrangment of previous Issue. No content change
This document is proprietary information of Kollmorgen that is furnished for customer use ONLY. No other
uses are authorized without written permission of Kollmorgen. Information in this document is subject to
change without notice and does not represent a commitment on the part the Kollmorgen Corporation.
Therefore, information contained in this manual may be updated from time-to-time due to product
improvements, etc., and may not conform in every respect to former issues.
Copyright Information
Copyright 1998 Kollmorgen - All rights reserved.
Printed in the United States of America.
NOTICE:
Not for use or disclosure outside of Kollmorgen except under written agreement. All rights are reserved. No part
of this book shall be reproduced, stored in retrieval form, or transmitted by any means, electronic, mechanical,
photocopying, recording, or otherwise without the written permission from the publisher. While every
precaution has been taken in the preparation of the book, the publisher assumes no responsibility for errors or
omissions. Neither is any liability assumed for damages resulting from the use of the information contained
herein.
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Kollmorgen Table of Contents
SILVERLINE®Product Family i
Contents Overview
SECTION 1 GENERAL INFORMATION............................................................................................... 1-1
1.1 HOW TO USE MANUAL........................................................................................................................................1-1
1.2 WARRANTY INFORMATION................................................................................................................................1-1
1.3 CUSTOMER SUPPORT.........................................................................................................................................1-1
1.4 ABBREVIATIONS ................................................................................................................................................1-2
1.5 LIST OF FIGURES................................................................................................................................................1-3
SECTION 2 SYSTEM DESCRIPTION .................................................................................................... 2-1
2.1 INTRODUCTION ..................................................................................................................................................2-1
2.2 PART NUMBER DESCRIPTION..........................................................................................................................2-1
2.3 SYSTEM TOPICS.................................................................................................................................................2-3
SECTION 3 OUTLINE DRAWINGS........................................................................................................ 3-1
OUTLINE DRAWINGS................................................................................................................................................3-1
SECTION 4 MOUNTING AND WIRING................................................................................................ 4-1
4.1 INTRODUCTION..................................................................................................................................................4-1
4.2 SAFETY INFORMATION .......................................................................................................................................4-1
4.3 UNPACKING AND INSPECTION ...........................................................................................................................4-2
4.4 INSTALLATION REQUIREMENTS .........................................................................................................................4-2
4.5 MOUNTING ....................................................................................................................................................4-2
4.6 WIRING OVERVIEW.....................................................................................................................................4-3
4.7 WIRING GROUND AND BUS.........................................................................................................................4-3
4.8 WIRING THE ENCODER ......................................................................................................................................4-5
4.9 WIRING THE AMPLIFIER.................................................................................................................................4-6
SECTION 5 COMMISSIONING............................................................................................................... 5-1
5.1 START UP AND CHECK OUT......................................................................................................................5-1
5.2 STABILITY AND PERFORMANCE................................................................................................................5-6
5.3 CURRENT LOOP TUNING..........................................................................................................................5-10
5.4 PROBLEMS...................................................................................................................................................5-12
5.5 EMPIRICAL METHOD: PHASING NON-KOLLMORGEN MOTORS ..........................................................................5-14
SECTION 6 MAINTENANCE................................................................................................................... 6-1
6.1 INTRODUCTION..................................................................................................................................................6-1
6.2 SPARE PARTS.....................................................................................................................................................6-1
6.3 PREVENTATIVE MAINTENANCE .........................................................................................................................6-1
6.4 PERIODIC MAINTENANCE ..................................................................................................................................6-3
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Kollmorgen Table of Contents
SILVERLINE®Product Family ii
Table of Contents
SECTION 1 GENERAL INFORMATION............................................................................................... 1-1
1.1 HOW TO USE MANUAL........................................................................................................................................1-1
1.2 WARRANTY INFORMATION................................................................................................................................1-1
1.3 CUSTOMER SUPPORT.........................................................................................................................................1-1
1.4 ABBREVIATIONS ................................................................................................................................................1-2
1.5 LIST OF FIGURES................................................................................................................................................1-3
SECTION 2 SYSTEM DESCRIPTION .................................................................................................... 2-1
2.1 INTRODUCTION ..................................................................................................................................................2-1
2.2 PART NUMBER DESCRIPTION..........................................................................................................................2-1
Current Loop ..................................................................................................................................................... 2-2
2.2.1 S/O Model Number................................................................................................................................... 2-2
2.2.2 SPS/R Model Number............................................................................................................................... 2-3
2.3 SYSTEM TOPICS.................................................................................................................................................2-3
2.3.1 Specifications and Ratings........................................................................................................................ 2-3
2.3.2 Physical Deminsions................................................................................................................................. 2-5
2.3.2 Current Control Wiring Diagram............................................................................................................. 2-6
2.3.3 Velocity Control Wiring Diagram ............................................................................................................ 2-7
SECTION 3 OUTLINE DRAWINGS........................................................................................................ 3-1
OUTLINE DRAWINGS................................................................................................................................................3-1
SECTION 4 MOUNTING AND WIRING................................................................................................ 4-1
4.1 INTRODUCTION..................................................................................................................................................4-1
4.2 SAFETY INFORMATION .......................................................................................................................................4-1
4.3 UNPACKING AND INSPECTION ...........................................................................................................................4-2
4.4 INSTALLATION REQUIREMENTS .........................................................................................................................4-2
4.4.1 Environmental Considerations................................................................................................................. 4-2
4.4.2 Ventilation ................................................................................................................................................ 4-2
4.5 MOUNTING ....................................................................................................................................................4-2
4.5.1 Mounting the SPS/R.................................................................................................................................. 4-2
4.5.2 Mounting S/O Units on an SPS/R............................................................................................................. 4-3
4.5.3 Mounting S/O Units without an SPS/R..................................................................................................... 4-3
4.6 WIRING OVERVIEW.....................................................................................................................................4-3
4.7 WIRING GROUND AND BUS.........................................................................................................................4-3
4.7.1 Wiring the Ground with an SPS/R............................................................................................................ 4-3
4.7.2 Providing the DC Bus............................................................................................................................... 4-3
4.7.2.1 Providing DC Bus Using an SPS/R.....................................................................................................................4-4
4.7.2.2 SPS/R Wire Preparation and Insertion .................................................................................................................4-4
4.7.2.3 Wiring SPS/R A/C Line .......................................................................................................................................4-4
4.7.2.4 Fusing...................................................................................................................................................................4-4
4.7.2.5 Motor Protection ..................................................................................................................................................4-4
4.8 WIRING THE ENCODER ......................................................................................................................................4-5
4.9 WIRING THE AMPLIFIER.................................................................................................................................4-6
4.9.1 Strain Relief.............................................................................................................................................. 4-6
4.9.2 Wiring J1, BUS Power and Motor Leads ................................................................................................. 4-6
4.9.2.1 Wiring Bus Leads.................................................................................................................................................4-6
4.9.2.2 Wiring Motor Leads for Kollmorgen BLDC Motors............................................................................................4-7
4.9.2.3 Wiring Motor Leads for Kollmorgen VMG Motors.............................................................................................4-7
4.9.2.4 Wiring Motor Leads for Other BLDC Motors......................................................................................................4-7
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Kollmorgen Table of Contents
SILVERLINE®Product Family iii
4.9.4.4 Wiring Motor Leads for Brush Motors.................................................................................................................4-8
4.9.5 Installing J2, 120
°
Commutation.............................................................................................................. 4-8
4.9.6 Installing RLin J4..................................................................................................................................... 4-9
4.9.7 Installing J5, Current-Loop Mode Select ............................................................................................... 4-10
4.9.8 Wiring J6, Amplifier Status and Control................................................................................................ 4-10
4.9.8.1 AMP OK Output ................................................................................................................................................4-10
4.9.8.2 ANALOG-CMD Input (non-Velocity Loop Only).............................................................................................4-11
4.9.8.3 ENABLE Input...................................................................................................................................................4-11
4.9.9 Wiring J7, Hall Sensors Input ................................................................................................................ 4-11
4.9.10 Wiring JB1, Bus Power Out.................................................................................................................. 4-12
4.9.11 Wiring JL1, Logic Out.......................................................................................................................... 4-12
4.9.12 Wiring J200, Power (Velocity Loop Only) ........................................................................................... 4-13
4.9.13 Wiring J201, Control (Velocity Loop Only) ......................................................................................... 4-13
4.9.14 Wiring J203 and 204, Feedback Encoder (Velocity Loop Only).......................................................... 4-13
4.9.15 Wiring J205,
±
15V Input (Velocity Loop Only).................................................................................... 4-14
SECTION 5 COMMISSIONING............................................................................................................... 5-1
5.1 START UP AND CHECK OUT......................................................................................................................5-1
5.1.2 Start up the Current Controller................................................................................................................ 5-1
5.1.2.1 Apply Power and Enable......................................................................................................................................5-1
5.1.2.2 Running the Motor ...............................................................................................................................................5-2
5.1.2.3 Offset Adjustment.................................................................................................................................................5-2
5.1.2.4 Command Scaling Adjustment.............................................................................................................................5-2
5.1.2.5 Improving Current Loop Performance..................................................................................................................5-2
5.1.2.6 LEDs.....................................................................................................................................................................5-3
5.1.2.7 Faults....................................................................................................................................................................5-3
5.1.3 Start up the Velocity Controller................................................................................................................ 5-3
5.1.3.1 Check-out the Encoder .........................................................................................................................................5-3
5.1.3.2 S1 DIP Switch Settings ........................................................................................................................................5-4
5.1.3.3 S2 DIP Switch Settings ........................................................................................................................................5-4
5.1.4 Velocity Loop Tuning................................................................................................................................ 5-5
5.1.4.1 Setting Velocity Loop Gain..................................................................................................................................5-5
5.1.4.2 Detuning the Velocity Loop ................................................................................................................................5-6
5.1.4.3 Checking the Velocity Loop Response.................................................................................................................5-6
5.1.4.4 Setting Velocity Offset .........................................................................................................................................5-6
5.1.4.5 Check Velocity Command Scaling.......................................................................................................................5-6
5.2 STABILITY AND PERFORMANCE................................................................................................................5-6
5.2.1 Critical Damping...................................................................................................................................... 5-9
5.2.1 Underdamping.......................................................................................................................................... 5-9
5.2.2 Overdamping............................................................................................................................................ 5-9
5.2.3 Ringing ................................................................................................................................................... 5-10
5.3 CURRENT LOOP TUNING..........................................................................................................................5-10
5.3.1 Theory of Operation ............................................................................................................................... 5-10
5.3.1.1 The Frequency Domain ......................................................................................................................................5-11
5.3.2 Measurement and Control...................................................................................................................... 5-11
5.3.3 Current-Loop Model............................................................................................................................... 5-11
5.4 PROBLEMS...................................................................................................................................................5-12
5.4.1 Compliance............................................................................................................................................. 5-12
5.4.2 Non-Linearities....................................................................................................................................... 5-13
5.4.3 Resonance............................................................................................................................................... 5-13
5.5 EMPIRICAL METHOD: PHASING NON-KOLLMORGEN MOTORS ..........................................................................5-14
SECTION 6 MAINTENANCE................................................................................................................... 6-1
6.1 INTRODUCTION..................................................................................................................................................6-1
6.2 SPARE PARTS.....................................................................................................................................................6-1
6.2.1 S/O Spare Parts List ................................................................................................................................. 6-1
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Kollmorgen Table of Contents
SILVERLINE®Product Family iv
6.2.2 SPS/R Spare Parts List ............................................................................................................................. 6-1
6.2.3 Ordering Information ............................................................................................................................... 6-1
6.3 PREVENTATIVE MAINTENANCE .........................................................................................................................6-1
6.3.1 Transient Voltages.................................................................................................................................... 6-2
6.3.2 Electrical Noise ........................................................................................................................................ 6-2
6.3.3 Radio Frequency Energy.......................................................................................................................... 6-2
6.4 PERIODIC MAINTENANCE ..................................................................................................................................6-3
6.4.1 Grounding Integrity.................................................................................................................................. 6-3
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Kollmorgen Agency
SILVERLINE®Product Family v
Safety Instructions
Only qualified personnel are permitted to transport, assembly, commission, and maintenance this equipment.
Properly qualified personnel are persons who are familiar with the transport, assembly, installation, commissioning
and operation of motors, and who have the appropriate qualifications for their jobs. The qualified personnel must
know and observe the following standards and regulations:
IEC 364 resp. CENELEC HD 384 or DIN VDE 0100
IEC report 664 or DIN VDE 0110
National regulations for safety and accident prevention or VBG 4
• Read all available documentation before assembly and commissioning. Incorrect handling of products in this
manual can result in injury and damage to persons and machinery. Strictly adhere to the technical information on
the installation requirements.
• It is vital to ensure that all system components are connected to earth ground. Electrical safety is impossible
without a low-resistance earth connection.
• The Kollmorgen SILVERLINE product series contains electrostatically sensitive components which can be
damaged by incorrect handling. Discharge yourself before touching the product. Avoid contact with high
insulating materials (artificial fabrics, plastic film, etc.). Place the product on a conductive surface.
• During operation keep all covers and cabinet doors shut. Otherwise, there are deadly hazards that could
possibility cause severe damage to health or the product.
• In operation, depending on the degree of enclosure protection, the product can have bare components which are
live or have hot surfaces. Control and power cables can carry a high voltage even when the motor is not rotating.
• Never pull out or plug in the product while the system is live. There is a danger of electric arcing and danger to
persons and contacts.
• After powering down the product, wait at least 10 minutes before touching live sections of the equipment or
undoing connections (e.g. contacts, screwed connections). Capacitors can store dangerous voltages for long
periods of time after power has been switched off. To be safe, measure the contact points with a meter before
touching.
• The safety-alert symbols are illustrated as follows:
Safety-Alert Symbols
When these symbols are seen in this manual, be alert to the potential for personal injury. Follow the
recommended precautions and safe operating practices included with the alert symbols. Safety notices in this
manual provide important information. Read and be familiar with these instructions before attempting
installation, operation, or maintenance. The purpose of this section is to alert users to possible safety hazards
associated with this equipment and the precautions that need to be taken to reduce the risk of personal injury
and damage to the equipment. Failure to observe these precautions could result in serious bodily injury,
damage to the equipment, or operational difficulty.
"Warning" alerts users to potential danger or harm. Failure to follow warning notices could result in personal
injury or death.
CAUTION WARNING NOTE
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Kollmorgen Agency
SILVERLINE®Product Family vi
"Caution" directs attention to general precautions, which if not followed, could result in personal injury and/or
equipment damage.
"Note" highlights information critical to the users understanding or use of these products.
Directives and Standards
The product has not be tested for any UL or European CE standards.
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Kollmorgen General Information
SERVOSTAR®Product Family 1-1
Section 1 General Information
1.1 HOW TO USE MANUAL
This manual is designed to lead the user through proper installation, setup, and understanding of a SERVOSTAR®
servo system. The user does not have to be an expect in motion control to install and operate. The manual was
developed with the assumption that there is a fundamental understanding of basic electronics, computers, mechanics,
and proper safety practices. It is recommended that the entire manual be read completely before installation and
operation is attempted.
The layout of material in this manual is designed to guide the user through the following process:
• Product description and features (Section 2)
• System hardware installation (Section 3)
• System startup through a host communicator (Section 4)
• The system’s various modes of operation (Section 5)
• System troubleshooting and customer support (Section 6)
Included along with this hardcopy installation portion is a Quick Reference Guide (QRG) and two floppy disks. The
QRG provides information on the Variable and Command set. An 8½ x 11 electronic copy in .PDF format of the
QRG is provide on disk 2 of 2 for easy notebook insertion. The floppy disks contain the MotionLink®software
program and other SERVOSTAR®technical information and theory in PDF format.
1.2 WARRANTY INFORMATION
All products covered in this manual are warranted to be free of defects in material and workmanship and to conform
to the specifications stated either in this document or a product catalog description. All Kollmorgen brushless motors
and electronics are warranty for a period of 24 months from the time of installation or 30 months from time of
shipment, which ever comes first. There are no other warranties, expressed or implied (including the warranty of
merchantability and fitness for a particular purpose, which extend beyond this warranty. Kollmorgen warrants that
the products covered in the manual are free from patent infringement when used for normal purposes.
1.3 CUSTOMER SUPPORT
Kollmorgen is committed to quality customer service. Our goal is to provide the customer with information and
resources as soon as they are needed. In order to serve our customers the most effective way, Kollmorgen offers a
one-stop service center to answer all our customer’s product needs. This one number provides order status and
delivery information, product information and literature, and application and field technical assistance:
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