Kollmorgen SERVOSTAR 300 User manual

SERVOSTAR 300
Digital Servo Amplifier S300
Instructions Manual
Edition: May 2020
Translation of the original instructions.
Valid for Hardware Revision 04.20
For safe and proper use, follow
these instructions.
Keep them for future reference.

Record of Document Revisions:
Revision Rermarks
... Table with life cycle information of this document see (➜# 141)
04/2018 X1 connector (male->female), HR table updated, Wiki links migrated to KDN, ventilation corrected
11/2018 Layout of the warning notes updated, user expertise updated, new readers note on cover page
05/2020 Layout updated, chapter "Used Standards" removed, motor temperatur sensor generalized, chapter
normal operation added, RoHS,REACH, EAC, PROFINET expansion card
Hardware Revision (HR)
Hardware Rev. Firmware Rev. Export Clas-
sification
Remarks
02.01 2.18 - 3.74 AL-3A225 Start HR
02.10 (03.01) 3.75 - 4.99 AL-3A225 AS->STO, new approval
04.00 5.18 - 5.99 AL-3A225 New CPU, front label S300
04.10 5.18_ND0 - 5.99_ND0 - New data structure
04.20 ≥ 6.00_ND0 - SFD3/DSL support
Trademarks
WINDOWS is a registered trademark of Microsoft Corp.
HIPERFACE is a registered trademark of Max Stegmann GmbH
SERCOS s a registered trademark of sercos® international e.V.
PROFIBUS and PROFINET are registered trademarks of PROFIBUS and PROFINET International (PI).
EnDat is a registered trademark of Dr. Johannes Heidenhain GmbH
EtherCAT is a registered trademark and patented technology, licensed by Beckhoff Automation GmbH.
Technical changes which improve the performance of the device may be made without prior notice!
This document is the intellectual property of Kollmorgen. All rights reserved. No part of this work may be reproduced
in any form (by photocopying, microfilm or any other method) or stored, processed, copied or distributed by electronic
means without the written permission of Kollmorgen.
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1 Table of Contents
1 Table of Contents 3
2 General 9
2.1 General 9
2.2 Using the PDF Format 9
2.3 Symbols Used 10
2.4 Abbreviations Used 11
3 Safety 12
3.1 You should pay attention to this 12
3.2 Warning notes placed on the product 14
3.3 Use as Directed 15
3.4 Prohibited Use 15
4 Product life cycle handling 16
4.1 Transport 16
4.2 Packaging 16
4.3 Storage 16
4.4 Installation, setup and normal operation 16
4.5 Decommissioning 17
4.6 Maintenance and cleaning 17
4.7 Disassembly 17
4.8 System Repair 18
4.9 Disposal 18
5 Approvals 19
5.1 Conformance with UL/cUL 19
5.2 Conformance with CE 20
5.2.1 European Directives and Standards for the machine builder 20
5.2.2 Functional Safety Conformance (STO) according to EC Machinery Directive 21
5.2.3 Conformance with RoHS 21
5.2.4 Conformance with REACH 21
5.3 Conformance with EAC 21
6 Package 22
6.1 Package Supplied 22
6.2 Nameplate 22
6.3 Part Number Scheme 23
7 Technical description 24
7.1 The SERVOSTAR 300 family of digital servo amplifiers 24
7.2 Technical Data 26
7.2.1 Technical Data 110 / 230 V (Types S3_ _6_) 26
7.2.2 Technical Data 230V ... 480 V (types S3_ _0_) 27
7.2.3 Inputs / outputs, Auxiliary voltage 28
7.2.4 Connectors 28
7.2.5 Recommended Tightening Torques 28
7.2.6 Fusing 28
7.2.7 Ambient Conditions, Ventilation and Mounting Position 29
7.2.8 Conductor cross-sections 29
7.3 Motor holding brake 30
7.4 LED display 31
7.5 Grounding system 31
7.6 Dynamic braking (brake circuit) 31
7.7 Switch-on and switch-off behavior 33
7.7.1 Behavior in standard operation 34
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7.7.2 Behavior in the event of an error (with standard setting) 35
7.8 Stop-, Emergency Stop-, Emergency Off Function to IEC 60204 36
7.8.1 Stop 36
7.8.2 Emergency Stop 37
7.8.3 Emergency Off 37
7.9 Safe Torque Off (STO) 38
7.9.1 Safety characteristic data 38
7.9.2 Safety Notes 39
7.9.3 Use as directed 40
7.9.4 Prohibited Use STO 40
7.9.5 Technical data and pinning 40
7.9.6 Enclosure 40
7.9.7 Wiring 40
7.9.8 Functional description 41
7.9.8.1 Safe operation sequence 41
7.9.8.2 Control circuit 42
7.9.8.3 Functional test 43
7.9.8.4 Mains supply circuit 43
7.10 Shock-hazard Protection 44
7.10.1 Leakage current 44
7.10.2 Residual current protective device (RCD) 44
7.10.3 Isolating transformers 44
8 Mechanical Installation 45
8.1 Important Notes 45
8.2 Guide to Mechanical Installation 45
8.3 Mounting 46
8.4 Dimensions 47
9 Electrical Installation 48
9.1 Important Notes 48
9.2 Guide to electrical installation 49
9.3 Wiring 50
9.3.1 Shielding connection to the front panel 51
9.3.2 Technical data for cables 52
9.4 Components of a servo system 53
9.5 Block diagram 54
9.6 Connector assignment 55
9.7 Connection overview 56
9.8 Voltage supply 58
9.8.1 Connection to various mains supply networks 58
9.8.2 24V auxiliary supply (X4) 59
9.8.3 Mains supply connection (X0), three phase 59
9.8.4 Mains supply connection (X0), two phase without neutral 59
9.8.5 Mains supply connection (X0), single phase with neutral 60
9.9 DC bus link (X8) 61
9.9.1 External brake resistor (X8) 61
9.9.2 Capacitor Module KCM (X8) 62
9.10 Motor power and motor holding brake connection (X9) 64
9.11 Feedback systems 65
9.12 Primary and secondary feedback types 66
9.12.1 SFD3 (X1), single cable connection 67
9.12.2 HIPERFACE DSL (X1), single cable connection 68
9.12.3 Resolver (X2) 69
9.12.4 Sine Encoder with BiSS analog (X1) 70
9.12.5 Encoder with BiSS digital (X1) 71
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9.12.6 Sine Encoder with EnDat 2.1 (X1) 72
9.12.7 Encoder with EnDat 2.2 (X1) 73
9.12.8 Sine Encoder with HIPERFACE (X1) 74
9.12.9 Sine Encoder with SSI (X5, X1) 75
9.12.10 Sine Encoder without data channel (X1) 76
9.12.11 Sine Encoder with Hall (X1) 77
9.12.12 ROD (AquadB) 5V, 1.5MHz (X1) 78
9.12.13 ROD (AquadB) 5V, 350kHz (X1) 79
9.12.14 ROD (AquadB) 5V, 350kHz with Hall (X1) 80
9.12.15 ROD (AquadB) 5V (X5, X1) 81
9.12.16 ROD (AquadB) 5V with Hall (X5, X1) 82
9.12.17 ROD (AquadB) 24V (X3) 83
9.12.18 ROD (AquadB) 24V with Hall (X3, X1) 84
9.12.19 SSI Encoder (X5, X1) 85
9.12.20 Hall sensors (X1) 86
9.13 Electronic Gearing, Master-Slave operation 87
9.13.1 Encoder control types 87
9.13.2 Connection to stepper motor controllers (step and direction) 88
9.13.2.1 Step / Direction with 5 V signal level (X1) 88
9.13.2.2 Step / Direction with 24 V signal level (X3) 88
9.13.2.3 Step / Direction with 5 V signal level (X5) 89
9.13.3 Anschluss für Master-Slave Betrieb 89
9.13.3.1 Master-Slave 5V (X1) 89
9.13.3.2 Master-Slave 5V (X5) 89
9.14 Encoder Emulation, position output 90
9.14.1 Incremental encoder output (AquadB) (X5) 90
9.14.2 SSI encoder output (X5) 91
9.15 Digital and analog inputs and outputs 92
9.15.1 Analog Inputs (X3) 92
9.15.2 Digital Inputs (X3/X4) 93
9.15.3 Digital Outputs (X3) 94
9.16 RS232 interface, PC connection (X6) 95
9.17 CAN-bus interface (X6) 96
10 Setup 97
10.1 Important Notes 97
10.2 Setup software 98
10.2.1 Use as directed 98
10.2.2 Software description 98
10.2.3 Hardware requirements, operating systems 99
10.2.4 Installation under WINDOWS 99
10.3 Quickstart, initial drive test 100
10.3.1 Preparation 100
10.3.2 Connect 102
10.3.3 Important Screen Elements 103
10.3.4 Setup Wizard 104
10.3.4.1 Basic Setup 104
10.3.4.2 Units/Mechanical 105
10.3.4.3 Motor (rotary) and Feedback 106
10.3.4.4 Motor (linear) / Feedback (Encoder) 106
10.3.4.5 Save Parameters and Restart 107
10.3.5 Motion Service (Jog Mode) 107
10.3.6 More Setup Screens 108
10.4 Multi axis system 109
10.5 Keypad operation and LED display 109
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10.5.1 Operation 110
10.5.2 Status display 110
10.5.3 Standard menu structure 110
10.5.4 Advanced menu structure 111
10.6 Error messages 112
10.7 Warning messages 113
10.8 Trouble shooting 114
11 Expansions 115
11.1 Guide to installation of expansion cards 115
11.2 Expansion card -I/O-14/08- 116
11.2.1 Technical data 116
11.2.2 LEDs 116
11.2.3 Entering a motion block number (example) 116
11.2.4 Connector assignments 117
11.2.5 Connection diagram (default) 118
11.3 Expansion card -PROFIBUS- 119
11.3.1 Connection technology 119
11.3.2 Connection diagram 119
11.4 Expansion card -SERCOS- 120
11.4.1 LEDs 120
11.4.2 Connection technology 120
11.4.3 Connection diagram 121
11.4.4 Setup 121
11.5 Expansion card - DEVICENET - 122
11.5.1 Connection technology 122
11.5.2 Connection diagram 122
11.5.3 Combined module status and network status LED 123
11.5.4 Setup 123
11.5.5 Bus cable 124
11.6 Expansion card -SYNQNET- 125
11.6.1 NODE ID Switch 125
11.6.2 NODE LED table 125
11.6.3 SynqNet Connection, Connector X21B / X21C (RJ-45) 125
11.6.4 Digital inputs and outputs, connector X21A (SubD 15-pin, socket) 126
11.6.5 Connection diagram digital inputs and outputs, connector X21A 126
11.7 Expansion card - FB-2to1 - 127
11.7.1 Pinout 127
11.7.2 Wiring example with BiSS digital (primary) and SinCos (secondary) 128
11.8 Expansion card -PROFINET- 129
11.8.1 Device master file 129
11.8.2 LED 129
11.8.3 Connection technology 129
11.8.4 Connection examples 130
11.9 Expansion module -2CAN- 131
11.9.1 Installation 131
11.9.2 Connection technology 131
11.9.3 Connector assignments 132
11.9.4 Setup of Station Address and Baud Rate 132
11.10 Option"EtherCAT" 133
11.10.1 NODE LED table 133
11.10.2 Connection diagram 133
11.11 Option "FAN", ventilator control 134
12 Appendix 135
12.1 Glossary 135
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12.2 Order codes 137
13 Index 139
14 Record of document revisions 141
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2 General
2.1 General
This manual describes the digital servo amplifiers of the SERVOSTAR 300 (S300, standard
version, 1.5 to 10 A nominal current).
A more detailed description of the expansion cards that are currently available and the digital
connection to automation systems can be found, together with our application notes, in
Acrobat-Reader format on the accompanying CD-ROM (system requirements:
WINDOWS, Internet Browser, Acrobat Reader) in different languages.
Technical data and dimensional drawings of accessories such as cables, brake resistors,
mains supplies, etc., can be found in the accessories manual.
This documentation (PDF) can be printed out on any standard commercial printer.
More background information can be found in our "Kollmorgen Developer Network" kdn.koll-
morgen.com.
2.2 Using the PDF Format
This document includes several features for ease of navigation
Cross References Table of contents and index include active cross references.
Table of contents and
index
Lines are active cross references. Click on the line and the appro-
priate page is accessed.
Page/chapter numbers
in the text
Page/chapter numbers with cross references are active links.
S300 Instructions Manual | 2 General
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S300 Instructions Manual | 2 General
2.3 Symbols Used
Warning Symbols
Symbol Indication
Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
Indicates a hazardous situation which, if not avoided, could res-
ult in death or serious injury.
Indicates a hazardous situation which, if not avoided, could res-
ult in minor or moderate injury.
Indicates situations which, if not avoided, could result in prop-
erty damage.
This symbol indicates important notes.
Warning of a danger (general). The type of danger is specified
by the text next to the symbol.
Warning of danger from electricity and its effects.
Warning of danger from hot surface.
Warning of danger from suspended loads.
Warning of danger from automatic start.
Drawing symbols
Symbol Description Symbol Description
Signal ground Diode
Chassis ground Relay
Protective earth Relay switch off delayed
Resistor Normally open contact
Fuse Normally closed contact
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