Kollmorgen SERVOSTAR CD Series User manual

KOLLMORGEN
www.DanaherMotion.com
NOTICE
DO NOT DISCARD
In a continuing effort to satisfy our customers, Danaher Motion has provided this packet of
instructions with your product. This information provides safety, warranty, and liability
information. This information enables you, the customer to get this unit up and running with
installation steps. Tuning information is contained in the technical manuals on this CD-ROM.
The software for this product is also contained on this CD-ROM. The included CD-ROM has all
the technical manuals in PDF format. For your convenience, Adobe®'s Acrobat Reader can also
be installed from this CD-ROM. Danaher Motion's technical documentation is subject to change
without notice. Be sure to check the website for the latest version (www.danahermotion.com).
Compare wiring diagrams to the latest version on the website to prevent damage to equipment.
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M-SS-017-07 Rev C 2SERVOSTAR CD
Table of Contents
SAFETY ...............................................................................................................................................3
DIRECTIVES AND STANDARDS ...........................................................................................................4
CE MARK CONFORMANCE ................................................................................................................4
UNPACKING AND INSPECTING ........................................................................................................5
GROUNDING......................................................................................................................................5
BONDING ..........................................................................................................................................5
CE FILTERING TECHNIQUES..............................................................................................................5
INPUT POWER FILTERING..................................................................................................................6
MOTOR LINE FILTERING ....................................................................................................................6
INSTALLATION ...................................................................................................................................7
WIRING ................................................................................................................................................8
OUTLINE DIMENSIONS.......................................................................................................................8
PA-LM UNITS ...................................................................................................................................8
CX SYSTEM WIRING DIAGRAM ..........................................................................................................9
CX FILTER AND BONDING DIAGRAM.................................................................................................10
SYSTEM FEEDBACK DIAGRAM .........................................................................................................11
PINOUT CONNECTORS.....................................................................................................................12
SERIAL COMMUNICATION WIRING DIAGRAM....................................................................................14
HARDWARE SPECIFICATIONS..........................................................................................................14
ELECTRICAL SPECIFICATIONS .........................................................................................................15
BUS MODULE ELECTRICAL SPECIFICATIONS...................................................................................16
REGEN INFORMATION......................................................................................................................16
PRODUCT FAMILY CONTROL SPECIFICATIONS.................................................................................17
FIRMWARE UPDATES ......................................................................................................................18
TROUBLESHOOTING.......................................................................................................................18
TROUBLESHOOTING TOOLS.............................................................................................................18
ERROR CODES ...............................................................................................................................18
ERROR CODES ...............................................................................................................................19
FATAL FAULT ERROR CODES ..........................................................................................................21
NON-FATAL ERROR CODES......................................................................................................22
NO MESSAGE FAULTS...............................................................................................................24
CUSTOMER SUPPORT......................................................................................................................24
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M-SS-017-07 Rev C 3SERVOSTAR CD
SAFETY
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 SERVOSTAR®product contains electro-statically sensitive components that 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 protectio
n, the product can have bare components
that 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 ten 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.
When the symbols below appear in this manual, be alert to the potential for personal injury and/or damage
to the equipment. 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
Potential physical danger or harm. Failure to follow warning notices could result in
personal injury or death.
CAUTION
General precautions, which if not followed, could result in personal injury and/or
equipment damage.
NOTE
Information critical to your understanding or use of the product.
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M-SS-017-07 Rev C 4SERVOSTAR CD
DIRECTIVES AND STANDARDS
The SERVOSTAR®CD product series have been successfully tested and evaluated to meet UL/cUL
508C for both U.S. and Canadian markets. This standard describes the fulfillment by design of minimum
requirements for electrically operated power conversion equipment, such as frequency converters and
servo amplifiers, which is intended to eliminate the risk of fire, electric shock, or injury to persons, being
caused by such equipment.
CE MARK CONFORMANCE
Servo drives are components that are intended to be incorporated into electrical plant and machines for
industrial use. When the servo drives are
built into machines or plants, drives cannot be operated until the
machine or plant fulfills the requirements of the EC Directive on Machines 89/392/EEC and the EC
Directive on EMC (89/336/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 amplifiers, together with EN 60439-1, EN 60146 and EN 60204.
The manufacturer of the machine or plant is responsible for ensuring that they meet the limits required by
the EMC regulations. Advice on the correct installation for EMC -such as shielding, grounding,
arrangement of filters, treatment of connectors and the laying out of cabling -can be found within this
documentation.
Conformance with the EC Directive on EMC 89/336/EEC and the Low Voltage Directive 73/23/EEC is
mandatory for the supply of servo drives within the European Community.
An authorized testing laboratory in a defined configuration with the system components has tested the
servo drives. Any divergence from the configuration and installation described in this documentation
means that you are responsible for the performance of new measurements to ensure that the regulatory
requirements are met.
Danaher Motion’s CD-Series drives and systems have been successfully tested and evaluated to the
limits and requirements of the EC Directive on EMC (89/336/EEC) and the EC Directive on Low Voltage
(72/73/EEC). The product lines have been evaluated to EN50178 and EN60204 as a component of a
machine and other relevant standards.
The EMC of a system can be identified by emissions and immunity. Emissions refer to the generation of
EMI (electromagnetic interference) and immunity refers to the susceptibility levels of the equipment.
Limits were derived from generic standards EN55081-2 and EN55082-2 for heavy industrial
environments. The SERVOSTAR CD series of drives and BUS Modules have been tested for radiated
emissions, conducted emissions, EFT, ESD, surge, conducted immunity, and radiated immunity. These
tests have been done in accordance with EN55011, EN61000-4-2, ENV50140, IEC 1000-4-4, EN61000-
4-5, and ENV50141.
CAUTION
Installation of the equipment is critical in designing for system and machine
electromagnetic compatibility (EMC). You must apply the installation recommendations
and the CE filtering Practices when mounting and installing the drive system for CE
conformance.
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M-SS-017-07 Rev C 5SERVOSTAR CD
UNPACKING AND INSPECTING
Open the box(es) and remove all the contents. Check to ensure there is no visible damage to any of the
equipment.
WARNING
Electronic components in this amplifier are design hardened to reduce static sensitivity.
However, proper procedures should be used when handling.
WARNING
Remove all packing material and equipment from the shipping container. Be aware that
some connector kits and other equipment pieces may be quite small and can be
accidentally discarded if care is not observed when unpacking the equipment. Do not
dispose of shipping materials until the packing list has been checked.
CAUTION
Upon receipt of the equipment, inspect components to ensure that no damage has
occurred in shipment. If damage is detected, notify the carrier immediately. Check all
shipping material for connector kits, manuals, diskettes, and other small pieces of
equipment.
GROUNDING
System grounding is essential for proper performance of the drive system. A ground bus bar may be used
as a single point ground for the system. Safety grounding should be provided to all pieces of the system
from a “star point." In addition to the safety grounding, a high frequency ground must be provided that
connects the back panel to the enclosure and, ultimately, to earth ground. The objective is to provide an
extremely low impedance path between the filters, drives, power supplies, and earth ground. This high
frequency ground is accomplished with the use of a flat braid or copper bus bar. It is important not to rely
on a standard wire for the high frequency ground. In general, a wire has an inductance of 8 nH-per-inch,
regardless of diameter. At higher frequencies, this unwanted inductance between grounds equates to
limited filter performance. When connecting high frequency grounds, use the shortest braid possible.
BONDING
The proper bonding of shielded cables is imperative for minimizing noise emissions and increasing
immunity levels of the drive system. Its effect is to reduce the impedance between the cable shield and
the back panel. Danaher Motion recommends that all shielded cables be bonded to the back panel.
Power input wiring does not require shielding (screening) if the power is fed to the cabinet (enclosure) via
metallized conduit. If the metallized conduit is used with proper high frequency grounds, bonding
technology, and recommended wire routing, then power input wire shielding has no affect. In the event
that metallized conduit is not implemented into the system, shielded cable is required on the power input
wires and proper bonding technologies should be implemented.
The motor and feedback cables should have the shield exposed as close to the drive as possible. This
exposed shield is bonded to the back panel using either non-insulated metallic cable clamps or cable
bonding clamps offered by Phoenix Contact (and others). Refer to the Installation Manual for details.
CE FILTERING TECHNIQUES
The SERVOSTAR®drive system (BUS Module, drive, motor) meets the CE Mark standards stated in the
front of this manual. It is imperative for you to apply proper bonding and grounding techniques, described
earlier in this section, when incorporating EMC noise filtering components for the purpose of meeting this
standard.
Noise currents often occur in two types. The first is conducted emissions that are passed through ground
loops. The quality of the system grounding scheme inversely determines the n
oise amplitudes in the lines.
These conducted emissions are of a common-
mode nature from line to neutral (or ground). The second is
radiated high-frequency emissions usually capacitively coupled from line-to-line and are differential in
nature.
To properly mount the filters, the enclosure should have an unpainted metallic surface. This allows for
more surface area to be in contact with the filter housing and provides a lower impedance path between
this housing and the back plane. The back panel, in turn, has a high frequency ground strap connection
to the enclosure frame or earth ground.
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M-SS-017-07 Rev C 6SERVOSTAR CD
INPUT POWER FILTERING
The SERVOSTAR CD electronic system components require EMI filtering in the input power leads to
meet the conducted emission requirements for the industrial environment. This filtering blocks conducted-
type emissions from exiting onto the power lines and provides a barrier for EMI on the power lines.
Care must be taken to adequately size the system. The type of filter is based on the voltage and current
rating of the system and whether the incoming line is single or three-
phase. One input line filter is used for
multi-axis control applications. These filters are mounted as close to the incoming power as possible so
noise is not capacitively coupled into other signal leads and cables. Similarly, care should be taken when
routing wires from the load side of the filter to the BUS Module. These lines may be noisy and should be
separated from other sensitive cabling to avoid unwanted coupling of noise. Several manufacturers of
these filters are listed below. They should be able to recommend the best filter design for most typical
motor control applications. Danaher Motion has also provided specific filters recommendations that
adequately attenuate the conducted noise to levels well below the CE limits. The implementation of the
EMI filter should be done in accordance with the following guidelines:
—Filter should be mounted on the same panel as the drive and BUS Module.
—Filter should be mounted as close as possible to incoming cabinet power.
—Filter should be mounted as close as possible to BUS Module. If separation exceeds 30cm. (1 ft.), flat cable
(braid) is used for the high frequency connection between filter and BUS Module.
—When mounting the filter to the panel, remove any paint or material covering. Use an unpainted metallic back
panel, if possible.
—Filters are provided with an earth connection. All ground connections are tied to ground.
—Filters can produce high leakage currents. Filters must be earthed before connecting the supply!
—Filters should not be touched for a period of 10 seconds after removing the supply.
BUS Module Model # Recommended EMI Line Filter Danaher Motion Part #
PALM*Corcom F7202A A-97181
Cx03 Filter Concepts SF7
Schaffner FN258-7/07 n/a A-96776-001
Cx06 Filter Concepts SF15
Schaffner FN258-16/07 n/a A-96776-002
Cx10 Schaffner FN258-16/07 A-96776-002
*PALM is not used for Series 5 (Version 2)
NOTE
The filters called out in the table on the previous page are used on a one-to-one
corresponedence with the drive. If drives are paralled off one filter, it needs to be sized.
Drives can be ganged off one EMI filter as shown in the Filter and Bonding Diagrams.
MOTOR LINE FILTERING
Motor filtering may not be necessary for CE compliance of SERVOSTAR systems. However, this
additional filtering increases the reliability of the system. Poor non-metallic enclosure surfaces and
lengthy, unbonded (or unshielded) motor cables that couple noise line-to-line (differential) are just
some of
the factors that lead to the necessity of motor lead filtering.
Motor lead noise may be either common-mode or differential. The common-mode conducted currents
occur between each motor lead and ground (line-to-neutral). Differential radiated currents exist from one
motor lead to another (line-to-line). The filtering of the lines feeding the motor provide additional
attenuation of noise currents that enter surrounding cables and equipment I/O ports in close proximity.
Refer to the Installation Manual for details.
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M-SS-017-07 Rev C 7SERVOSTAR CD
INSTALLATION
These installation steps are designed to lead you through the proper installation and setup of a
SERVOSTAR®CD system. They were developed with the assumption that you have a fundamental
understanding of basic electronics, computers, mechanics, and proper safety practices. However, you do
not have to be an expert in motion control to install and operate the drive system. It is recommended that
you read the entire manual completely before attempting installation or operation.
CAUTION
High voltage can present dangerous and hazardous conditions if not performed by a
qualified electrician. Be certain to follow all national and local codes during installation.
Follow all safety precautions outlined in the accompaning CD-ROM documentation.
1. Open the box(es) and remove all the contents. Check to ensure there is no visible damage to any of
the equipment.
2. Mount the SERVOSTAR CD to the back panel. Refer to the Outline Dimension. Metal-to-metal
contact is important for electrical noise control!
3. Wire the SERVOSTAR CD according to the System Wiring Diagram.
4. Connect solid earth ground to frames of all components.
5. Wire the main power (115/230 VAC). For CDxx260, CDxx261, CDxx560 or CDxx561 product, wire
the 24 volt supply to the connector at the top of the drive.
6. Wire user I/O at connector C3: At a minimum, 24 volts must be brought in to the enable circuit. Be
certain that connector C3 is inserted correctly.
7. Wire the motor and feedback. Refer to the Feedback Wiring Diagram for additional information.
8. Wire Regen Resistor kit, if applicable.
9. Verify that all wiring is correct.
10. Verify that earth grounds are connected.
11. Verify all electrical and safety codes are met.
12. Connect the serial cable to connector C2 and PC. Refer to the System Wiring Diagram.
13. Install MOTIONLINK on the PC (from the CD-ROM or website (www.DanaherMotion.com)).
WARNING
Startup processes can cause motor motion. Be certain that all applicable safety
precautions are taken to ensure that no harm to personal or machine can occur.
14. Using the Startup Wizard in MOTIONLINK:
A. Configure the SERVOSTAR CD for your particular motor, if this was not done at the factory.
Refer to the MOTIONLINK Startup Wizard.
B. Enable the system.
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M-SS-017-07 Rev C 8SERVOSTAR CD
WIRING
OUTLINE DIMENSIONS
2 ? 10.0
[0.39]
3 ? 5.5
[0.22]
36.6
[1.44]
244.0
[9.61]
33.7
[1.33]
216.0
[8.50]
163.0
[6.42] 2.0
[0.08]
256.0
[10.08]
83.3 [3.28]
HEAT SINK
Cx 06
Cx 03
67.3 [2.65]
Cx10
99.1 [3.90]
6.7
[0.26]
15.5
[0.61]
PA-LM UNITS
NOTE
NOT USED IN SERIES 5 UNITS!!
+8V
LOGIC POWER SUPPL Y
EAR TH
INPUT
LINE
LC
N/C
LA
C5
185.4
[7.30] MAX.
175.5
[6.91] 26.2
[1.03]
3.1
[0.12]
56.9
[2.24]
52.1
[2.05]
158.8
[6.25]
147.3
[5.80]
2x 5.8
[0.23]
4
1
2
3
LOGIC
-15V
+15V
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M-SS-017-07 Rev C 9SERVOSTAR CD
CX SYSTEM WIRING DIAGRAM
C
MA MB MC B+ L3 L2
WARNING
HIGHVOLTAGEMAY EXISTUPTO5 MINUTES AFTERINPUTVOLTAGEISREMOVED.
WARNING
STATUSDISPLAY
FEEDBACK(D25)
TOMOTOR
FEEDBACK
DEVICE
DRIVE DC COMMON(SEE TE XTINMANUAL)
B B
I I
A A
ENCODEREQUIVALENTOUTPUT(D9P)
24V
RTN
CFAULTOUTPUTRELAY
(DRYCONTACTS)
ANALOG INPUT+/-10V
REMOTEENABLE
HIGH
LOW
DRIVE DC COMMON
SUPPLY
SUPPLY
C1
(IN1) (IN2) (IN3)
METER
TX
RX
(O1)
CONFIG.OUTPUT(ANOUT)
CONFIG.INPUT CONFIG.INPUT
CONFIG.INPUT CONFIG.OUTPUT
REPLACES C4ONSER COSMODELS
TRANSMIT
RECEIVE
25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10
9 8 7 6 5 4 3 2 1
6 7 8 9
1 2 3 4 5
C2
C1
C4
1 2 3 4 5 6 7 8 9 10 11 12 13
C3
9 6
5
3
1
MAINPOWER
CONTACTOR
NORMALLYOPENAUXILLARY
POWERCONTACTORFROM
MAINPOWERCONTACTOR
RESISTOR
THERMOSTAT
E-STOP
EXTERNAL RESISTIVE REGENUNIT(ERH-26)
MOTORPOWER
Cx5Drive
HEAT SINK
MOMENTARY PUSHBUTTON
TOENERGIZE
MAINPOWER.
(SEE NOTE16)
(SEE NOTE13)
(SEE NOTE5)
FUSE 1 FUSE 2
CUSTOMERSUPPLIED
(SEE NOTE1)
(SEE NOTE14)
CONFIGUREABLEI/OINTERFACE(SEE NOTE13)
(SEE NOTE10)
(SEE NOTE10)
(SEE NOTE11)
(Cx06 & Cx10)
(SEE NOTE13)
(SEE NOTE13)
(SEE NOTE10)
STAR POINT
SHIELDTO
STARPOINT
(SEE NOTE6)
THESERVOSTARCD OPERATES WITHVOLTAGES AS HIGHAS 230 VACAND 400 VDC. USE CAUTION. REFERINSTALLATIONAND TROUBLESHOOTING TOQUALIFIEDPERSONNEL ONLY.
COMMUNICATIONS(D9S)
RS-485 SERIALLINK
COMMON
C1
DATAFROMSERVOSTAR
DATATOSERVOSTAR
DIAGRAMREPRESENTS
TYPICALCONNECTION
1 2 3 4 5
C1RS-232 SERIALLINK(SEE NOTE12)
6 7 8 9 5
COMMON
1 2 3 4
5
6 7 8 9
Tx- Tx+
Rx-
Rx+
(RXD) (TXQ)
FUSE 3
*Optional24 VDC
LogicInput
L1
Front of Drive
+
-
+24V
INPUT FILTER
(SEE NOTE2)
MAININPUT
POWER
L1 L2 L3 SinglePhaseUsers
Connectanytwolines
USERSUPPLIED POWERSUPPLY
*SEE SERVOSTAR ELECTRICAL
SPECIFICATIONSFOR
LOADINGI NFORMATION
(SEE NOTE13)
(SEE NOTE18)
B
B
I I
A A
C8
9 6
5
3
1
COMMON
~5V
REMOTEENCODERINPUT
Optional
DeviceNetExtended
I/O
A B
1
10
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M-SS-017-07 Rev C 10 SERVOSTAR CD
CX FILTER AND BONDING DIAGRAM
Cabinet/Enclosure
CDCD
Routed to
Motors
Controller I/O
Routed to
Motors
Contactor,
Fuses,
Xfmr,
etc.
230
VAC
XFMR
CNC / PLC / Controller
EMI
filter
EMI
filter
Back Plane
2
3
4
5
6
7
8
9
1
Note 1
Input power enters enclosure from metal conduit. This
eliminates the need for shielded input power cable.
Note 2
Single point ground. A bus bar (ground bus) is an
excellent way to achieve this.
Note 3
High frequency ground between non-conductive back
panel and enclosure. Also, a high frequency ground is
required between the enclosure and earth ground.
Note 4
EMI filter grounding. Safety grounds must be provided
on the filters. Hazard potentials exist even when the
power is off because of the capacitors internal to the
filters.
Note 5
Bonding of motor cables. The use of armored
(screened) motor cables bonded as close to the drive
as possible are essential for CE compliance and
strongly recommended to better the overall
performance and reliability of the system.
Note 9
Motor cables and feedback cables exiting the cabinet going to the motor should be
separated as much as possible. Ideally, the use of separate conduits provides good isolation,
which can limit coupling of noise from motor to feedback cables.
Note 6
Feedback cable bonding is required for CE compliance. As with the motor cables, the
feedback cables should be bonded to the back panel. This bonding does two things. First, it
cuts down radiation from the drive, which may be in the form of high frequency energy
resulting from internal processor clocks. Second, it provides immunity for the drive. Since the
feedback device is located internal to the motor, it is going to pick up some noise currents and
transmit them along the feedback cable. The bonding directs the currents from the shield of
the feedback cable to back panel ground. This reduces the amount of noise entering the
drive.
Note 7
AC power lines that must be routed past other lines (such as motor cables or I/O lines) should
cross at a 90º angle. This minimizes the coupling effect. Additionally, the power lines should
be routed as close to the back panel as possible. Any noise currents on the lines are
capacitively coupled to the ground plane and not to other lines.
Note 8
Control (I/O) signals should be kept separate from all power and motor cables, if possible.
Keep control wiring as short as possible and use screened wire. Bonding is also
recommended but not required for CE compliance. A separation distance of 20 cm. (8 in.) is
sufficient in most cases. Where control cables must cross power cables, they should cross at
a 90º angle.
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M-SS-017-07 Rev C 11 SERVOSTAR CD
SYSTEM FEEDBACK DIAGRAM
FEEDBACK
(D25P)
25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
DRIVE
-1 TWO ENCODER SUPPL YCONNECTIONS ARE PROVIDED TO MINIMIZE VOLTAGE DROP IN CABLE. ONLYONE SET NEED BE USED IN LOW CURRENT ENCODERS USING SHOR T CABLE LENGTH. NOTES:
RESOLVER VERSION
HALL 3 A HALL 3 B HALL 2 A(D)* HALL 2 B (D)* HALL 1 A (C)* HALL 1 B (C)*
COMMON
+5V
COMMON
+5V CH B CH B
CH A
CH A
MARKER
MARKER
MOTOR THERMOSTATMUST BE CLOSED TO RUN (SEE BELOW)
MOTOR THERMOSTATMUST
BE CLOSED TO RUN
(SEE BELOW)
REF HI REF LO COS LO COS HI SINE LO SINE HI
RESOLVER 0.45 X RATIO
ENCODER POWER SUPPL Y
(SEE NOTE 1)
OPTIONAL HALL
CHANNEL INPUTS DIFFERENTIAL LINE DRIVES
TYPICAL HALL INPUT SCHEMATIC
CONNECTING HALLS WITH
LINE DRIVERS
CONNECTING HALLS WITH
OPEN COLLECTOR
ENCODER
HALL n B
HALL n A
HALL n A HALL n B PIN 18 (+5V) COMMON
COMMON
HALL n A HALL n B
150
150
1K
ENCODER TYPES AND OPTIONS VARYGREA TLY. PROVISIONS FOR OPERA TING WITHOUT HALL CHANNELS USING SOFTW ARE SWITCHES ARE AVAILABLE.
SERVOST AR
SERVOST AR
SERVOST AR INTERNAL
CIRCUITRY
HI (TRUE)
LO (COMPLEMENT)
MOTOR OVERLOAD PROTECTION MOTORS MUST HAVE INTEGRAL THERMAL PROTECTION OR EXTERNAL MOTOR OVERLOAD MUST BE USED. THERMOST ATSWITCH MAYSEE +12 VOLTS AND 20 ma.
ENCODER/SINE ENCODER VERSION
*INPUTS FOR SINE ENCODER THAT HAVE C & D CHANNELS
MOTOR OVERLOAD PROTECTION MOTORS MUST HAVE INTEGRAL THERMAL PROTECTION OR EXTERNAL MOT OR OVERLOAD MUST BE USED. THERMOST ATSWITCH MAYSEE +12 VOLTS AND 20 ma.
C4
C1
C2
6 7 8 9
25 24 23 22 21 20 19 18 17 16 15 14
5 4 3 2 1
9 8 7 6
C3
1 2 3 4 5 6 7 8 9 10 11 12 13
13 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5
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M-SS-017-07 Rev C 12 SERVOSTAR CD
PINOUT CONNECTORS
C1: Communications Connector
Pin Function
1Shield
2REC (RXD) (RS232)
3XMIT (TXD) (RS232)
4Reserved DO NOT CONNECT
5Common
6TxD+ (RS485)
7TxD-(RS485)
8RxD+ (RS485)
9RxD-(RS485)
C3: User I/O Connector
Pin Function
1Analog Signal Shield
2Analog Differential Input + (High)
3Analog Differential Input -(Low)
4DC Reference for ANOUT*
5Fault Output Relay Contact
6Fault Output Relay Contact
7+24V Input (Common Rail for return
pins 8,9,10,11)
8Remote Enable Input
9Configurable Input(See IN)
10 Configurable Input (See IN2)
11 Configurable Input (See IN3)
12 Configurable Output (See O1)
13 *Configurable Output (See ANOUT)
* Internal DC common for Referencing
ANOUT. It is also used to tie electrical
equipment commons together (inside the
drive) to prevent excess common mode
voltage from destroying I/O (internally-fused).
C4: Encoder Equivalent Output
Pin Function
1Channel A Output + (High)
2Channel A Output -(Low)
3DC Common
4Channel B Output + (High)
5Channel B Output -(Low)
6Shield
7Index Output + (High)
8Index Output -(Low)
9Shield
C2: Feedback Connector
Pin Resolver Encoder Sine Encoder
1Sine High AA
2Sine Low /A /A
3Shield Shield Shield
4Cosine High BB
5Cosine Low /B /B
6Shield Shield Shield
7E5V Return E5V Return
8E5V Return E5V Return
9H1B H1B(/C) (/Data)
10 H2B H2B(/D) (/Clock)
11 H3B H3B
12 Shield Shield Shield
13 Thermostat
High Thermostat High Thermostat High
14 Shield Shield Shield
15 Ref. High Out Index Index
16 Ref. Low Out /Index /Index
17 Shield Shield Shield
18 E5V Supply E5V Supply
19 E5V Supply E5V Supply
20 E5V Supply E5V Supply
21 Shield Shield Shield
22 H1A H1A (C) (Data)
23 H2A H2A (D) (Clock)
24 H3A H3A
25 Thermostat
Low Thermostat Low Thermostat Low
SERCOS Ports
(Replaces C4)
Tx
Rx
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M-SS-017-07 Rev C 13 SERVOSTAR CD
Notes for DIP switch:
The 10 position DIP switch is provided for drive
configuration. The first 6 switches control
communications parameters and are read only at
power up. Any changes in these settings will
require cycling the power. The other two switch
functions (7, 8) control the motor operation and are
monitored in real-time. This switch provides the
following functions:
MultiDrop Address Select: Switches 1 through 5
set the drive's address. A drive having address 0
powers up in the addressed state. If these five
switches are set to anything but 0, the drive will
assume an address code indicated by the switch
settings.
Baud Rate: Switch 6 sets the Serial/SERCOS
baud rate to either 9600/2M (switch off) or
19200/4M (switch on).
Position Hold: Activating switch 7 causes the
drive to enter a position hold mode. The condition
is enunciated to the user by a flashing status
display. The display maintains its current
OPMODE code. If the drive is running during a
HOLD command detection, the motor will ramp to
a stop at the DECSTOP rate.
Enable: Switch 8 is an input to the drive enable
circuitry and can be used to force the drive to a
disabled state.
SERCOS Power Level: Functions only on
SERCOS interfaceTM products. If switch 9 is set to
0, the SERCOS transmitter uses a low power
setting so the receiver is not overdriven when
using short cables. Long cables require more
power.
Factory Reserved: Must be set to 0.
NOTE
Setting the switch to “1”
means “Closed” or “On”.
C7 C8
24V
1
10
OFF
DIP (Configuration) Switch
Switch Function Settings
1Bit 0 of MultiDrop Address
(LSB)
2Bit 1 of MultiDrop Address
3Bit 2 of MultiDrop Address
4Bit 3 of MultiDrop Address
5
MultiDrop
Addressing
Bit 4 of MultiDrop Address
(MSB)
6Serial/SERCOS
Baud Rate 0 = 9600 (2M)
1 = 19200 (4M)
7HOLD Mode Switch 0 = Hold Mode Inactive
1 = Hold Mode Active
8Drive Enable /
Disable 0 = Drive Enable
1 = Drive Disable
9
SERCOS Transmit
Power 0 = Low Power
1 = High Power
10 Factory Reserved Must Be set to 0
C7: MultiDrop Communications
Type: 10 Pin (0.1”x 0.1”) Female Ribbon
Cable. Connector and cable are included in
the optional CK100 kit.
This connector functions only when using the
RS232 interface. It will NOT function using
RS485.
C8: Remote Encoder Input
Pin Function
1A Input + (High)
2A Input -(Low)
3DC Common
4B Input + (High)
5B Input -(Low)
6Shield Connection
7Reserved
8Index +
9Index -
C9: External User I/O*
Pin Function
A3 Configurable input (see IN5)
B3 Configurable input (see IN4)
B4 Configurable input (see IN6)
B5 Common for IN4, IN5, and IN6
A8 Output O3
B8 Output O2
B9 Common for O2 and O3
*Valid for Series 5 ONLY
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M-SS-017-07 Rev C 14 SERVOSTAR CD
SERIAL COMMUNICATION WIRING DIAGRAM
C2 SERIAL RS-232 INTERCONNECT
C2 SERIAL RS-485 INTERCONNECT
NOTE: Do NOT connect unused pins!
1
5
6
9
RXD+
RXD-
TXD+
TXD-
COM
TD+
TD-
RD+
RD-
COM
SHIELD
CUSTOMER
TERMINAL
(DE-9S)
FEMALE
CUSTOMER
TERMINAL
1
5
6
9
SHIELD
RXD
TXD
COM
TXD
RXD
COM
(DE-9S)
FEMALE
HARDWARE SPECIFICATIONS
Amplifier Model Cx03 Cx06 Cx10
Unit Weight Lbs./Kgs. 3.56/1.61 4.9/2.22 5.94/2.69
English (Metric) 10-32 (M4)
Mounting
Hardware Applied Torque 20 lb-in. (2.26 Nm.)
Line Screw Size/Torque
BUS Screw Size/Torque
Motor Screw Size/Torque
Connection
Hardware
Ground Screw Size/Torque
M3.5/12 lb-in. (1.35 N-m)
Control Logic (AWG/ mm2) 16 / 1.5
Motor Line (AWG/ mm2)14 / 2.5
Main Input (AWG/ mm2)14 / 2.5 12 / 4
Configurable I/O wire gauge 22-18 AWG (0.3-0.75 mm2) Ferrules recommended:
18 AWG Type H0 -75/14 Weidmuller 4629.0 or equivalent
20 AWG Type H0 -5/14 Weidmuller 6907.0 or equivalent
22 AWG Type H0 –34/12 Weidmuller 90257.7 or equivalent
Wire Size
(AWG#) Spade Terminals 16/14 AWG (1.5 mm2):
Hollingsworth XSS0954S OR SS20947SF or equivalent
12/10 AWG (4-6 mm2):
Hollingsworth XSS20836 OR SS20832F or equivalent
Side-to-Side 0.5 in (12.7 mm)
Clearance
Distance Top/Bottom 2.5 in (63.5 mm)
CK100 Kit Includes: C1, C2, C4, C7 (plus 2 ft./0.69 m. of stranded bus ribbon), C8
C3 Danaher Motion #: A-93899-013
Vendor Info: Weidmuller BL3.5/13 Cat.No. 161574
C5 Danaher Motion #: A-81014-004 Vendor Info: PCD ELFP04110
Connector Screw Torque 2.25 lb-in. (0.25 N-m)
Mating
Connector
Hardware
24 V Logic (optional) Danaher Motion #:A-81014-002 Vendor Info: PCD ELFP02210
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M-SS-017-07 Rev C 15 SERVOSTAR CD
ELECTRICAL SPECIFICATIONS
Product Model Cx03* Cx06* Cx10
Voltage (VACL-L) Nominal ?10% 110 to 230 230
115 VAC 1?or 3?3?only
230 VAC 1?or 3?3?only
Line Frequency 47-63
KVA at 115 VAC 0.44 (1?)
0.6 (3?)0.89 (1?) 1.1 (3?)
2.4 (3?only)
KVA at 230 VAC 0.88 (1?)
1.4 (3?)1.8 (1?) 2.8 (3?)
4.6 (3?only)
Continuous Current (A) 6.2 (1?)
4(3?)10 (1?) 7.8 (3?)
13 (3?only)
Peak Current (amps) for 500 ms 18.6 (1?)
12 (3?)30 (1?) 23.4 (3?)
26 (3?only)
Peak Current (amps) for 2s 12.4 (1?)
8 (3?)20 (1?) 15.6 (3?)
26 (3?only)
Main Input Power
Line Fuses (FRN-R, LPN, or equiv.) 10 15 15
+24 VDC Ext. Logic Voltage (V) 22 to 27
+24 VDC Ext. Logic Current (amps sink) 1.5
Logic Input Power
CxXX26X and CxXXX56x
Models ONLY +24 VCD Ext. Logic Current (amps max surge) 2.6
Max. Surge Current (A) 30
SoftStart
Max. Charge Time (sec) 0.25
Fault Contact Rating (A) 1
Fault Contact Closing Period (ms) Close = 3 ms, Open = 2 ms Protection Functions
Over-Temperature Trip (?C/?F) 80/176
Continuous Power (KVA) at 115 VAC
Line Input (45?C (113?F) Ambient) 0.35 (1?)
0.55 (3?)
0.7 (1?)
1.1 (3?)
1.8 (3?)
Continuous Power (KVA) at 230 VAC
Line Input (45?C (113?F) Ambient) 0.7 (1?)
1.1 (3?)
1.4 (1?)
2.2 (3?)
3.5 (3?)
Continuous Current (ARMS)3610
Peak Current (Arms) for 500 ms 918 20
Peak Current (Arms) for 2 sec 612 20
PWM Frequency (kHz) 16 88
PWM Motor Current Ripple (kHz) 32 16 16
Rated Main Output
(Ma, Mb, Mc)
Form Factor (rms/avg) ?1.01
Under-Voltage Trip (nominal) (VDC) 90
Over-Voltage Trip (VDC) 430
Over-Temperature Trip (?C/?F) 80/176
Protective Functions
Internal heat dissipation (watts) 60 80 132
Operation temperature (?C/?F) 5/41 to 45/113
Storage temperature (?C/?F) 0/32 to 70/158
Ambient humidity (%) 10 to 90
Atmosphere without corrosive gasses or dust
Altitude Derate 5% per 1000 ft.(300 m)
above 3300 ft. (1000 m)
Environment
Vibration (g) 0.5
*Model Numbers Cx0x200 are single phase only!
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M-SS-017-07 Rev C 16 SERVOSTAR CD
BUS MODULE ELECTRICAL SPECIFICATIONS
NOTE
NOT USED FOR SERIES 5.
Product Model PA-LM
Logic Input Power Voltage (AC) Nom. ?10% 110 to 120
Max. Current 1?(A) 1
Line Frequency 47-63
Internal Fuse (amps) (internal) 2.5
+8 VDC Supply Voltage (VDC) +7.25 to +8.5
+8 VDC Supply Current (amps) 2.2
15 V Supply Voltage (±VDC) 14.25 to 16
15 V Supply Current (amps) 0.8
Internal Fuses (amps) (?15V/+8 V) 1.5/3.5
Logic Output
Power (Source)
Max. # of Drives Sourced Refer to Bus Module Sizing Application Note
Internal heat dissipation 7
Operation temperature (?C/?F) 5/41 to 45/113
Storage temperature (?C/?F) 0/32 to 70/158
Ambient humidity (%) 10 to 90
Atmosphere without corrosive gasses or dust
Altitude Derate 5% per 1000 ft. above 3300 ft.
Environment
Vibration (g) 0.5
REGEN INFORMATION
Product Model Cx03 Cx06 Cx10
Peak current (amps) 20
Minimum resistance (ohms) 20
External Shunt Regulator
watts 200
Capacitance (Farads) 0.00082 0.00164
BUS Voltage (nominal) (VDC) 325
VHYS (Regen circuit turn-off) (VDC) 370
Application Information
VMAX (Regen circuit turn-on) (VDC) 390
External Regen Kits ERH-26 ???
*See the SERVOSTAR®S/CD-Series Regeneration Requirements Application Note on the PSP CD-
ROM for guidance on application sizing of Regen Kits.
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M-SS-017-07 Rev C 17 SERVOSTAR CD
PRODUCT FAMILY CONTROL SPECIFICATIONS
Current Loop Update Rate 62.5 ?S (16 kHz)
Bandwidth <2000 Hz
Commutation Loop Update Rate 62.5 ?S (16 kHz)
Max. Commutation Frequency 400Hz
Output Waveform Sinusoidal
Velocity Loop Update Rate 250 ?S (4k Hz)
Bandwidth <400 Hz
Speed Command Resolution Serial: 1 RPM or 1mm/sec or VLIM/16384
Analog: (1/6554) * VMAX
Long-term Speed Regulation 0.01% (?P clock tolerance)
Position Loop Update Rate 500 ?S (2 kHz)
I/O Connector (C3 by pinout)
Analog Input (2, 3) Absolute Maximum Voltage 13 V differential
Input Resolution 14 Bit/1.2
Sensitivity 1.53 mV min
Voltage Range -10V to +10V = -120% Motor rated speed to +120%
Motor rated speed (Adjustable Vscale parameter)
Input Impedance/CMR > 10 K?/50 dB
Long-term Drift 100 ppm (0.075%/?C)
Fault Output Relay (5, 6) Max Capacity 1 A at 24 VDC
Remote Enable (7, 8)
Configurable Inputs(7, 9, 10, 11) Bandwidth 2.5 kHz (Opto-isolated)
Input Voltage Range 12 V to 24 V Nominal (bi-directional)
Min. On/Max. Off 10 V/1 V
Current Demand per Input 20 mA (max)
Configurable Digital Output (7, 12) Output Voltage (max.) 0 V to 48 V Nominal –bi-directional (Open
Collector)
(Min. On) 1V
Max. Output Current 60 mA
Configurable Analog Output (13, 4) Max. Output Current 1 mA (1 K?internal series resistance)
Sensitivity / Resolution 4.9 mV/12 Bit
Voltage Range -10 V to +10V
Encoder Equivalent Output (C4 by pinout)
A/B/I & Complements
(1, 2, 4, 5, 7, 8) Output Voltage (high level) at 25?C2.5 V min. at 20mA Differential
RS 485 Line Drive Type DS26C31TM
Remote Encoder Input (C8 by pinout)
A/B/I & Complements
(1, 2 ,4, 5, 7, 8) Input Voltage at 25?C±5 V Differential
Input Sensitivity ±0.2V
Input Impedance 100?
RS 485 Line Receiver Type SN75173
Extended I/O Connector (C9 by pinout)
Analog Input (A1, B1) Absolute Maximum Voltage 12.5 V differential
Input Resolution 14 Bit
Sensitivity 1.53 mV min
Voltage Range -10V to +10V = -120% Motor rated speed to +120%
Motor rated speed (Adjustable Vscale parameter)
Input Impedance/ CMR > 10 k ?/50 dB
Long-term Drift 100 ppm (0. 075%/ ?C)
Configurable Inputs
(A3, B3, A4, B4, A5, A6, B6, A7))Bandwidth 4.6 kHz (Opto-isolated)
Input Voltage Range 12 V to 30 V typical, 24 V Nominal (bi-directional)
Min. On/ Max. Off 10 V/ 1 V
Current Demand per Input 20 mA (max)
Configurable Digital Outputs
(A8, B8,A9, B10) Output Voltage (max.) 0 V to 48 V Nominal –uni-directional (Opto isolated
Open Collector) type Source
(Min. On) 1V
Max. Output Current 60 mA
Configurable Analog Output (B2) Max. Output Current 1 mA (1 K ??internal series resistance)
Sensitivity / Resolution 4.9 mV/ 12 Bit
Voltage Range -10 V to +10V
See the section on Position Loop in for features using this input.
A flyback diode is necessary for inductive loads connected across the 01 output.
Extended I/O (C9) only A3,B3 and B4 are available.
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M-SS-017-07 Rev C 18 SERVOSTAR CD
FIRMWARE UPDATES
NOTE
NOT APPLICABLE FOR SERIES 5.
If your unit has the following label:
It requires firmware version 4.0.0 or higher. Other unit types will work with all firmware versions.
NOTE
Firmware version 4.0.0 and higher is not compatible with the
older versions of IGNITE (firmware loading software).
Attempting to load incompatible firmware results in the
IGNITE program generating an error.
TROUBLESHOOTING
Additional troubleshooting information is found in the Installation Manual.
TROUBLESHOOTING TOOLS
The SERVOSTAR’s MOTIONLINK package comes with a comprehensive monitoring and
troubleshooting help set. For troubleshooting the drive, it provides a Status screen. The Status screen
allows you to check the drive enable switches, the Status Display LED, fault status with complete error
history, and mode settings for several of the drive’s protection features. If using the terminal mode, you
can simply check the contents stored in the STATUS, FLTHIST, and ERR variables.
An additional help provided by MOTIONLINK is the I/O screen. The I/O screen gives you the ability to
check the status of the hardware position limit switches, the motor thermostat, and the encoder equivalent
output. It also allows you to set up the I/O on the C3 connector for a variety of troubleshooting and
monitoring approaches.
For monitoring system performance, MOTIONLINK comes with a variety of monitoring tools. You can
monitor a variety of variables from the Monitor screen to comp
are up to three variables against themselves
at one time. The Tune and Record screen allows you to evaluate the system’s actual performance against
a predefined command profile. Also from this screen, adjusting the gains until optimum following is
achieved can vary the performance.
ERROR CODES
In most cases, the SERVOSTAR
communicates error codes with a text message via the serial port to the
host. Some error codes are also transmitted to the Status Display. The same message is saved in the
EEPROM under an error history log (FLTHIST, ERR) so that nothing is lost when power is removed. Not
all errors reflect a message back to the host. In these cases, the no-message errors communicate to the
Status Display only.
The response of the SERVOSTAR to an error depends on the error's severity. There are three levels of
severity:
1) Warnings, simply called errors, are not considered faults and do not disable operation
2) Non-fatal errors, or simply faults, that disable the drive and indicate a fault status
3) Fatal errors, or fatal faults, that disable almost all drive functions (including communications)
NOTE
The drive is automatically disabled at the occurrence of a fault. Executing a drive
disable command (DIS or K) followed by the EN command, or toggling the
Remote Enable line (REMOTE) resets the fault latch, and if the fault condition is
no longer present, re-enables the system.
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M-SS-017-07 Rev C 19 SERVOSTAR CD
ERROR CODES
Series 5 Error Codes
Error Code Fault Message Fatal Non-Fatal LED Display
0.No Error
1.Power stage over temperature t
2.Over voltage o
3.Over current P
4.0 .External feedback fault r 0
4.1 .Resolver line break r 1
4.2 .RDC error r 2
4.3 .Sine Encoder init fail r 3
4.4 .A/B line break r 4
4.5 .Index line break r 5
4.6 .Illegal halls r 6
4.7 .C/D line break r 7
4.8 .A/B out of range r 8
4.9 .Burst pulse overflow r 9
4.10 EnDat comm error r 10
4.12 Hiperface comm error r 12
4.13 Sw R2D Feedback Fault r 13
5.Under voltage u
6.Motor over temperature H
6.1 EnDat over temperature H1
7.1 .Positive analog supply fail A 1
7.2 .Negative analog supply fail A 2
8.Over speed J
8.1 .Over speed (1.8*VLIM) J 1
9.EEPROM failure E
10 .EEPROM checksum failure e
12 .Foldback F
14.1 .Positive over travel fault d 5
14.2 .Negative over travel fault d 6
15.1 .Numeric position deviation d 1
15.2 .Excessive position deviation d 2
16 .Communication interface c
20 Unknown command
21 Unknown variable
22 Checksum error
23 Drive active
24 Drive inactive
25 Value out of range
26 Value negative
27 Not in proper Opmode
28 Syntax error
33 Auto tune failed
34 Bad bandwidth
35 Bad stability
36 Not programmable
37.01 Current loop design failed
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M-SS-017-07 Rev C 20 SERVOSTAR CD
Series 5 Error Codes
Error Code Fault Message Fatal Non-Fatal LED Display
37.02 MENCRES out of range
37.03 MENCOFF out of range
37.04 MSPEED out of range
37.05 MBEMF out of range
37.06 MJ out of range
37.07 ACC out of range
37.08 DEC out of range
37.09 DECSTOP out of range
37.10 VLIM out of range
37.11 VOSPD out of range
37.12 VSCALE out of range
37.13 O1TRIG out of range
37.14 O1RST out of range
37.15 DISSPEED out of range
37.16 MENCTYPE out of range
38 Communication error
39 Not in proper Compmode
40 EXT vel param warning
41 Vel loop design failed
42 Invalid EEPROM
43 Recording active
44 Rec data not available
45 EEPROM is empty
46 Argument must be binary
47 Burnin is active
48 Burnin is not active
49 Conflicts with ENCOUT
50 Conflicts with VLIM
51 Not available
52 Drive is in Hold mode
53 Limit switch Hold
54 Command into limit
55 Drive is in Zero mode
56 Motor is jogging
57 Argument not divisible by 20
58 Encoder init process active
60 Tune failed -No rotation
62,66
70,74 Tune failed -Current sat
63,67
71,75 Tune failed -No vel design
76 Disable during Tune
77 Hold during Tune
78 Low velocity limits
79 Use lower bandwidth
80 Drive is in Dual Fb mode
81 Drive is in Gear mode
82 Functionality is occupied
83 Warning: A/B line not routed
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