nord NORDAC SK 1000E-101-340-A Guide

BU 1100 GB
Status: 22 März 2006
Hardware description
NORDAC SK 1000E
Servo controller
SK 1000E-101-340-A ... SK 1000E-102-340-A
T.-Nr. 0604 1192
Getriebebau NORD
GmbH&Co. KG

NORDAC SK 1000E Hardware description
2 BU1100 GB
Safetyand operating instructions
forthe drive powerconverter
(asper: Lowvoltageguideline73/23/EEC)
1. General information
During operation, drive powerconvertersmay have,
depending ontheir protectionclass,live,bare,moving or
rotating partsor hot surfaces.
Thereisariskofseriousinjurytopersonsand/ordamage
toequipment resulting fromunpermittedremovalofcovers,
incorrect use, installation or operation.
Further information can befound in this
documentation.
All transport, installationand commissioning work,and
maintenance,mustbecarriedout byqualifiedpersonnel
(complywith IEC 364, CENELEC HD 384, DIN VDE 0100,
IEC 664 and DIN VDE 0110, and nationalaccident
prevention regulations).
Qualifiedpersonnelin thesenseofthesebasicsafety
instructionsarepersonswhoarefamiliarwith theerection,
mounting, commissionand operationofthisproductand
whohave therelevant qualificationsfor their activities.
2. Intended use
Drive powerconvertersarecomponentsintendedfor
installation in electrical systemsor machines.
Whenbeing installedin machines,thedrive power
convertercannotbecommissioned(i.e. implementationof
theintendeduse)until it hasbeenensuredthatthemachine
meetstheprovisionsoftheEC guideline89/392/EEC
(machineguideline); EN 60204 must alsobecomplied with.
Commissioning (i.e.implementationoftheintendeduse)is
onlypermittedwhentheEMCguideline(89/336/EEC) is
complied with.
Thedrive powerconvertersmeettherequirementsofthe
lowvoltageguideline73/23/EEC. Theharmonised
standardsin prEN 50178/DIN VDE 0160, togetherwith EN
60439-1/VDE 0660 Part 500 and EN 60146/VDE 0558 were
applied for thedrive power converter.
Technicaldataand informationforconnectionconditions
canbefound ontherating plateand in thedocumentation,
and must becomplied with.
3. Transport, storage
Informationregarding transport, storageand correct
handling must becomplied with.
4. Erection
Theerectionand cooling oftheequipment mustbe
implementedaspertheregulationsin thecorresponding
documentation.
Thedrive powerconvertermustbeprotectedagainst
unpermittedloads.During transport and handling in
particular, componentsmustnotbedeformedand/or
insulationdistancesmustnotbechanged. Touching of
electroniccomponentsand contactsmust beavoided.
Drive powerconvertershave electrostaticallysensitive
componentsthatcanbeeasilydamagedbyincorrect
handling. Electricalcomponentsmustnotbemechanically
damaged or destroyed (thismay causeahealth hazard!).
5. Electrical connections
Whenworking onlive drive powerconverters,the
applicablenationalaccident preventionregulationsmustbe
complied with (e.g. VBG 4).
Theelectricalinstallationmustbeimplementedasperthe
applicableregulations(e.g. cablecross-section, fuses,
ground leadconnections). Furtherinstructionscanbefound
in thedocumentation.
Informationabout EMC-compliant installation – suchas
shielding, earthing, locationoffiltersand installationof
cables – canbefound in thedrive powerconverter
documentation. Theseinstructionsmustbecompliedwith
evenwith CE markeddrive powerconverters.Compliance
with thelimit valuesspecifiedin theEMCregulationsisthe
responsibilityofthemanufacturer ofthesystemor machine.
6. Operation
Systemswheredrive powerconvertersareinstalledmust
beequipped, wherenecessary,with additionalmonitoring
and protective equipment aspertheapplicablesafety
requirements,e.g. legislationconcerning technical
equipment, accident preventionregulations,etc.
Modificationstothedrive powerconverterusing the
operating softwarearepermitted.
Afterthedrive powerconverterisdisconnectedfromthe
powersupply,live equipment componentsand power
connectionsshould notbetouchedimmediatelybecauseof
possiblechargedcapacitors.Complywith theapplicable
information signslocated on thedrive power converter.
All coversmust bekept closed during operation.
7. Maintenance and repairs
Themanufacturer documentation must becomplied with.
These safetyinstructions must be kept ina safe place!

Contents
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Special safety and operating instructions forthe SK 1000E
NORDAC SK 1000E servocontrollersare equipment for usein industrialhigh voltage
systemsand are operated at voltagesthat couldlead to severe injuries or death ifthey
are touched.
• Theequipment continuestocarry hazardousvoltagesforup to5minutes afterbeing switchedoff atthe
mains. Theequipment may onlybeopenedorthecoverorcontrolelement removed5minutesafterthe
equipment hasbeendisconnectedfromthepowersupply. All coversmustbeput backin place before
thelinevoltageisswitched backon again.
• Evenduring motorstandstill (e.g. causedbyareleaseblock,blockeddrive oroutput terminalshort
circuit), thelineconnectionterminals,motorterminals and braking resistorterminalsmay still conduct
hazardousvoltages. A motor standstill isnot identical togalvanicisolation fromthemains.
• Warning:evenpartsofthecontrolcard and, in particular, theconnectionplug forFlash-JTAG program
programming canconducthazardousvoltages. Whenprogramming theDSP viatheJTAG plug, a
speciallyavailableopto-isolatormustbeused. Theexternalcontrolterminalsarelinepotential-free. The
JTAG interfaceisanon-proprietarystandardisedprogramming interfaceforDSP and controllerfor
whichseveralcompanies,e.g. SpectrumDigital, offersuitableconnectionadapters.Theinternalsafety
coverson theseitemsmust not beremoved.
• Warning,undercertain settingstheservo controllercanstart automaticallyafterthemainsareswitched
on.
• Thecircuit boardscontain highly-sensitive MOS semiconductorcomponentsthatareparticularly
sensitive tostaticelectricity. Avoid touching circuit tracksand componentswith thehand ormetallic
objects. Onlytheterminal strip screwsmay betouchedwith insulatedscrewdriverswhenconnecting the
cables.
• Theservo controllersareonlyintendedforpermanent connectionand may notbeoperatedwithout
effective earthing connectionsthatcomplywith localregulationsregarding largeleakcurrents(> 3.5
mA). VDE 0160 requirestheinstallationofasecond earthing conductororanearthing conductorcross-
section ofat least 10 mm2.
• NormalFI circuit breakers aregenerallynotsuitableasthesoleprotectionin servo controllerswhenthe
localregulationsdonotpermit apossibleDC proportionin thefaultycurrent. Thestandard FI circuit
breaker must complywith thenewdesign asper VDE 0664.
• NORDAC SK 1000E servo controllersaremaintenance-free when usedcorrectly. Thecooling surfaces
must beregularlycleaned with compressed air iftheambient air isdusty.
ATTENTION! DANGER TO LIFE!
The power unit can continue to carryvoltages for up to 5minutes after being switched off at the mains. Terminals,
motor cables and motor terminals maybe live! Touching open or free terminals, cables and equipment components
can lead to severe injuryor death!
CAUTION
• Children and thegeneral publicmust bekept away fromtheequipment!
• Theequipment may onlybeusedforthepurposeintendedbythemanufacturer. Unpermitted
modificationsand theuseofsparepartsand additionalequipment thathasnotbebought fromor
recommended bytheequipment manufacturer can lead tofire, electricshockand injury.
• Keep theseoperating instructionsin an accessiblelocation and ensurethat everyoperator usesthem!
EuropeanEMC guideline
When the NORDAC SK 1000E isinstalled according to the instructions inthis manual,it
will meet all requirementsin the EMC guideline, asper the EMC product standard for
motor-operated systemsEN 61800-3 (see also the chapter Electromagnetic
compatibility [EMC]).
UtilisationinNorthAmerica, UL and CSA authorisation
“Suitable for use on a circuit capable of delivering not more than 5000 rms symmetrical amperes, up to
460 Volts (three phase)”and “when protected by J class fuses.”as indicated.
In preparation

NORDAC SK 1000E Hardware description
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1GENERAL INFORMATION................................................................................................. 5
1.1 NORDAC SK 1000E ServoController................................ ................................ ........................5
1.2 Variantsand options................................ ................................ ................................ ..................5
1.3 Equipmentproperties................................ ................................ ................................ .................6
1.4 Delivery................................ ................................ ................................ ................................ .....7
2MOUNTING AND INSTALLATION ..................................................................................... 8
2.1 Installation................................ ................................ ................................ ................................ .8
2.2 Dimensions................................ ................................ ................................ ................................ 9
2.3 Wiring guidelines................................ ................................ ................................ .....................10
2.4 Line and motor connections................................ ................................ ................................ .....11
2.5 Controller connections................................ ................................ ................................ .............13
2.5.124VI/O .............................................................................................................................................13
2.5.2Connectionterminals(leftsideX5).....................................................................................................13
2.5.3Connectionterminals(rightsideX5)...................................................................................................14
2.5.4Front panels......................................................................................................................................14
2.5.5 RS232andRS485 (X4)...................................................................................................................15
2.5.6 CANBus(X3)....................................................................................................................................15
2.5.7Secondencoderin, Out, PulseDir./ SS1 (X2)....................................................................................17
2.5.8Resolver or encoderunit(X1) ............................................................................................................17
2.5.9Asynchronousmotorcableconnections..............................................................................................18
2.5.10 CANconnector(optionalaccessories)..............................................................................................18
2.6 Display................................ ................................ ................................ ................................ .....19
2.7 Rated /peak current................................ ................................ ................................ ................19
2.8 Brake................................ ................................ ................................ ................................ .......19
2.9 Basic settings ................................ ................................ ................................ .......................... 20
2.10 Commissioning................................ ................................ ................................ ...................... 20
3 TECHNICAL DATA........................................................................................................... 21
3.1 Electricaldata................................ ................................ ................................ .......................... 21
3.2 Functions................................ ................................ ................................ ................................ .21
3.3 Accessories................................ ................................ ................................ ............................. 22
3.3.1AuxiliarylinefilterclassB...................................................................................................................22
3.3.2Brakeresistor(Optional)....................................................................................................................23
3.3.3Cableset...........................................................................................................................................23
3.3.4CANconnectingterminalscrewconnection........................................................................................23
4ADDITIONAL INFORMATION .......................................................................................... 24
4.1 Electromagnetic compatibility (EMC)................................ ................................ ........................ 24
4.2 Limit value classes................................ ................................ ................................ ...................25
4.2.1WiringrecommendationsforcompliancewithClass3in3phasenetworks..........................................26
5MAINTENANCE AND SERVICE NOTES.......................................................................... 26
6REPRESENTATIVES, BRANCHES.................................................................................. 27

NORDAC SK 1000E Hardware description
5 BU1100 GB
1 General information
1.1NORDAC SK 1000E ServoController
The NORD dynamic intelligence
The NORDAC SK 1000E isthe bestchoice where rapidacceleration, fastmovement and high
standstill moment, coupled with high speed and positioning precision, are essential.Combined with
the integrated PLC, technicalfunctionsand CANopen fieldbusconnection, itisthe solution for
demanding drive problems.
Rated current: 3.5-20Aeff, 3 AC380-460V 50-60Hz
Speed range: Servo controller with resolver +/- 22500 rpm,
Servocontroller with incrementalencoder isproportionallyresolution
dependent, e.g. at 4096 increments+/- 18500 rpm(Attention:note the limit
frequency ofthe encoder, thisisoften only 250 kHz!)
NORDAC SK 1000E servocontrollers are designed using fullydigitalsignalprocessor technology
(DSP) with fieldbusconnectionsfor torque, speed and positioning regulation ofsynchronousand
asynchronousmotors.
The field-orientated controlconcept with current, speed, position controland speed profiledepiction in
just50µssampling timemeansthat thissystemhasextremelyhigh dynamicsand full motor
movement even when at standstill.Extremelyhigh, load-independent speed and positioning accuracy
isachieved by the rotor position feedback. Demanding drivetaskscan therefore be resolved.
Implemented technicalfunctionsunderline customer benefits.
An integrated PLC roundsoff the function spectrumofthiscontroller.
The controller iscommissioned with the operating software running under Windows 95/95, 2000, NT
and XP. Commissioning isfacilitated by the supplied motor/controller database, oscilloscope and
numeroustest functions, while the assistant meansthat anyone can commission the controller.
Somespecifications are currentlyinpreparation.Technicaldevelopments means that thisproduct
description continuouslyundergoes changes and these changes are collected and the productdescription
isupdated with the latest developments as and when necessary.
1.2Variants andoptions
Variant Description Data
R = resolver Feedback= Resolver 12 bit resolution
E = encoder Feedback= incremental encoder
Hall supplement recommended from500 increment resolution, freely
selectableincrement number
RS Resolver with option: 1 MBaud CAN and absolutevalueencoder,
nostepper motor interface
ES Encoder with option: 1 MBaud CAN and absolutevalueencoder, no
stepper motor interface
RT Resolver with option: technical functions See Nord applicationspublication
ET Encoder with option: technical functions See Nord applicationspublication
RST Resolver with option: 1 MBaud CAN and absolutevalueencoder,
nostepper motor interface, with technical functionsoption
EST Encoder with option: 1 MBaud CAN and absolutevalueencoder, no
stepper motor interface, with technical functionsoption
All servocontrollerscan operate synchronousand asynchronousmotors.During commissioning, the
connected motor data record simply hasto be loaded fromthe database.

NORDAC SK 1000E Hardware description
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1.3Equipment properties
• Operation ofsynchronousand asynchronousmotors
• High dynamics,motorscan be operated with up to 0.5 mselectricaland mechanicaltimeconstants.
• Full torque at standstill
• Sinusoidalcommutation
• Fully digitalcontrolconcept
• Integrated line filter A
• Integrated brake chopper with externalbrake resistor
• Torque, speed and positioning control– all in a controlcycle time of50µs
• Ramp generator / speed profile generator
• Newpositions,travelspeedsand rampscan be set at any timeduring the procedure inthe
positioning control.
• Stepper motor interface with up to 5 MHz input frequency
• Technicalfunctions, e.g. electronic gears, flying saws, winders
Note ->you can obtain the publication: NORD applicationsfor thispurpose
• Encoder, resolver or absolute value encoder(SSI)
• Incrementalencoder emulation output
• CAN field bus(up to 1 MBit/s), RS 232 and RS 485 (up to 56000 Bit/s)
• CAN- Open ProtocolDS301V4.01&DS402V1.1, EDS configuration file provided
• Variable PDO mapping
• ±10 V analog setpoint interface
• 6 freely programmable inputs
• 6 freely programmable short-circuit proofoutputs
• 1 freely programmable relay, e.g. for integrated brake control
• Integrated PLC with input assistant for particularly easy intuitive operation
• Logic and arithmetic operationscan be implemented with variablesand constants
• Integrated reference switch logic
• Integrated limit switch monitoring
• Comfortableand rapidcommissioning viaoperating software with databasefunctionsand
oscilloscope function
• Can be mounted adjacent to each other without spacing required
• Permissible ambient temperature up to 40°C
• Suitable for high speeds(encoder-dependent)

NORDAC SK 1000E Hardware description
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1.4Delivery
Check the equipment immediately after delivery/unpacking for transport damage such as deformation
or looseparts. Ifthere isany damage, contact the carrier immediatelyand implement athorough
assessment.
Important! This also applies even if the packaging is undamaged.
The place before the decimalpoint on the firmware version (can be found under NORD SERV:
equipment/controller info) and that ofthe operating programversion ofNORD SERV (displayed top left
in NORD SERV) must coincide otherwise they will not be compatible.
Orderversion: Mounting unit IP 20 with resolver or encoder design
1MbaudCAN and SSI input or 500kbaudCAN and stepper motor input
with or without technicalfunctions
Standarddesign Integrated brake chopper
Integrated line filter for limit curve A asper EN 55011
Integrated shield angle
CAN Bus, RS232/RS485, 2.Resolver/ Encoder input/output
PLC and programmable 6 inputsand 6 outputs
+/- 10 V input, reference and limit switch inputs
Motor temperature and motor brake logic
Internallogic and power supply
PC operating programwith integrated online help (NORD SERV)
Operating instructions
Available accessories Substructure brake resistorsIP 20, variousoutputs
Substructure line filter for limit curve B, asper EN 55011, IP 20
Line choke, IP 00
Interface converter RS 232 →RS 485
Cable set (see description in NORD cable documentation)

NORDAC SK 1000E Hardware description
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2 Mounting and installation
2.1Installation
NORDAC SK 1000E servocontrollersare availableinthree sizesdepending on the output. The
equipment variantshave different widthsand installation depths.
The equipment requiressufficient ventilation to protect againstoverheating. Guide valuesapplyhere
for aboveand belowthe servocontroller up to the limits ofthe controlcabinet(above>100 mm,below
>100 mm).
Electricalcomponents(e.g. cable ducts, contactors, etc.) can be located within these limits. There isa
height-dependent minimumdistance fromthe servo controller for theseobjects.This distance mustbe
minimum2/3 the object height. (Example: cableduct height 60 mm high ->2.3 *60 mm =40 mm
distance)
Additionaldistancesat the sides are not required. Mounting can be implemented directly next to each
other, e.g. on DIN rails. The installation position isnormally vertical.
The heated air must be vented!
Ifseveralservo controllersare arranged above eachother, ensure that the airentry temperature limits
are not under or overshot. In thiscase, itisrecommended that any “obstacles” (e.g. a cable duct) are
mounted between the servo controllersso that the air flow(rising warmair) isnot hindered.
>100mm
>100mm

NORDAC SK 1000E Hardware description
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2.2Dimensions
Detail: Attachment
Size Equipment type L1 B1 Equipment
depth
D L2 B2 L3
Weight
ca.
1 SK 1000E-101-340-A to
SK 1000E-301-340-A 281 121 217 267 100 222 4 kg
2 SK 1000E-401-340-A to
SK 1000E-501-340-A 331 121 217 310 100 272 5 kg
3 SK 1000E-801-340-A to
SK 1000E-102-340-A 381 163 250 367 140 344 10 kg
Equipment depth without front plug All measurementsin mm
L3
L1
B1
B2
L2

NORDAC SK 1000E Hardware description
10 BU1100 GB
2.3Wiringguidelines
The servocontroller isdeveloped for operation inindustrialenvironmentswhere high valuesof
electromagneticinterference are expected. In general,correct installation ensuressafeand problem-
free operation. Iflimitvaluesexceeding the EMC guidelinesare probable, the following information
may be useful.
(1)Ensure that all equipment inthe cabinet issecurelyearthed using short earthing cablesthat have
large cross-sectionsand which are connected to a common earthing point or earthing rail. It isvery
important that every connected controller (e.g. an automation device) isconnected, using ashort
cablewith large cross-section, to the sameearthing point asthe servocontroller itself.Flat
conductors(e.g. metalbrackets) are preferable asthey have lowimpedance at higher frequencies.
The PE lead ofthe motor controlled by the servocontroller mustbe connected asdirectlyas
possibleto the earth connection ofthe cooling element together with the PE ofthe relevant servo
controller electricalsystem.The presence ofacentralearthing rail inthe controlcabinet and the
bringing together ofall PE conductorsto thisrail normallyensuressafeoperation. (See alsothe
chapters: Line and motor connections, EMC)
(2)Where possible, shielded cablesmustbe used for the controlcircuits.Carefullyterminate cable
endsand ensure that the wiresdo not run over longer sectionsunshielded.
The shieldsofanalog setpoint cablesshouldonlybe earthed on one side on the servocontroller.
(3)The controlcablesmustbe kept distant fromload cablesby using separate cableducts,etc. If
cablesintersect, then an angle of90° should be used where possible.
(4)Ensure that the contactorsinthe cabinet are interference protected, either by RC circuitsinthe
caseofDC contactorsor by free-wheeling diodesfor AC contactors, whereby the interference
traps must be positioned on the contactor coils.Varistorsfor over-voltage limitation are also
effective. Thisinterference suppression isparticularly important when the contactorsare controlled
by the servo controller.
(5)Shielded or armoured cablesmustbe used for the load connectionsbetween motor and brake
resistor. Thesemustbe applied to asmuch surface aspossible on the shield anglesdirectly on the
servo controller with the supplied earthing clamps.
(6)When the driveisto operate inan environment sensitiveto electromagneticinterference, itis
recommended that noisesuppression filtersare used to restrict the cable-dependent and radiated
interference fromthe servocontroller. In thiscase, the filter mustbe mounted ascloselyas
possible to the servo controller and fully earthed.
In addition, the servocontroller mustbe installed, together with the line filter, inan EMC-proof
enclosure with EMC-proofcabling.
Thesafetyregulationsmust becomplied with under all circumstanceswhen installing
theservo controller!
Note
The controlcables,line cablesand motor cablesmustbe laidseparately. In no case
shouldthey be laidinthe sameprotectivepipes/installation ducts.
The testequipment for high voltage insulationsmustnot be used on cablesthat are
connected to the servo controller.