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TRANSCRIPT
www.DanaherMotion.com
Digital Servo Amplifier
SERVOSTAR® 400
Assembly, Installation, Setup
Edition 07/03
File sr400_d.xxx
Order No.: 102530
Previous editions
Edition Comments
10/01 First edition
02/02 new layout
07/03 new layout, technical data adapted to new hardware, equipment matching removed
PC-AT is a registered trademark of International Business Machines Corp.
MS-DOS is a registered trademark of Microsoft Corp.
WINDOWS is a registered trademark of Microsoft Corp.
HIPERFACE is a registered trademark of Max Stegmann GmbH
EnDat is a registered trademark of Dr.Johannes Heidenhain GmbH
SERVOSTAR is a registered trademark of Kollmorgen Corporation
Technical changes to improve the performance of the equipment may be made without notice !
Printed in the Federal Republic of Germany
All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm or any other
method) or processed, copied or distributed by electronic means without the written permission of Danaher Motion.
SERVOSTAR®
400 Installation manual 3
Kollmorgen 07/03 Contents
1 General1.1 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Equipment description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.1 Package as supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.2 Digital servo amplifiers in the series SERVOSTAR 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4.3 Operation directly from the supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4.4 Digital servo amplifier concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Components of a servo system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7 Technical data for SERVOSTAR 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.7.1 External fusing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7.2 Permissible ambient conditions, ventilation, mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7.3 Conductor cross-sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7.4 Recommended tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.7.5 LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.8 Grounding system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.9 Motor holding brake conrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.10 Regen circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.11 Switch-on/-off behaviour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.11.1 Stop function as per EN 60204 (VDE 0113) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.11.2 Emergency stop methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2 Installation2.1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2.1 Dimensions SERVOSTAR 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3.1 Wiring diagram SERVOSTAR 400M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3.2 Wiring diagram SERVOSTAR 400A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.3 Example of connections for multi-axis system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.4 Connector assignments SERVOSTAR 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3.5 Connection techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3.5.1 Shield connection on the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3.5.2 Technical data of connecting cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.4 Setup software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4.1.1 Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4.1.2 Software description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4.1.3 Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4.1.4 Operating systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4.2 Installation under WINDOWS 95 / 98 / 2000 / ME / NT / XP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Page
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
European Directives and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
-Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Abbreviations and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 SERVOSTAR®
400 Installation manual
Contents 07/03 Kollmorgen
3 Interfaces3.1 Supply voltage (master only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1.1 Supply connection (X0) for 3-phase supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1.2 Supply connection (X0) for single-phase supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1.3 24V auxiliary voltage (X0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1.4 DC-link/DC-bus (X0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2 Motor connection with brake (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3 External ballast resistor (X0)(master only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4.1 Resolver connection (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4.2 Encoder connection (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.5 Control and monitoring signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.5.1 Analog setpoint input (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.5.2 Digital control inputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.5.3 Digital control outputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.5.4 Digital control signals on the PSU (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.6 Encoder emulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.6.1 Incremntal encoder interface (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.6.2 SSI interface (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.7 RS232 interface, PC connection (X8)(master only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.8 Interface for stepper motor controls (pulse/direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.8.1 Connection of stepper motor controls with 5V signal level (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.8.2 Connection of stepper motor controls with 24V signal level (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.9 Interface for master-slave operation, encoder control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.9.1 Connection to SERVOSTAR 400 master, 5V level (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.9.2 Connection to encoder with 24V signal level (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.9.3 Connection for Sin/Cos encoder (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.10 Fieldbus connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.10.1 CANopen interface (X7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.10.2 PROFIBUS interface (X7)(option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.10.3 SERCOS interface (X7)(option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.10.3.1 Light emitting diodes (LEDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.10.3.2 Connection diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4 Commissioning4.1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.2 Parameterization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.2.1 Multi-axis systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.2.2 Key pad controls and status displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.2.2.1 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.2.2.2 Status display on the axis module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.2.2.3 Status display on the master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.3 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.4 Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5 Accessories5.1 External PSU 24V DC / 5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2 External PSU 24V DC / 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3 External ballast resistor BARxxx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.4 Add-on fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6 Appendix6.1 Transport, storage, maintenace, disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.2 Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.3 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.4 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Page
Safety Instructions
� Only properly qualified personnel are permitted to carry out activities such
as transport, installation, commissioning and maintenance. Properly
qualified persons are those who are familiar with the transport, assembly,
installation, commissioning and operation of the product, and who have the
appropriate qualifications for their job. The qualified personnel must know
and observe the following standards and regulations:
IEC 364 and CENELEC HD 384 or DIN VDE 0100
IEC Report 664 or DIN VDE 0110
national accident prevention regulations or BGV A2
� Read this documentation before carrying out the installation and
commissioning. Incorrect handling of the servo amplifier can lead to
personal injury or material damage. It is vital that you keep to the technical
data and information on connection requirements (nameplate and
documentation).
� The manufacturer of the machine must produce a hazard analysis for the
machine and take appropriate measures to ensure that unforeseen
movements do not result in personal injury or material damage.
� The servo amplifiers contain electrostatically sensitive components which
may be damaged by incorrect handling. Discharge your body before
touching the servo amplifier. Avoid contact with highly insulating materials
(artificial fabrics, plastic film etc.). Place the servo amplifier on a conductive
surface.
� Do not open the equipment. Keep all covers and cabinet doors closed during
operation. Otherwise, there are deadly hazards, with the possibility of death,
severe injury or material damage.
� During operation, servo amplifiers may have uncovered live components,
depending on their level of enclosure protection. Control and power
connections may be live, even though the motor is not rotating.
� Servo amplifiers may have hot surfaces during operation. Since the front
panel is used for cooling, it can reach temperatures above 80°C.
� Never undo any electrical connections to the servo amplifier while it is live.
There is a danger of electrical arcing with damage to contacts and personal
injury.
� Wait at least five minutes after disconnecting the servo amplifier from the
main supply power before touching potentially live sections of the
equipment (e.g. contacts) or undoing any connections. Capacitors can still
have dangerous voltages present up to five minutes after switching off the
supply power. To be sure, measure the voltage in the DC-link circuit and wait
until it has fallen below 40V.
SERVOSTAR®
400 Installation manual 5
Kollmorgen 07/03 Safety Instructions
European Directives and Standards
Servo amplifiers are components that are intended to be incorporated into electrical plant and machines for in-
dustrial use.
When the servoamplifiers are built into machines or plant, the intended operation of the amplifier is forbidden
until it has been established that the machine or plant fulfills the requirements of the EC Machinery Directive
98/37/EG and the EC Directive on EMC (89/336/EEC).
To fulfill the EC Machinery directive (98/37/EG), the following standards have to be applied:
EN 60204-1 (Safety and electrical equipment of machines)
EN 292 (Safety of machines)
The manufacturer of the machine must produce a hazard analysis for the machine and take appropria-
te measures to ensure that unforeseen movements do not result in personal injury or material dama-
ge.
To fulfill the Low Voltage Directive 73/23/EEC, the following standards have to be applied:
EN 60204-1 (Safety and electrical equipment of machines)
EN 50178 (Equipment of high voltage plant with electronic devices)
EN 60439-1 (Low-voltage switchgear and controlgear assemblies)
To fulfill the EC EMC regulations (89/336/EEC), the following standards have to be applied:
EN 61000-6-1 or EN 61000-6-2 (noise immunity within the domestic range/industrial range)
EN 61000-6-3 or EN 61000-6-4 (noise emission within the domestic range/industrial range)
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
connectors and cable routing – can be found in this documentation.
The machine / plant manufacturer must examine whether with its machine / plant still further or other
standards or EEC guidelines are to be used.
Conformity
Conformity with the EC Directive on EMC 89/336/EEC and the Low Voltage Directive 73/23/EEC is mandatory
for servoamplifiers supplied within the European Union.
To fulfill the EMC directive, the standard EN 61800-3 is applied.
In the reference to noise immunity the servoamplifier fulfills the requirement to the category second environ-
ment (industrial environment).
For the range of the noise emission the rvo amplifier fulfills the requirement to a product of the category redu-
ced availability.
Warning!
This is a product with reduced availability according to IEC 61800-3. This product can cause in-
terferences within domestic range; if required you must accomplish appropriate measures.
The servo amplifiers have been tested by an authorized testing laboratory in a defined configuration with the
system components which are described in this documentation. Any divergence from the configuration and in-
stallation described in this documentation means that you will be responsible for carrying out new measure-
ments to ensure that the regulatory requirements are fulfilled.
To fulfill the Low Voltage Directive, the standard EN 50178 has to be applied.
6 SERVOSTAR®
400 Installation manual
Directives and Standards 07/03 Kollmorgen
UL and cUL- Conformance
In preparation
SERVOSTAR®
400 Installation manual 7
Kollmorgen 07/03 UL and cUL- Conformance
Abbreviations used in this Manual
The abbreviations used in this manual are explained in the table below.
Symbols used in this Manual
danger to personnel
from electricity
and its effects
general warning
general instructions
mechanical hazard
� p. see Page (cross-reference) � special emphasis
Keys on the master:
� press once : move up one menu item, increase number by one
press twice in rapid succession : increase number by ten
�
press once : move down one menu item, decrease number by one
press twice in rapid succession : decrease number by ten
�
�
hold right key pressed, and then press left key as well :
to enter number, Return function
8 SERVOSTAR®
400 Installation manual
Abbreviations and Symbols 07/03 Kollmorgen
Abbrev. Meaning
AGND Analog ground
BTB/RTO Ready to operate
CAN Fieldbus (CANopen)
CE Communité Europeenne (=EC)
CLK Clock signal
COM Serial interface for a PC-AT
DGND Digital ground
DIN Deutsches Institut für Normung
Disk Magnetic storage (diskette, hard disk)
EEPROM Electrically erasable memory
EMC Electromagnetic compatibility
EMI Elektromagnetic interference
EN European standard
ESD Electrostatic discharge
IEC International Electrotechnical Commission
IGBT Insulated gate bipolar transistor
INC Incremental Interface
ISO International Standardization Organization
LED Light-emitting diode
MB Megabyte
MS-DOS Operating system for PC-AT
Abbrev. Meaning
NI Zero pulse
NSTOP Limit-switch input, rot. dir. CCW (left)
PC-AT Personal Computer with 80x86 processor
PELV Protected low voltage
PLC Programmable logic controller
PSTOP Limit-switch input, rot. dir. CW (right)
PWM Pulse-width modulation
RAM Volatile memory
RBallast Ballast (regen) resistor
RBext External ballast (regen) resistor
RBint Internal ballast (regen) resistor
RES Resolver
ROD 426 A quad B Encoder
SRAM Static RAM
SSI Synchronous serial interface
SW/SETP. Setpoint
UL Underwriter Laboratory
V AC AC voltage
V DC DC voltage
VDE Verein deutscher Elektrotechniker
1 General
1.1 About this manual
This manual describes the digital servo amplifiers of the SERVOSTAR 400 series.
In this manual you can find information about:
� Technical data of the servo amplifiers Chapter I
� Assembly / installation of the servo amplifiers Chapter II
� Interfaces Chapter III
� Commissioning the servo amplifiers Chapter IV
� Accessories for the servo amplifiers Chapter V
� Transport, storage, maintenance, disposal Chapter VI
A more detailed description of the field bus interfaces and the digital connection to automation sys-
tems can be found on the accompanying CD-ROM in PDF format (system requirements: WIND-
OWS 95 or higher, Internet browser, Acrobat Reader 4.0 or higher) in English, German, French and
Italian versions.
You can print out this documentation on any standard printer. A printed copy of the documentation
is available from us at extra cost.
This manual makes the following demands on qualified personnel :
Transport: only by personnel with knowledge of handling electrostatically
sensitive components.
Installation: only by electrically qualified personnel
Commissioning: only by qualified personnel with extensive knowledge of electrical
engineering / drive technology
SERVOSTAR®
400 Installation manual 9
Kollmorgen 07/03 General
1.2 Use as directed
The servo amplifiers are components which are built into electrical equipment or machines, and can
only be commissioned as integral components of such equipment.
The manufacturer of the machine must produce a hazard analysis for the machine and
take appropriate measures to ensure that unforeseen movements do not result in perso-
nal injury or material damage.
Use the servo amplifiers only on the following types of supply:
1 x 115V AC (only SERVOSTAR 40xM, unearthed operation is permissible)
3 x 115V AC (only SERVOSTAR 40xM, unearthed operation is permissible)
1 x 230V AC (only SERVOSTAR 40xM, unearthed operation is permissible)
3 x 230V AC (all types, unearthed operation is permissible)
3 x 400V AC (only SERVOSTAR 44xM, TN-system or TT-system with earthed
neutral point, max. 5000A symmetrical rated current)
If the servo amplifiers are used in residential areas, or in business or commercial premises, then
additional filter measures must be implemented by the user.
The SERVOSTAR 400 family of servo amplifiers is only intended to drive specific brushless syn-
chronous servomotors with closed-loop control of torque, speed and/or position. The rated voltage
of the motors must be at least as high as the DC-link voltage of the servo amplifier.
The servo amplifiers may only be operated in a closed switchgear cabinet, taking into account the
ambient conditions defined on Page 18. Ventilation or cooling measures may be required to keep
the temperature below 45°C.
Use only copper-cored cables for wiring. The conductor cross-sections can be taken from the Euro-
pean standard EN 60204 (or Table 310-16 of NEC for 60°C or 75°C in the column for AWG
cross-sections).
We can only guarantee that the system will conform to the standards cited on Page 6 if the compo-
nents used are exclusively those supplied by us (servo amplifier, motor, cables etc.).
10 SERVOSTAR®
400 Installation manual
General 07/03 Kollmorgen
1.3 Nameplate
The nameplate depicted below is attached to the side of the servo amplifier.
The information described below is printed in the individual fields.
1.4 Equipment description
1.4.1 Package as supplied
If you order a SERVOSTAR 400 series amplifier from us, you will receive:
— SERVOSTAR 4xxM (master)
— Mating connectors for X0, X1, X3
— Protective cover for the axis-side (required only once per system)
— Assembly and Installation Instructions
— Setup software DRIVE.EXE and online documentation on CD-ROM
alternatively
— SERVOSTAR 4xxA (axis module)
— Mating connector for X3
— Short-form instructions
The mating SubD connectors are not part of the package supplied!
Accessories: (must be ordered separately if required)
— Electrical add-on fan (for max. 2 axes, required for SERVOSTAR 4x6)
— Synchronous servomotor (linear or rotary)
— Motor lead (pre-assembled), or motor cable as cut-off length + loose connectors
(motor- and amplifier-side)
— Feedback cable (pre-assembled, see also App. Report “Cables & Connectors”) or
Both feedback connectors, loose with feedback cable as cut-off length
— External regen resistor (� p.65)
— Communication cable to PC(� p.45) for parameterizing the master and any
attached axis modules
— Power cable, control cables, fieldbus cables (as lengths)
SERVOSTAR®
400 Installation manual 11
Kollmorgen 07/03 General
Typenbezeichnung
Spannungsversorgung
Model Number
Power Supply
Ser. Nr
Nennstrom
Ser. No.
Nom. Current
Bemerkung
Schutzart
Comment
Encl.Rating
Danaher Motion GmbH & Co. KGWacholderstr. 40-42D-40489 Düsseldorfwww.DanaherMotion.de
Customer ServiceEurope Tel. +49 (0)203 / 99790Italy 3 36 594260North America 1 80 777-3786
Tel. + 9 (0) 2 /Tel. + ( 0)
Instrument codeSerial numberServo amplifier type
Electrical supply,
installed loadOutput current
in S1 operationEnclosure rating
1.4.2 Digital servo amplifiers in the series SERVOSTAR 400
Standard version
� 2 supply voltage versions: SERVOSTAR 40xM up to 3x230VAC and
SERVOSTAR 44xM up to 3x400VAC
� one size for the master and axis modules each, see Page 25
� shield connection directly on the servo amplifier
� analog input
� fieldbus interface is integrated
(standard: CANopen for integration into CAN bus systems)
� RS232 is integrated
� pulse-direction interface is integrated
Options
� PROFIBUS DP interface instead of CANopen, see page 53
� SERCOS interface instead of CANopen, see page 54
Open architecture
� open hardware and software architecture
� macro language and compiler are integrated
1.4.3 Operation directly from the supply
Supply power (master only)
� operation directly from electrical supply:
1 x 115V AC (SERVOSTAR 40xM only, unearthed operation is permitted)
3 x 115V AC (SERVOSTAR 40xM only, unearthed operation is permitted)
1 x 230V AC (SERVOSTAR 40xM only, unearthed operation is permissible)
3 x 230V AC (all types, unearthed operation is permissible)
3 x 400V AC (SERVOSTAR 44xM only, TN-system or TT-system with
earthed neutral point, max. 5000A sym. rated current)
� fusing (e.g. fusible cutout) provided by the user
Auxiliary voltage 24V DC
� electrically isolated via an external 24V DC PSU, e.g. with isolating transformer
Power input filter
� interference suppression filter for the supply input (for reduced availability according to
EN61800-3) is integrated
� interference suppression filter for the 24V auxiliary supply (for general availability according
to EN 61800-3) is integrated
12 SERVOSTAR®
400 Installation manual
General 07/03 Kollmorgen
1.4.4 Digital servo amplifier concept
Operation and parameter setting
� with the comfortable setup software, via the serial interface of a PC to a single connection for
all axes in a system
� station address setting through two keys and a 3-digit LED status display on the master
� fully programmable via RS232 interface
Power section
� power supply B6 rectifier bridge, directly off electrical supply
input, integral power input filter and inrush circuit
� all shielding connections directly on the amplifier
� output stage IGBT module with isolated current measurement
Clock frequency can be switched from 8 to 16 kHz with
ASCII command (with power reduction, please contact
our customer support)
� regen (ballast) circuit internal regen resistor as standard,
external regen resistor if required
� DC-link voltage 160...310V DC for SERVOSTAR 40xM
310...560V DC for SERVOSTAR 44xM
160...560V DC for SERVOSTAR 4xxA
Completely digital control
� digital current controller (space vector pulse-width modulation, 62.5 µs)
� freely programmable digital speed controller (62.5 µs or 250 µs)
� integral position controller, with adaptation possibilities for every application (250 µs)
� integrated pulse direction interface, for connection of a servomotor to a stepper-motor con-
trol
� evaluation of the resolver signals or sine/cosine signals from a high-resolution encoder
� encoder emulation (incremental ROD 426-compatible or SSI)
SERVOSTAR®
400 Installation manual 13
Kollmorgen 07/03 General
Comfort functions
� adjustable setpoint ramps
� 4 programmable digital inputs
(two are normally defined as limit-switch inputs)
� 2 programmable digital outputs
� freely programmable combinations of all digital signals
Integrated safety
� safe electrical separation to EN 50178 between the power input / motor connections and the
signal electronics, provided by appropriate creepage distances and complete electrical isola-
tion
� Soft-start, overvoltage detection, short-circuit protection, phase-failure monitoring
� temperature monitoring of servo amplifier and motor (when using our motors with our pre-as-
sembled cables)
Minimum complexity
� up to 8 axes in a single system
� only one power supply feed and one auxiliary voltage supply per system
� all axes in a system can be parameterized through a single interface
� Strongly reduced wiring expenditure by modular structure
� Simple mechanical structure on DIN rails
14 SERVOSTAR®
400 Installation manual
General 07/03 Kollmorgen
1.5 Block diagram
SERVOSTAR®
400 Installation manual 15
Kollmorgen 07/03 General
1.6 Components of a servo system
16 SERVOSTAR®
400 Installation manual
General 07/03 Kollmorgen
24V supply
fuses
drive contactor
terminals
motor
SERVOSTAR 400
PC
Controls / PLC
1.7 Technical data for SERVOSTAR 400
max. 230VAC max. 400VAC
SERVOSTAR SERVOSTAR
Rated data DIM 403M 406M 403A 406A 443M 446M 403A 406A
Rated supply voltage V~
1 x 115V-10%
to
3 x 230V+10%
—
3 x 230V-10%
to
3 x 400V+10%
—
Max. installed load for S1 operation
(in a multi-axis system)kVA 7 — 12 —
Rated DC-link voltage V= 160 - 310 310 - 560
Rated output current (rms value, � 3%, @ 8kHz) Arms 3 6* 3 6* 3 6* 3 6*
Peak output current (max. ca. 5s, � 3%, @ 8kHz) Arms 9 12* 9 12* 9 12* 9 12*
Clock frequency of output stage kHz 8 (can be switched to 16, see page 13)
Technical data of regen circuit — � p.20 — � p.20 —
Overvoltage switch-off threshold V 450 — 750 —
maximum load inductance mH 75 40 75 40 75 40 75 40
minimum load inductance mH 12 7,5 12 7,5 12 7,5 12 7,5
Form factor of the output current
(rated conditions and min. load inductance)— 1.01 1.01
Bandwidth of subordinate current controller kHz > 1.2 > 1.2
Residual voltage drop at rated current V < 5 < 5
Quiescent dissipation, output stage disabled W 12 15 12 15 12 15 12 15
Dissipation at rated current
(without regen dissipation)W 35 60 30 40 35 60 30 40
Internal fusing (for external fusing � p.18)
Auxiliary supply 24V — int. 20 AM—
int. 20 AM—
Regen resistor — electronic electronic
Inputs/outputs
Analog input, 14-bit resolution V �10 �10
common-mode voltage max. V �10 �10
input resistance k� 20 20
Digital control inputs low 0...7 / high 11...30V, 7mA low 0...7 / high 11...30V, 7mA
Digital control outputs, open emitter max. 30V, 10mA max. 30V, 10mA
BTB/RTO output, relay contactsV
DC max. 30,
AC max 42 —
DC max. 30,
AC max 42 —
mA 500 500
Auxiliary supply, electrically isolated,
without brake, without fan
V 20...30—
20...30—
A 0.5 0.5
Auxiliary supply, electrically isolated,
with brake or fan (check voltage drop !)
V24
(-0% +15%) —
24
(-0% +15%) —
A 2.5 2.5
Max. output current for brake A 2 2
Connections
Control signals — Combicon spring terminal
Power supply —Power
Combicon—
Power
Combicon—
Motor — Combicon Combicon
Resolver input — SubD 9-pin (socket) SubD 9-pin (socket)
Incremental encoder input — SubD 15-pin (socket) SubD 15-pin (socket)
PC interface — SubD 9-pin (plug) SubD 9-pin (plug)
Encoder emulation, ROD/SSI — SubD 9-pin (plug) SubD 9-pin (plug)
Mechanical
Weight kg 3 1.7 3 1.7
Height, without connectors mm 230 267* 230 267* 230 267* 230 267*
Width mm 100 50 100 50
Depth, without connectors mm 240 240 240 240
* with add-on ventilation
SERVOSTAR®
400 Installation manual 17
Kollmorgen 07/03 General
1.7.1 External fusing
Fusible cutouts or similar
AC feed FN1/2/3 16 A slow
24V feed FH1/2 16 A slow
regen resistor FB1/2 6 A slow
1.7.2 Permissible ambient conditions, ventilation, mounting position
Storage temp. / humidity / duration � p.65
Transport temperature / humidity � p.65
Supply voltage tolerances
main power
SERVOSTAR 40xM
SERVOSTAR 44xM
auxiliary supply
w/o brake, w/o fan
with brake or fan
min 1x115V-10% AC / max 1x230V+10%
, 50/60 Hz
min 3x115V-10% AC / max 3x230V+10%
, 50/60 Hz
min 3x230V-10% AC / max 3x400V+10%
, 50/60 Hz
20 VDC ... 30 VDC
24 VDC (-0% +15%)
Ambient temperature in operation0...+45
oC at rated conditions
+45...+55°C with power derating 2.5% / K
Humidity in operation rel. humidity 85%, no condensation
Site altitude
up to 1000m amsl without restrictions
1000...2500m amsl with derating
1.5% / 100m
Pollution level Pollution level 2 as per EN 60204 / EN 50178
Enclosure rating IP 20
Mounting position normally vertical � p.24
Ventilationfree convection for SERVOSTAR4x3,
add-on fan (� p.66) required for SERVOSTAR4x6
Make sure that there is adequate forced ventilation within the closed switchgear cabinet.
1.7.3 Conductor cross-sections
Following EN 60204-1, we recommend for single-axis systems:
AC connection 4 mm², depending on the system fusing
Motor cables 1 mm², shielded, capacitance <150pF/m, max. 25m
Resolver, motor thermostat4x2x0.25 mm², twisted pairs, shielded, max.100m,
capacitance <120pF/m
Encoder, motor thermostat7x2x0.25 mm², twisted pairs, shielded, max. 50m,
capacitance <120pF/m
Analog signals 0.25 mm² , twisted pairs, shielded
Control signals, BTB, DGND 0.5 mm²
Holding brake (motor) 0.75 mm², shielded, check voltage drop
+24 V / XGND max. 2.5 mm², check voltage drop
Technical data for connecting cables � p.33. Please note our Application Report “Cables & Connectors”.
1.7.4 Recommended tightening torques
Connector Tightening torque
X1, X3, X6 0.3 Nm
X0 1.3 Nm
Earthing bolts 3.5 Nm
lower mounting bolt 3,5 Nm
18 SERVOSTAR®
400 Installation manual
General 07/03 Kollmorgen
1.7.5 LED display
A 3-digit LED display indicates the amplifier status after switching on the 24V supply
(� p.59). The address can be read out while it is being set on the master by using the keys.
1.8 Grounding system
AGND – ground reference for analog signals, internal analog ground
DGND – ground reference for digital signals and auxiliary supply voltage, optically isolated
The electrical isolation is indicated in the block diagram (� p.15).
1.9 Motor holding brake conrol
A motor holding brake (24V / max.1,5A) can be controlled directly by the servo amplifier. This
function does not ensure personnel safety! The brake function must be enabled through the
BRAKE parameter (on the screen page for Motor): the setting is WITH. In the diagram below you
can see the timing and functional relationships between the ENABLE signal, speed setpoint, speed
and braking force.
During the internal ENABLE delay time of 100ms the speed setpoint of the servo amplifier is inter-
nally driven down a 10ms ramp to 0V. The brake output is switched on when 3% of the final speed
is reached, at the latest after 1 second.
The rise (fbrH) and fall (fbrL) times of the holding brakes that are built into the motors vary for the dif-
ferent types of motor (see motor manual).
A description of the interface can be found on Page 38.
Personnel-safe operation of the holding brake requires an additional “make” contact in the brake cir-
cuit and a spark suppressor device (e.g. a varistor) in the recommended brake circuit:
SERVOSTAR®
400 Installation manual 19
Kollmorgen 07/03 General
SERVOSTAR
1.10 Regen circuit
During braking with the aid of the motor, energy is fed back to the servo amplifier. This energy is
converted into heat in the regen resistor (ballast resistor). The regen resistor is switched in and out
by the regen circuit. The switching thresholds for the regen circuit are adjusted to suit the supply
voltage with the aid of the setup software.
Our customer support can help you with the calculation of the regen power which is required. A des-
cription of the interface can be found on Page 39 .
Internal regen resistor 33 �
External regen resistor 33 �
Functional description
The regen circuit starts to respond when the DC-link voltage reaches the set value.
If the energy which is fed back from the motor, as an average over time or as a
peak value, is higher than the preset regen power, then the servo amplifier will
output the status regen power exceeded and the circuit will be switched off.
At the next internal check of the DC-link voltage (after a few milliseconds) an
overvoltage will be detected and the servo amplifier will be switched off, with the
error message overvoltage (� p.60).
The BTB/RTO contact (terminals X1/1,2) will be opened simultaneously (� p.44).
Technical data: regen circuit
Supply voltage Rated data DIM Value
3 x 230 V
Upper switch-on threshold for regen circuit V 400
Switch-off threshold for regen circuit V 380
Continuous int. power in regen circuit (RBint) W 55
Continuous ext. power in circuit (RBext) max. kW 0,4
Pulse power, internal (RBint max. 1s) kW 4.8
Pulse power, external (RBext max. 1s) kW 4.8
External regen resistor � 33
3 x 400 V
Upper switch-on threshold for regen circuit V 720
Switch-off threshold for regen circuit V 680
Continuous int. power in regen circuit (RBint) W 80
Continuous ext. power in circuit (RBext) max. kW 0,6
Pulse power, internal (RBint max. 1s) kW 16
Pulse power, external (RBext max. 1s) kW 16
External regen resistor � 33
20 SERVOSTAR®
400 Installation manual
General 07/03 Kollmorgen
1.11 Switch-on/-off behaviour
The diagram below illustrates the correct functional sequence for switching the servo amplifier on
and off.
1.11.1 Stop function as per EN 60204 (VDE 0113)
If a fault occurs (� p.60), the output stage of the servo amplifier is switched off and the BTB/RTO
contact is opened. In addition, a global error signal can be given out at one of the digital outputs
(terminals X3/8 and X3/9) (see the Online help in the setup software, or the manual for the setup
software). These signals can be used by the higher-level control to terminate the current PLC cycle
or to shut down the drive (through an additional brake or similar means).
Instruments with a selected Brake function use a special sequence for switching off the output stage
(� p.19).
The Stop functions are defined in EN 60204 (VDE 0113), Paras. 9.2.2 and 9.2.5.3.
There are three categories of Stop functions:
Category 0: Shut down by immediate switch-off of the supply of energy to the
drive machinery (i.e. an uncontrolled shut-down)
Category 1: A controlled shut-down, during which the supply of energy to the
drive machinery is maintained to perform the shut-down, and where
the supply is only interrupted when standstill has been reached
Category 2: A controlled shut-down, where the supply of energy to the drive
machinery is maintained
Every machine must be equipped with a Stop function to Category 0.
Categories 1 and/or 2 must be provided if the safety or functional requirements of the machine
make this necessary.
SERVOSTAR®
400 Installation manual 21
Kollmorgen 07/03 General
1.11.2 Emergency stop methods
The Emergency Stop function is defined in EN 60204 (VDE 0113), Para. 9.2.5.4.
Implementation of the Emergency Stop function :
You can find wiring recommendations in our application note
“Stop and Emergency Stop functions with SERVOSTAR”
Category 0:
The amplifier is disabled, the electrical supply is disconnected.
The drive must be held by an electromagnetical clamping device (brake).
In multi-axis systems (several SERVOSTAR 400-systems or combinations of
SERVOSTAR 400 and SERVOSTAR 600) using a coupled DC-link (= DC bus) the motor
cable must also be disconnected by a changeover switch (a contactor, such as Siemens
type 3RT1516-1BB40) and short-circuited by resistors wired in a star configuration.
Category 1:
If hazardous conditions can result from an Emergency Stop disconnection,
because of an unbraked run-down, then the drive can be switched off by a
controlled shut-down.
Stop Category 1 permits electromotive braking with a switch-off when zero
speed has been reached.
Safe shut-down can be achieved if the disappearance of the supply power is not
evaluated as a fault, but the control system takes on the task of disabling the
amplifier.
In the normal situation only the main supply power is switched off in a safe
manner. The 24V auxiliary supply remains switched on.
22 SERVOSTAR®
400 Installation manual
General 07/03 Kollmorgen
2 Installation
2.1 Important notes
� Protect the servo amplifier from impermissible stresses. In particular, do not let any compo-
nents become bent or any insulation distances altered during transport and handling. Avoid
contact with electronic components and contacts.
� Check the combination of servo amplifier and motor (� p.72). Compare the rated voltage
and current of the units. Carry out the wiring according to the instructions on Page 26.
� Make sure that the maximum permissible rated voltage at the terminals for L1, L2, L3 and
+RBext, –DC is not exceeded by more than 10%, even in the most unfavourable conditions
(see EN 60204-1 Section 4.3.1). An excessive voltage on these terminals can lead to de-
struction of the regen circuit and the servo amplifier.
Use the SERVOSTAR 44x only on an earthed 3-phase supply system. Use the amplifier only
to drive a synchronous servomotor.
� The fusing of the AC supply input and the 24V supply is installed by the user (� p.18).
� Take care that the servo amplifier and motor are properly earthed. Do not use painted
(non-conductive) mounting plates.
� Route power and control cables separately. We recommend a separation of at least 20 cm.
This improves the interference immunity required by EMC regulations. If a motor power ca-
ble is used which includes cores for brake control, the brake control cores must be sepa-
rately shielded.
Earth the shielding at both ends (� p.28).
� Install all heavy-current cables with an adequate cross-section, as per EN 60204-1
(� p.18).
� Wire the BTB/RTO contact in series into the safety circuit of the installation.
Only in this way is the monitoring of the servo amplifier assured.
� Install all shielding with large area (low impedance) connections, with metallised connector
housings or shield connection clamps where possible.
Notes on connection techniques can be found on Page 32 and the Application Note “Cables
& Connectors”.
� Ensure that there is an adequate flow of cool, filtered air into the bottom of the switchgear
cabinet. Note the conditions on Page 18 .
� It is permissible to alter the servo amplifier settings by using the operator software.
Any other alterations will invalidate the warranty.
Caution
Never disconnect the electrical connections to the servo amplifier while it is live.
In unfavourable circumstances this could result in destruction of the electronics.
Residual charges in the capacitors can have dangerous levels up to 300 seconds after
switching off the mains supply voltage. Measure the voltage in the DC-link
(+RBext/-DC) and wait until the voltage has fallen below 40V.
Control and power connections can still be live, even when the motor is not rotating.
SERVOSTAR®
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Kollmorgen 07/03 Installation
2.2 Mounting
Material: 2 mounting rails to EN60715, min. length = system width + 40mm,
make sure there is a conductive connection to the mounting plate
Mount the protective cover (7mm) on the left side of the system.
Tools required: Screwdriver with approx. 5 mm blade width
24 SERVOSTAR®
400 Installation manual
Installation 07/03 Kollmorgen
SERVOSTAR 400
60715
2.2.1 Dimensions SERVOSTAR 400
SERVOSTAR®
400 Installation manual 25
Kollmorgen 07/03 Installation
SERVOSTAR 400M
SERVOSTAR 400A
2.3 Wiring
Only professional staff who are qualified in electrical engineering are allowed to install the
servo amplifier.
The installation procedure is described as an example. A different procedure may be appropriate or
necessary, depending on the application of the equipment.
We provide further know-how through training courses (on request).
Caution !
Only install and wire up the equipment when it is not live, i.e. when neither the mains
power supply nor the 24 V auxiliary voltage nor the operating voltages of any other
connected equipment is switched on.
Take care that the cabinet is safely disconnected (with a lock-out, warning signs etc.).
The individual voltages will be switched on for the first time during commissioning.
Note !
The ground symbol�, which you will find in all the wiring diagrams, indicates that
you must take care to provide an electrically conductive connection with the largest
possible area between the unit indicated and the mounting plate in the switchgear cabi-
net. This connection is for the effective grounding of HF interference, and must not be
confused with the PE symbol � (protective earth to EN 60204).
Use the following wiring and connection diagrams :
— Power and control connections : Page 28
— Multiaxis systems : Page 30
— Resolver : Page 39
— High-resolution encoder : Page 40
— Encoder emulation ROD : Page 45
— Encoder emulation SSI : Page 46
— RS232 / PC : Page 45
— Pulse/direction interface : Page 48
— Master/slave interface : Page 50
— CAN interface : Page 52
— PROFIBUS interface : Page 53
— SERCOS interface : Page 54
26 SERVOSTAR®
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Installation 07/03 Kollmorgen
The following notes should assist you to carry out the installation in a sensible sequence, without
overlooking anything important.
In a closed switchgear cabinet. Observe Page 18 .
The site must be free from conductive or corrosive materials.
For the mounting position within the cabinet� p.24
Check that the ventilation of the servo amplifier is unimpeded and keep
within the permitted ambient temperature� p.18 .
Keep the required space clear above and below the servo amplifier
� p.24.
Mount the servo amplifier on mounting rails (DIN-rails) on the conduc-
tive, earthed mounting plate in the cabinet.
Select cables according to EN 60204-1,� p.18
EMC-conform shielding and grounding (� p.28)
Earth the mounting plate, motor housing and CNC-GND of the con-
trols.Notes on connection techniques are on Page 32
— Route power leads separately from control cables
— Wire the BTB/RTO contact in series into the safety loop of the
installation
— Connect the digital control inputs to the servo amplifier
— Connect up AGND
— Connect the analog setpoint, if required
— Connect the feedback unit (resolver or encoder)
— If required, connect the encoder emulation
— If required, connect the fieldbus
— Connect the motor cable
— Connect shielding to EMC connectors at the motor end, and the
— shielding lug at the amplifier end
— Connect motor-holding brake, with shielding to EMC connector at
— the motor end, and to shielding lug at the amplifier end
— If required, connect the external regen resistor (with fusing)
— Connect the auxiliary supply
— (maximum permissible voltages� p.18)
— Connect main power supply
— (maximum permissible voltages� p.18)
— Connect PC (� p.45).
Make a final check of the wiring carried out against the wiring diagrams
that have been used
SERVOSTAR®
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Kollmorgen 07/03 Installation
Site
Ventilation
Mounting
Grounding,
Shielding
Cable selection
Check
Wiring
2.3.1 Wiring diagram SERVOSTAR 400M
28 SERVOSTAR®
400 Installation manual
Installation 07/03 Kollmorgen
� p.37
� p.52
� p.45
� p.50
� p.38
� p.40
� p.39
� p.41
� p.42
� p.43
� p.44
� p.38
� p.39
SERVOSTAR 400MFollow the safety instructions (� p.5)
and the use as directed (� p.10) !
2.3.2 Wiring diagram SERVOSTAR 400A
SERVOSTAR®
400 Installation manual 29
Kollmorgen 07/03 Installation
� p.52
� p.50
� p.38
� p.40
� p.39
� p.41
� p.42
� p.43
SERVOSTAR 400AFollow the safety instructions (� p.5)
and the use as directed (� p.10) !
2.3.3 Example of connections for multi-axis system
30 SERVOSTAR®
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Installation 07/03 Kollmorgen
SERVOSTAR 400A
SERVOSTAR 400A
SERVOSTAR 400M
MM
M
Follow the safety instructions (� p.5)
and the use as directed (� p.10) !
2.3.4 Connector assignments SERVOSTAR 400
SERVOSTAR®
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Kollmorgen 07/03 Installation
2.3.5 Connection techniques
Please consult our application note “Cables & Connectors”.
2.3.5.1 Shield connection on the front panel
32 SERVOSTAR®
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Installation 07/03 Kollmorgen
The pre-assembled cables for
SERVOSTAR 400 are provided
with an overall metal ferrule at the
amplifier end that is electrically
connected to the shielding.
Thread a cable tie through each slot
in the shielding strip (front panel) of
the servo amplifier.
Tighten up the cable ties so that the
shielding ferrule and the sheathing
of the cable is pressed down tightly
against the shielding strip.
SERVOSTAR400
SERVOSTAR400
2.3.5.2 Technical data of connecting cables
Further information on the chemical, mechanical and electrical characteristics of the cables can be
obtained from our customer support.
Insulation material
Sheathing PUR (polyurethane, code 11Y)
Core insulation PETP (polyesteraphthalate, code 12Y)
Capacitance
Motor cable less than 150 pF/m
RES/encoder cable less than 120 pF/m
Technical data
— The brackets in the cable designation indicate the shielding.
— All cables are suitable for use as trailing cables.
— The technical data refer to the use as moveable cables.
operating life : 1 million bending cycles
— The permissible operating temperature range is from -30°C to +80°C.
— All cables are colour-coded according to IEC 757.
Cores
[mm²]
External diameter
[mm]
Bending radius
[mm]Remarks
(4x1.0) 10 100 Motor cable
(4x1.0+(2x0.75)) 10.5 100Motor cable with extra cores
for controls
(4x2x0.25) 6.9 60
twisted pairs(7x2x0.25) 9.9 80
(10x2x0.14) 8.8 80
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This page has been deliberately left blank.
34 SERVOSTAR®
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Installation 07/03 Kollmorgen
2.4 Setup software
2.4.1 General
This chapter describes the installation of the setup software DRIVE.EXE for the SERVOSTAR 400
digital servo amplifiers.
We offer training and familiarization courses on request.
2.4.1.1 Use as directed
The operator software is intended to be used for altering and storing the operating parameters for
the SERVOSTAR 400 series of servo amplifiers. The attached servo amplifier is commissioned with
the assistance of the software - during this process the drive can be controlled directly by the ser-
vice functions.
Only professional personnel who have the relevant expertise described on Page 9 are
permitted to carry out online parameter setting for a drive which is running.
Sets of data which are stored on data media are not safe against unintended alteration
by other persons. After loading a set of data you must therefore check all parameters
thoroughly before enabling the servo amplifier.
2.4.1.2 Software description
The servo amplifiers must be adapted to the requirements of your installation. Usually you will not
have to carry out this parameter setting yourself on the amplifier, but on a PC, with the assistance of
the operator software. The PC is connected to the servo amplifier by a null-modem (serial) cable.
The setup software provides the communication between the PC and SERVOSTAR 400.
You will find the setup software on the accompanying CD-ROM and in the download section of the
Danaher Motion web appearance.
With very little effort you can alter parameters and immediately observe the effect on the drive,
since there is a continuous (online) connection to the amplifier. At the same time, important actual
values are read out from the amplifier and displayed on the PC monitor (oscilloscope function).
Any interface modules which may be built into the amplifier are automatically recognized, and the
additional parameters which are required for position control or motion-block definition are made
available.
Sets of data can be stored on data media (archived) and loaded again. You can also print out the
data sets.
We provide you with motor-specific default sets of data for all the reasonable combinations of servo
amplifier and motor. In most applications you will be able to use these default values to get your
drive running without any problems.
SERVOSTAR®
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Kollmorgen 07/03 Installation
2.4.1.3 Hardware requirements
The PC interface (X6, RS232) of the master is connected to a serial interface on the PC by a
null-modem cable (not a null-modem link cable !) (� p.45).
Connect / disconnect the interface cable only when the supply is switched off for both
the PC and the servo amplifier.
The interface in the servo amplifier is electrically isolated by an optocoupler, and is at the same
potential as the CANopen interface.
Minimum requirements for the PC:
Processor : 80486 or higher
Operating system : WINDOWS 95(c) / 98 /2000 / ME, WINDOWS NT4.0 / XP
Graphica adapter : Windows compatible, color
Drives : Diskette drive 3.5"
Hard disk (5 MB free space)
CD-ROM drive
Main memory : at least 8MB
Interface : one free serial interface (COM1:, 2:, 3: or 4:)
2.4.1.4 Operating systems
WINDOWS 95(c) / WINDOWS 98 / WINDOWS 2000 / WINDOWS ME / WINDOWS NT / XP
DRIVE.EXE can run under WINDOWS 95c / 98 / 2000 / ME / XP or WINDOWS NT 4.0.
The help system can not be used under Windows 95a and 95b.
WINDOWS FOR WORKGROUPS 3.xx, DOS, OS2, Unix, Linux
DRIVE.EXE does not run under WINDOWS 3.xx, DOS, OS2, Unix and Linux.
Emergency operation is possible with an ASCII terminal-emulation (without user interface).
Interface setting: 9600 bps, no parity, no handshake
2.4.2 Installation under WINDOWS 95 / 98 / 2000 / ME / NT / XP
The CD-ROM includes an installation program called SETUP.EXE that makes it easier to install the
setup software on your PC.
Connection to the serial interface of the PC:
Connect the interface cable to a serial interface on your PC and the PC interfaces (X8) of the
SERVOSTAR 400 (� p.45).
Switch-on:
Switch on your PC-AT and the monitor.
After the start phase (boot-up) is finished, the Windows user-interface appears on the screen.
Installation:
Click on START (task bar), then on Run.
Enter the program call x:\setup.exe (where x= is the drive letter for the CD drive).
Click on OK and follow the instructions.
Setting up the graphics card (font size)
Click on the desktop with the right mouse button. The dialogue window “Properties” will appear.
Select the file card “Settings”. Set the Font size to “Small Fonts”. Follow the instructions provided
by the system.
36 SERVOSTAR®
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Installation 07/03 Kollmorgen
3 Interfaces
This chapter presents all the important interfaces, divided between master and axis module. The
precise location of the connectors and terminals can be seen on Page 31.
3.1 Supply voltage, master only
3.1.1 Supply connection (X0) for 3-phase supplies
Directly to earthed supply, filter is integrated, fusing (e.g. fusible cut-outs) to be provided by the user
� p.18
3.1.2 Supply connection (X0) for single-phase supplies
Directly to supply, filter is integrated, fusing (e.g. fusible cut-outs) to be provided by the user� p.18
SERVOSTAR®
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Kollmorgen 07/03 Interfaces
SERVOSTAR 400
SERVOSTAR 400
for SERVOSTAR40xM
for SERVOSTAR44xM
for SERVOSTAR40xM
3.1.3 24V auxiliary voltage (X0)
— Electrically isolated supply from an external 24V DC PSU, e.g. with isolating transformer
— Required current rating� p.17
— Integrated EMC filter for the 24V auxiliary supply
3.1.4 DC-link/DC-bus (X0)
Can be connected in parallel with further, identical masters (via terminals -DC and RBext).
3.2 Motor connection with brake (X6)
Max. admisible length of the motor cable is 25 m.
38 SERVOSTAR®
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Interfaces 07/03 Kollmorgen
SERVOSTAR 400
SERVOSTAR 400
3.3 External ballast resistor (X0), master only
Remove the plug-on link between terminals X0/5 (-RB) and X0/4 (+Rbint).
3.4 Feedback
3.4.1 Resolver connection (X5)
Our rotary servomotors have 2-pole hollow-shaft resolvers built in as a standard.
It is possible to connect 2- to 32-pole resolvers to SERVOSTAR 400.
If lead lengths of more than 25m are planned, please consult our customer support.
The thermostat contact in the motor is connected via the resolver cable to the SERVOSTAR 400
and evaluated there.
SERVOSTAR®
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Kollmorgen 07/03 Interfaces
SERVOSTAR 400
SERVOSTAR 400SubD9 12-pin round
3.4.2 Encoder connection (X2)
As an option, the motors can be fitted with a single-turn or multiturn sine-cosine encoder. Preferred
types are the ECN1313 and EQN1325 encoders.
The encoder is used by the SERVOSTAR 400 as a feedback device for drive tasks that require
highly precise positioning or extremely smooth running.
If lead lengths of more than 25m are planned, please consult our customer support.
The thermostat contact in the motor is connected via the encoder cable to the SERVOSTAR 400
and evaluated there.
40 SERVOSTAR®
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Interfaces 07/03 Kollmorgen
SERVOSTAR 400 SubD15 17-pin round
3.5 Control signals
3.5.1 Analog setpoint input (X3)
The servo amplifier has a programmable input for analog setpoints.
AGND (X3/1) must always be joined to the CNC-GND of the controls to provide a ground reference.
Technical data
— Input voltage max. ± 10 V
— Resolution 1.25 mV
— Ground reference AGND, terminal X3/1
— Input resistance 20 k�
— Common mode voltage range for both inputs ± 10 V supplementary
Analog input (terminals X3/2-3)
Input voltage max. ± 10 V, 14-bit resolution, scalable
Standard setting speed setpoint
Fixing the direction of rotation
Standard setting clockwise rotation of the motor shaft (looking at shaft end)
with positive voltage on terminal X3/3 (+ ) against X3/2 ( - )
To reverse the direction of rotation you can swap the connections to terminals X3/2-3 or change the
DIRECTION parameter in the SPEED screen.
SERVOSTAR®
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SERVOSTAR 400
3.5.2 Digital control inputs (X3)
All digital inputs are electrically isolated through optocouplers.
Technical data
— Reference ground is digital-GND (DGND, terminal X1/4,5 on the master)
— The logic is dimensioned for +24V / 7mA (PLC-compatible)
— H-level from +12...36V / 7mA, L-level from 0...7V / 0 mA
You can use the digital inputs PSTOP / NSTOP / DIGITAL-IN1 and DIGITAL-IN2 to initiate pre-pro-
grammed functions that are stored in the servo amplifier.
You will find a list of the pre-programmed functions in the Online Help.
If an input has to be re-assigned to a pre-programmed function, then the data set must be stored in
the EEPROM of the servo amplifier, and the 24V auxiliary supply for the servo amplifier must be
switched off and then on again (to reset the amplifier software).
Limit-switches PSTOP / NSTOP
Terminals X3/6 and X3/7 are normally programmed for the connection of limit switches.
If these inputs are not needed for the connection of limit switches, then they can be used for other
input functions.
Limit-switch positive/negative (PSTOP / NSTOP, terminals X3/6 and X3/7), high level in normal
operation (fail-safe for cable break).
A low signal (open) inhibits the corresponding direction of rotation, the ramp functions remain
effective.
DIGITAL-IN 1 / DIGITAL-IN 2
You can link the digital inputs at terminals X3/4 (DIGITAL-IN 1) and X3/5 (DIGITAL-IN2) with a
pre-programmed function.
42 SERVOSTAR®
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SERVOSTAR 400
3.5.3 Digital control outputs (X3)
Technical characteristics
— Ground reference is Digital-GND (DGND, terminal X1/4,5 on the master)
— Alle digital outputs are floating
— DIGITAL-OUT1 and 2 : Open-collector, max. 30V DC, 10mA
Programmable digital outputs DIGITAL-OUT 1 / 2:
You can use the digital outputs DIGITAL-OUT1 (terminal X3/8) and DIGITAL-OUT2
(terminal X3/9) to output messages from pre-programmed functions that are stored in the servo
amplifier.
A list of the pre-programmed functions can be found in the Online Help.
If an input is freshly assigned to a pre-programmed function, then the data set must be stored in the
EEPROM of the servo amplifier, and the 24V auxiliary supply of the servo amplifier must be swit-
ched off and on again (to reset the amplifier software).
SERVOSTAR®
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Kollmorgen 07/03 Interfaces
SERVOSTAR 400
3.5.4 Digital control signals on the PSU (X1)
Technical characteristics
— Ground reference is Digital-GND (DGND, terminal X1/4,5)
— The logic is dimensioned for +24V / 7mA (PLC-compatible)
— H-level from +12...36V / 7mA, L-level from 0...7V / 0 mA
BTB/RTO: Relay output, max. 30V DC or 42V AC, 0.5A
ENABLE input
The output stage of the servo amplifier is activated by the enable signal
(terminal X1/3, input 24V, active-high).
In the inhibited state (low signal) the motor which is attached does not have any torque.
Ready-to-operate contact BTB/RTO
Operational readiness (terminals X1/1 and X1/2 ) is signalled via a floating relay contact.
The contact is closed when all servo amplifiers in the system are ready for operation. This signal is
not influenced by the enable signal, the I²t- limit, or the regen threshold.
All faults cause the BTB/RTO contact to open and the output stage to switch off
A list of the error messages can be found on Page 60.
44 SERVOSTAR®
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SERVOSTAR 400
3.6 Encoder emulations
3.6.1 Incremental encoder interface (X4)
The incremental-encoder interface is part of the package supplied.
Select the encoder function ROD (screen page Encoder).
In the servo amplifier, the position of the motor shaft is calculated from the cyclic-absolute signals of
the resolver or encoder.
This information is used to generate incremental-encoder compatible pulses.
Pulses are output on the SubD-connector X4 as two signals, A and B, with 90° phase difference
and a zero pulse.
The resolution can be changed with the ENCOUT parameter:
32/64/128/256/512/1024 pulses per turn for Feedback=Resolver
2048/4096 pulses per turn for Feedback=EnDat or HIPERFACE
8192 pulses per turn for Feedback=EnDat or HIPERFACE up to 3000 rpm
16384 pulses per turn for Feedback=EnDat or HIPERFACE up to 1500 rpm
You can also adjust and store the position of the zero pulse within one mechanical turn
(parameter NI-OFFSET). Because of the compatibility with normal commercial pulse encoders, you
can only set the zero pulse when A=B=1.
The ground reference for the interface is AGND.
This must always be connected to the ground for the control input signals.
Connections and signal description for the incremental-encoder interface :
SERVOSTAR®
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Kollmorgen 07/03 Interfaces
SERVOSTAR 400
3.6.2 SSI interface (X4)
The SSI interface (synchronous serial absolute-encoder emulation) is part of the package delivered.
Select the encoder function SSI (screen page Encoder).
In the servo amplifier, the position of the motor shaft is calculated from the cyclic-absolute signals of
the resolver or encoder. The information is used to generate a position output compatible with the
data format of normal commercial SSI absolute encoders. This synchronous-serial, cyclic-absolute
12-bit information is output on the SubD-Connector X4.
24 bits are transmitted. The upper 12 bits are fixed at ZERO, the lower 12 bits contain the position
information.
The interface must be read in as a multi-turn encoder, but delivers valid single-turn data. The signal
sequence can be output in Gray code (standard) or in binary code (parameter SSI-CODE).
A serial signal is read out from the control, with a synchronous clock frequency of max. 1.5 MHz.
The servo amplifier can be adjusted to the clock frequency of your SSI-evaluation with the
SSI-CLOCK parameter (200 kHz or 1.5MHz and inverted).
The ground reference for the interface is AGND.
This must always be connected to the ground for the control input signals.
Connections and signal description for the SSI interface :
The count direction for the SSI interface is upwards when the motor shaft is rotating clockwise (loo-
king at the shaft end).
46 SERVOSTAR®
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SERVOSTAR 400
3.7 RS232 interface, PC connection (X8), master only
The setting of the operating, position control, and motion-block parameters, can be carried out by
using the setup software on an ordinary commercial PC.
Connect the PC interface (X8) of the servo amplifier while the supply to the equipment is swit-
ched off via a null-modem cable to a serial interface on the PC (do not use a null-modem link
cable!).
The interface has the same potential as the internal logic, and uses AGND as the ground reference.
The interface is selected and set up in the setup software.
Further notes can be found on Page 35 .
Interface cable between the PC and servo amplifiers of the SERVOSTAR 400 series:
(View: front view of the built-in SubD connectors, this corresponds to looking at the solder side of
the SubD connector on the cable.)
SERVOSTAR®
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Kollmorgen 07/03 Interfaces
SERVOSTAR 400
3.8 Interface for stepper motor controls (pulse/direction)
This interface can be used to connect the servo amplifier to a third-party stepper-motor controller.
The parameters for the servo amplifier are set up with the aid of the setup software (electrical gea-
ring). The number of steps can be adjusted, so that the servo amplifier can be adjusted to the
pulse/direction signals of any stepper-motor controller. Various monitoring signals can be output.
The analog input is inactive.
AGND (terminal X3/1) must be connected to the ground of the control system! Observe the
limit frequency!
Speed profile and signal diagram
Note:
Encoder Input A quad B offers more EMI supression.
48 SERVOSTAR®
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3.8.1 Connection of stepper motor controls with 5V signal level (X4)
You can use this interface to connect the servo amplifier to a stepper motor control with a 5V signal
level. The SubD connector X4 is used for this purpose.
Limit frequency: 1 MHz
AGND (terminal X3/1) must be connected to the ground of the control system!
3.8.2 Connection of stepper motor controls with 24V signal level (X3)
You can use this interface to connect the servo amplifier to a stepper motor control with a 24V sig-
nal level. The digital inputs DIGITAL-IN 1 and 2 on connector X3 are used for this purpose.
Limit frequency: 100 kHz
AGND (terminal X3/1) must be connected to the ground of the control system!
SERVOSTAR®
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Kollmorgen 07/03 Interfaces
SERVOSTAR 400
SERVOSTAR 400
3.9 Interface for master-slave operation, encoder control
This interface can be used to link several SERVOSTAR 400 amplifiers in master-slave operation.
The parameters for the slave amplifier are set up with the aid of the setup software (electrical gea-
ring). The resolution (no. of pulses/turn) can be adjusted. The analog setpoint input is inactive.
AGND (terminal X3/1) must be connected to the ground of the control system! Observe the
limit frequency!
Please contact our customer support for information on connecting external SSI encoders.
Signal diagram (for encoders with RS422 or 24V outputs)
3.9.1 Connection to SERVOSTAR 400 master, 5V level (X4)
This interface can be used to link several SERVOSTAR 400 amplifiers in master-slave operation.
Up to 16 slave amplifiers can be controller by the master via the encoder output. The SubD connec-
tor X4 is used for this purpose.
Limit frequency: 1 MHz, transition speed tv � 0.1µsec
AGND (terminal X3/1) must be connected to the ground of the control system!
50 SERVOSTAR®
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Interfaces 07/03 Kollmorgen
SERVOSTAR 400 SERVOSTAR 400
3.9.2 Connection to encoder with 24V signal level (X3)
You can use this interface to set up the SERVOSTAR 400 as a slave following an encoder with a
24V signal level (master-slave operation). This application uses the digital inputs DIGITAL-IN 1 and
2 on connector X3.
Limit frequency: 100 kHz, transition speed tv � 0.1µsec
AGND (terminal X3/1) must be connected to the ground of the control system!
3.9.3 Connection for Sin/Cos encoder (X2)
You can use this interface to set up the SERVOSTAR 400 as a slave following a sine/ cosine enco-
der (master-slave operation). This application uses the SubD connector X2.
Limit frequency: 250 kHz
AGND (terminal X3/1) must be connected to the ground of the control system!
SERVOSTAR®
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Kollmorgen 07/03 Interfaces
SERVOSTAR 400
SERVOSTAR 400
3.10 Fieldbus connection
3.10.1 CANopen interface (X7)
The interface for connection to the CAN bus (default: 500 kbps). The integrated profile is based on
the communication profile CANopen DS301 and the drive profile DSP402.
The following functions are available in connection with the integrated position controller:
Jogging with variable speed, homing, start motion task, start direct task, digital setpoint provision,
data transmission functions and many others.
Detailed information can be found in the CANopen manual.
The interface is at the same potential as the internal logic, and uses AGND as the ground refer-
ence. The analog input can still be used.
Even if the analog input is not used, AGND must nevertheless be joined to the control sys-
tem ground!
CAN bus cable
To meet ISO 11898 you should use a bus cable with a 120 � characteristic impedance. The maxi-
mum usable cable length for reliable communication decreases with increasing transmission speed.
As a guide, you can use the following values which we have measured, but they must not be assu-
med to be limits:
Cable data: Characteristic impedance 100-120 �
Cable capacitance max. 60 nF/km
Conductor loop resistance 159.8 �/km
Cable length, depending on the transmission rate
Transmission rate / kbps max. cable length / m
1000 20
500 70
250 115
Lower cable capacitance (max. 30 nF/km) and lower lead resistance (loop: 115 �/km) make it pos-
sible to transmit over longer distances.
(Characteristic impedance 150 ± 5� � terminating resistance 150 ± 5�).
For EMC reasons, the SubD connector housing must fulfil the following conditions:
— metal or metallized housing
— provision for connecting the cable shielding within the housing,
large-area connections
The master is fitted with a CAN input. All axis modules in the system are connected to this through
the internal bus. The last axis module has a CAN output, where the CAN bus either continues to
other bus participants or is terminated by a termination resistor.
52 SERVOSTAR®
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SERVOSTAR 400
3.10.2 PROFIBUS interface (X7), option
This section describes the PROFIBUS interface for SERVOSTAR 400.
Information on the range of functions and the software protocol can be found in the description
“Communication profile PROFIBUS-DP”.
The selection of cables, cable routing, shielding, bus connectors, bus termination and propagation
times are described in the “Setup guidelines for PROFIBUS-DP/FMS” from PNO, the PROFIBUS
User Organization, Order No. 2.111.
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Kollmorgen 07/03 Interfaces
SERVOSTAR 400
3.10.3 SERCOS interface (X7), option
This section describes the SERCOS interface of the SERVOSTAR 400.
Information on the range of functions and the software protocol can be found in the manual “IDN
Reference Guide SERCOS”.
For the optical fibre (LWL) connection, only use SERCOS components to the SERCOS Standard
IEC 61491.
3.10.3.1 Light emitting diodes (LEDs)
RT: indicates whether SERCOS telegrams are being correctly received. In the final
Communication Phase 4 this LED should flicker, since cyclical telegrams are being received.
TT: indicates that SERCOS telegrams are being transmitted. In the final Communication Phase
4 this LED should flicker, since cyclical telegrams are being transmitted.
Check the stations addresses for the controls and the servo amplifier if:
- the LED never lights up in SERCOS Phase 1 or
- the axis cannot be operated, although the RT LED is lighting up cyclically.
Err: indicates that SERCOS communication is faulty or suffering from interference.
If this LED is very bright, then communication is suffering strong interference, or is
non-existent.
Check the SERCOS transmission speed for the controls and the servo amplifier
(BAUDRATE) and the fibre-optic connection.
If this LED flickers, this indicates a low level of interference for Sercos communication, or the
optical transmitting power is not correctly adjusted to suit the length of cable.
Check the transmitting power of the (physically) previous SERCOS station.
The transmitting power of the servo amplifier can be adjusted in the setup software
DRIVE.EXE on the SERCOS screen page, by altering the LWL length parameter for the
cable length.
3.10.3.2 Connection diagram
Layout of the SERCOS bus system in ring topology, with optical fibre cables (schematic).
54 SERVOSTAR®
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4 Commissioning
4.1 Important notes
Only professional personnel with extensive knowledge in the fields of electrical engineering
and drive technology are allowed to commission the servo amplifier.
The procedure for commissioning is described as an example. Depending on the application, a dif-
ferent procedure may be appropriate or necessary.
In multi-axis systems, commission each servo amplifier individually.
Before commissioning, the manufacturer of the machine must produce a hazard analy-
sis for the machine and take appropriate measures to ensure that unforeseen move-
ments do not result in personal injury or material damage.
Caution !
Check that all live connecting elements are protected from accidental contact.
Deadly voltages can be present, up to 800V.
Never disconnect any of the electrical connections to the servo amplifier while it is live.
Capacitors can still have residual charges with dangerous levels up to 300 seconds af-
ter switching off the supply power.
Heat sinks and front panels of the amplifier can reach a temperature of up to 80°C in
operation. Check (measure) the heat sink temperature. Wait until the heat sink has
cooled down below 40°C before touching it.
Warning !
If the servo amplifier has been stored for longer than 1 year, then the DC-link capaci-
tors will have to be re-formed.
To do this, disconnect all the electrical connections.
Supply the servo amplifier for about 30 min. from single-phase 230V AC to the termi-
nals L1 / L2. This will re-form the capacitors.
Further information on commissioning:
The adaptation of parameters and their effects on the control loop behaviour are des-
cribed in the manual for the setup software.
The commissioning of the fieldbus interface is described in the corresponding manual.
We can provide further know-how through training courses (on request).
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Kollmorgen 07/03 Commissioning
The following instructions should help you to carry out the commissioning in a sensible order, wit-
hout any hazards to people or machinery.
See Chapter 2. Disconnect the servo amplifier from the supply.
0V on terminal X1/3 (Enable)
24V DC on terminal 0/1, ground on terminal X0/2
After the initialization procedure (about 0.5 sec.) the status is
shown in the LED display (� p.58)
Select the interface to which the servo amplifier is connected.
The parameters which are stored in the SRAM of the servo
amplifier are transferred to the PC.
Caution !
Check the parameters described below especially carefully.
If you ignore these basic data, system components may be
damaged or destroyed.
Supply voltage : set to the actual mains supply voltage
(observe supply voltage limits,� p.17)
Rated motor voltage : at least as high as the DC-link voltage of the amplifier
Motor pole-no. : must match the motor (see motor manual)
Feedback : must match the feedback unit in the motor
IRMS : maximum is the motor standstill current I0 (as on nameplate)
IPEAK : maximum is 4 x motor standstill current I0Limit speed : maximum is the rated motor speed (as on nameplate)
Regen power : maximum is the rated dissipation for the regen resistor
Station address : unique address on the master
Caution !
Make sure that any unintended movement of the drive
cannot cause danger to machinery or personnel.
through the ON/OFF button of the contactor control
apply 0V to terminals X3/2-3
(500 msec after switching on the supply power) 24V DC on
terminal X1/3 (Enable), motor is at rest with standstill torque M0
apply a small analog setpoint (about 0.5V is recommended) to
terminals X3/2-3
If the motor oscillates, the Kp parameter in the screen page
Speed controller must be reduced – the motor is in danger !
optimize the speed, current and position controllers
see commissioning instructions in the corresponding
manual on the CD-ROM
56 SERVOSTAR®
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Check installation
Negate enable signal
Switch on 24V
aux. supply
Switch on PC, start
setup S/W
Check the displayed
parameters, and
correct them if
necessary
Check safety devices
Switch on power
Apply 0V setpoint
Enable amplifier
Optimization
Commission fieldbus
Setpoint
4.2 Parameterization
A default parameter set is loaded into your servo amplifier at the factory. This contains valid and
safe parameters for the current and speed controllers.
A database for motor parameters is stored in the servo amplifier. During commissioning you must
select the data set for the motor that is connected and store it in the servo amplifier. For most appli-
cations these settings will already provide good to very good control loop characteristics.
An exact description of all parameters and the options for optimizing the control loop characteristics
can be found in the manual “Setup Software DRIVE.EXE”.
4.2.1 Multi-axis systems
All the axes in a system can be parameterized through the RS232 interface in the master. To do
this, there is an internal connection between the master and the axis modules. The PC cable only
has to be connected to the master.
The internal address assignment is carried out automatically, so that it is only necessary to set up
the basic station address for the master.
After changing the station address it is necessary to turn off the 24V auxiliary
supply, and then turn it on again.
Starting at the master, descending addresses are assigned automatically to the axis modules. The
following table shows an example with one master and three axis modules:
Axis Address Remark
Master 10 Master address, set by user
Axis module 3 9
assigned automaticallyAxis module 2 8
Axis module 1 7
The highest permitted master address is 128. When choosing the master address, please
consider that at least address 1 will be assigned to the last (leftmost) axis module.
In CAN and PROFIBUS field bus systems the automatically assigned addresses must
not match the address of other nodes.
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Kollmorgen 07/03 Commissioning
PC
COMx
RS232
X8
PC
Axismodule
1
MasterAxis
module2
Axismodule
3
4.2.2 Key pad controls and status displays
Two keys are fitted in the operating panel of the master. Here you can enter the basic address for
the system and call up status information on all the axes that are connected.
4.2.2.1 Operating
The two keys can be used to perform the following functions:
Key symbol Functions
� press once : go up one menu item, increase number by one
press twice in rapid succession : increase number by ten
�
press once : go down one menu item, decrease number by one
press twice in rapid succession : decrease number by ten
�
�
press and hold right key, then press left key as well :
enters a number, return function
4.2.2.2 Status display on the axis module
Each axis module is fitted with 2 LEDs that provide a quick indication of the instrument status.
LED
red green Interpretation
lit off axis is not ready for operation (fault)
blinking off a warning has been generated
off lit axis is ready for operation, and enabled
off blinking axis is ready for operation, but not enabled
blinking blinking axis is selected for editing by the master
A detailed display of the warnings and faults can be called up in the display on the master (� p.59).
58 SERVOSTAR®
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4.2.2.3 Status display on the master
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4.3 Error messages
Any errors that occur are shown in coded form by an error number in the LED display on the front
panel. All error messages result in the BTB/RTO contact being opened, and the output stage of the
amplifier being switched off (motor loses all torque). The motor-holding brake is activated.
Number Designation Explanation
F00 no error no error in the selected axis module
F01* heat sink temperatureheat sink temperature too high
limit is set by manufacturer to 80°C
F02* overvoltageovervoltage in DC-link
limit depends on the mains supply voltage
F03* contouring error message from the position controller
F04 feedback cable break, short circuit, short to ground
F05* undervoltageundervoltage in DC-link
limit is set by manufacturer to 100V
F06 motor temperaturemotor temperature too high (or temp. sensor defect)
limit is set by manufacturer to145°C
F07 aux. voltage internal aux. voltage not OK
F08* overspeed motor runs away, speed is too high
F09 EEPROM checksum error
F10 Flash-EPROM checksum error
F11 brake cable break, short circuit, short to ground
F12 motor phase motor phase missing (cable break or similar)
F13* internal temperature internal temperature too high
F14 output stage fault in the output stage
F15 I²t max. I²t max value exceeded
F16* supply BTB/RTO 2 or 3 phases missing in the supply feed
F17 A/D converter error in the analog-digital conversion
F18 regen regen circuit faulty or incorrect setting
F19* supply phase a phase is missing in the supply power feed
F20 slot error slot error
F21 handling error software error on the expansion card
F22 earth/ground fault only for 40/70 A instruments: earth fault
F23 CAN bus off severe CAN bus communication error
F24 warning warning display is evaluated as fault
F25 commutation error commutation error
F26 limit-switch homing error (drove onto hardware limit-switch)
F27 AS-optionoperational error with -AS- option (control signal for -AS- option ap-
pears simultaneously with the ENABLE signal)
F28 reserve reserve
F29 Sercos error only in SERCOS systems
F30 SERCOS timeout Sercos timeout, leads to emergency stop
F31 reserve reserve
F32 system error system software nor responding correctly
* = these error messages can be cleared without a reset, by using the ASCII command CLRFAULT.
If only one of these errors is present and the RESET button or the I/O RESET function is used, only the
CLRFAULT command will be executed.
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4.4 Warning messages
Faults which occur, but which do not cause a switch-off of the amplifier output stage (BTB/RTO con-
tact remains closed), are indicated in the LED display on the front panel by a coded warning num-
ber.
Number Designation Explanation
n01 I²t I²t threshold exceeded
n02 regen power reached preset regen power limit
n03* S_fault exceeded preset contouring error limit
n04* response monitoring response monitoring (fieldbus) has been activated
n05 supply phase supply phase missing
n06* Sw limit-switch 1 passed software limit-switch 1
n07* Sw limit-switch 2 passed software limit-switch 2
n08 motion task error a faulty motion task was started
n09 no reference point no reference point set at start of motion task
n10* PSTOP PSTOP limit-switch activated
n11* NSTOP NSTOP limit-switch activated
n12 default values only for HIPERFACE®
: motor default values loaded
n13* expansion card expansion card not operating correctly
n14 SinCos feedback SinCos commutation failure
n15 table fault fault as per speed/current table INXMODE 35
n16-n31 reserve reserve
n32 firmware beta version firmware version has not been released
* = these warning messages result in a controller shut-down of the drive (braking by emergency stop ramp)
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This page has been deliberately left blank.
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5 Accessories
5.1 External PSU 24V DC / 5A
Technical data
Input voltage 120 / 230V
Input current 0.9 / 0.6A
Frequency 50/60Hz
Primary fusing 3.15AT
Output voltage 24V ± 1%
Max. output current 5A
Residual ripple <150mVss
Switching peaks <240mVss
Output fusing short-circuit proof
Temperature range 0 to +60°C
Mounting methodDIN-rail, vertical mounting
50mm free space required above and below the instrument
Weight 0.75kg
Order No. 83034
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5.2 External PSU 24V DC / 20A
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Technical data
Input voltage 3 x 400V AC ± 10%
Input current approx. 1.1A
Frequency 50/60Hz
Primary fusing none
Output voltage 24V ± 1%
Max. output current 20A
Residual ripple <0.1%
Output fusing short-circuit proof
Test voltage to VDE 0550
Temperature range -20 to +60°C
Mounting methodon mounting plate (supplied)
Keep space free
Weight 3.5kg
Order No. 81279
5.3 External ballast resistor BARxxx
Caution:
Surface temperature may exceed 200°C.
Observe the requested free space.
Do not mount to combustible surface
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Kollmorgen 07/03 Accessories
5.4 Add-on fan
Electrical add-on fan for two axes to achieve rated power even under unfavourable ambient condi-
tions, required for SERVOSTAR4x6.
To mount the fan, just hook it in the designated slots at the bottom of the SERVOSTAR and screw
the fixing bolt into the thread in the housing
The electrical connection takes place automatically when mounting the fan.
Please consider that a mounted fan increases the required space underneath the ampli-
fier! (� p. 24)
The drawing below shows, how the fan should be mounted.
With an odd number of axes (master included), the fan must also cover the power supply unit at the
master.
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Single master Master with 2 Axis modulesMaster with 1 Axis module
6 Appendix
6.1 Transport, storage, maintenace, disposal
Transport: — only by qualified personnel
— only in the manufacturer’s original recyclable packaging
— avoid shocks
— temperature -25 to +70°C, max. rate of change 20°C/hour
— humidity max. 95% relative humidity, no condensation
— the servo amplifiers contain electrostatically sensitive components
— which can be damaged by incorrect handling. Discharge yourself
— before touching the servo amplifier. Avoid contact with highly
— insulating materials (artificial fabrics, plastic films etc.).
— Place the servo amplifier on a conductive surface.
— if the packaging is damaged, check the unit for visible damage.
— In such a case, inform the shipper and the manufacturer.
Packaging: — recyclable cardboard with inserts
— dimensions SERVOSTAR 4xxA (HxWxD) 100x300x270 mm
SERVOSTAR 4xxM (HxWxD) 150x300x270 mm
— labelling instrument label on outside of box
Storage : — only in the manufacturer’s original recyclable packaging
— the servo amplifiers contain electrostatically sensitive components
— which can be damaged by incorrect handling. Discharge yourself
— before touching the servo amplifier. Avoid contact with highly
— insulating materials (artificial fabrics, plastic films etc.).
— Place the servo amplifier on a conductive surface.
— max. stacking height: 8 cartons
— storage temp. –25 to +55°C, max. rate of change 20°C/hr
— humidity relative humidity max. 95%, no condensation
— storage duration < 1 year without restriction
> 1 year: capacitors must be re-formed before
the servo amplifier is commissioned.
To do this, remove all electrical connections and
supply the servo amplifier for about 30 min. from
230V AC, single-phase, on terminals L2 / L3.
Maintenance: — the instruments do not require any maintenance
— opening the instruments invalidates the warranty
Cleaning : — if the casing is dirty : cleaning with Isopropanol or similar
do not immerse or spray
— if there is dirt inside the unit: to be cleaned by the manufacturer
— dirty protective grill (fan) : clean with a dry brush
Disposal : — you can dismantle the servo amplifier into its principal components
— by screwing it apart (aluminium heat sink, steel housing sections,
— electronics boards)
— disposal should be carried out by a certified disposal company.
— We can give you suitable addresses on request.
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Kollmorgen 07/03 Appendix
6.2 Fault-finding
The table below should be regarded as a “First-aid” box.
Depending on the conditions in your installation, there may be a wide variety of reasons for the
fault. In multi-axis systems there may be further hidden causes of a fault.
Our customer support can give you further assistance with problems.
Fault possible causesMeasures to remove the cause of
the fault
HMI message:
communication
fault
— wrong cable used
— cable plugged into wrong position
in servo amplifier or PC
— wrong PC interface selected
— use null-modem cable
— plug cable into the correct sockets
on the servo amplifier and PC
— select correct interface
F01 message:
heat sink
temperature
— permissible heat sink temperature
exceeded
— improve ventilation
F02 message:
overvoltage
— regen power is insufficient. regen power
limit was reached and the regen resistor
was switched off. This causes excessive
voltage in the DC-link circuit.
— supply voltage too high
— shorten the braking time RAMP or
use an external regen resistor
with a higher power rating and
adjust the regen power parameter
— use mains transformer
F04 message:
feedback unit
— feedback connector not properly inserted
— feedback cable is broken, crushed or
otherwise damaged
— check connector
— check cable
F05 message:
undervoltage
— supply voltage not present or too low
when servo amplifier is enabled
— only enable the servo amplifier
when the mains supply voltage has
been switched on delay > 500 ms
F06 message:
motor temperature
— motor thermostat has been activated
— feedback connector is loose or break in
feedback cable
— wait until motor has cooled down,
then check why it became so hot
— tighten connector or use
new feedback cable
F07 message:
aux. voltage
— the aux. voltage produced by the servo
amplifier is incorrect
— return the servo amplifier to the
manufacturer for repair
F08 message:
motor runs away
(overspeed)
— motor phases swapped
— feedback set up incorrectly
— faulty connection to feedback unit
— correct motor phase sequence
— set up correct offset angle
— check connector
F11 message:
brake
— short-circuit in the supply cable for the
motor-holding brake
— motor-holding brake is faulty
— fault in brake cable
— no brake connected, although the
brake parameter is set to "WITH"
— remove short-circuit
— replace motor
— check shielding of brake cable
— brake parameter set to "WITHOUT"
F13 message:
internal tempera-
ture
— permissible internal temperature exceeded — improve ventilation
F14 message:
output stage fault
— motor cable has short-circuit/ground short
— motor has short-circuit / ground short
— output module is overheated
— output stage is faulty
— short-circuit / short to ground in the
external regen resistor
— replace cable
— replace motor
— improve ventilation
— return the servo amplifier to the
manufacturer for repair
— remove short-circuit / ground short
F16 message:
mains BTB/RTO
— enable was applied, although the
supply voltage was not present.
— at least 2 supply phases are missing
— only enable the servo amplifier
when the mains supply voltage
has been switched on
— check electrical supply
F17 message:
A/D converter
— error in the analog-digital conversion,
usually caused by excessive EMI
— reduce EMI,
check screening and grounding
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Appendix 07/03 Kollmorgen
Fault possible causesmeasures to remove the cause of
the fault
F25 message:
Commutation error
— wrong cable
— wrong phasing
— check wiring
— check resolver poles (RESPOLES)
check motor poles (MPOLES)
check offset (MPHASE)
F27 message:
error AS-option
— -AS-24V relay AND hardware enable AND
software enable are active
— check PLC programming and
wiring
motor does not rotate
— servo amplifier not enabled
— break in setpoint cable
— motor phases swapped
— brake not released
— drive is mechanically blocked
— no. of motor poles set incorrectly
— feedback set up incorrectly
— apply enable signal
— check setpoint cable
— correct motor phase sequence
— check brake control
— check mechanism
— set no. of motor poles
— set up feedback correctly
motor oscillates
— gain too high (speed controller)
— shielding in feedback cable has a break
— AGND not wired up
— reduce Kp (speed controller)
— replace feedback cable
— join AGND to CNC-GND
drive reports
following error
— Irms or Ipeak is set to low
— setpoint ramp is too long
— increase Irms or Ipeak
(keep within motor data !)
— shorten setpoint ramp +/-
motor overheating — Irms/Ipeak set too high — reduce Irms/Ipeak
drive too soft
— Kp (speed controller) too low
— Tn (speed controller) too high
— PID-T2 too high
— T-Tacho too high
— increase Kp (speed controller)
— use motor default value for
Tn (speed controller)
— reduce PID-T2
— reduce T-Tacho
drive runs
roughly
— Kp (speed controller) too high
— Tn (speed controller) too low
— PID-T2 too low
— T-Tacho too low
— reduce Kp (speed controller)
— use motor default value for
Tn (speed controller)
— increase PID-T2
— increase T-Tacho
axis drifts at
setpoint = 0V
— offset not correctly adjusted for analog
setpoint provision
— AGND not joined to the CNC-GND of the
controls
— adjust setpoint-offset (analog I/O)
— join AGND and CNC-GND
n12 message:
Motor default values
loaded
— Motor number stored in sine encoders
EEPROM different than what drive is
configured for
— If n12 is displayed, default values
for the motor are loaded.
Motor number will be automatically
stored in EEPROM with SAVE.
n14 message:
Wake & shake active— Wake & shake not executed — Enable the drive
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Kollmorgen 07/03 Appendix
6.3 Glossary
C clock Clock signal
common-mode voltage The maximum amplitude of a disturbance (on both
inputs) which a differential input can eliminate
continuous power of regen circuit Mean power which can be dissipated in the regen circuit
counts Internal count pulses, 1 pulse = 1/220
turn-1
current controller Regulates the difference between the current setpoint
and the actual value to 0
Output : power output voltage
D DC-link Rectified and smoothed power voltage
disable Removal of the enable signal (0V or open)
E earth short electrical connection between a phase and
the protective earth (PE)
enable Enable signal for the servo amplifier (+24V)
F fieldbus interface CANopen, PROFIBUS, SERCOS
free convection Free movement of air for cooling
G GRAY-code Special format for representing binary numbers
H holding brake Brake in the motor, which should only be used when the
motor is at standstill
I I²t threshold Monitoring of the r.m.s. current that is actually required
incremental encoder interface Position signalling by 2 signals with 90° phase
difference, not an absolute position output
input drift Temperature and age-dependent alteration of an
analog input
Ipeak, peak current The effective value of the peak current
Irms, effective current The r.m.s. value of the continuous current
K Kp, P-gain Proportional gain of a control loop
L limit speed Maximum value for speed normalization at ±10V
limit-switch Switch limiting the traverse path of the machine;
implemented as n.c. (break) contact
M machine The complete assembly of all connected parts or
devices, of which at least one is movable
motion-block Set of all the position control parameters
which are required for a motion task
multi-axis system Machine with several driven axes
N natural convection Free movement of air for cooling
O optocoupler Optical connection between two electrically
independent systems
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P P-controller Control loop with purely proportional behaviour
phase shift Compensation for the lag between the electromagnetic
and magnetic fields in the motor
PID-controller Control loop with proportional, integral and
differential behaviour
PID-T2 Filter time constant for the speed controller output
position controller Regulates the difference between the position setpoint
and the actual position to 0
Output : speed setpoint
potential isolation electrically decoupled
power contactor System protection device with phase monitoring
pulse power of the regen circuit Maximum power which can be dissipated in the
regen circuit
R regen circuit Converts superfluous energy, which is fed back
during braking, into heat in the regen resistor
reset New start of the microprocessor
reversing mode Operation with a periodic change of direction
ring core Ferrite rings for interference suppression
ROD-interface Incremental position output
S servo amplifier Control device for regulating the speed, torque
and position of a servomotor
setpoint ramps Limits for the rate of change of the speed setpoint SW
short-circuit here: electrically conductive connection between
two phases
speed controller Regulates the difference between the speed setpoint
and the actual value to 0
Output : current setpoint
SSI-interface Cyclic-absolute, serial position output
supply filter Device to divert interference on the power supply
cables to PE
T T-tacho, tachometer time constant Filter time constant in the speed feedback of
the control loop
tachometer voltage Voltage proportional to the actual speed
thermostat Temperature-sensitive switch built into the
motor winding
Tn, I-integration time Integral section of a control loop
Z zero pulse Output once per turn from incremental encoders,
used to zero the machine
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6.4 Index
72 SERVOSTAR®
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Appendix 07/03 Kollmorgen
! 24V aux. supply, interface . . . . . . . . . . . 38
A Abbreviations . . . . . . . . . . . . . . . . . . 7
Accessories . . . . . . . . . . . . . . . . . . 63
AGND . . . . . . . . . . . . . . . . . . . . . 19
ambient conditions . . . . . . . . . . . . . . . 18
ambient temperature . . . . . . . . . . . . . . 18
B Block diagram . . . . . . . . . . . . . . . . . 15
brake . . . . . . . . . . . . . . . . . . . . . . 19
BTB/RTO. . . . . . . . . . . . . . . . . . . . 44
C CANopen interface . . . . . . . . . . . . . . . 52
CE conformity . . . . . . . . . . . . . . . . . . 6
commissioning . . . . . . . . . . . . . . . . . 55
conductor cross-sections. . . . . . . . . . . . 18
Connection cables . . . . . . . . . . . . . . . 33
Connection techniques. . . . . . . . . . . . . 32
connector assignments . . . . . . . . . . . . 31
contents . . . . . . . . . . . . . . . . . . . . . 3
Control signals . . . . . . . . . . . . . . . . . 41
D DC-link, interface. . . . . . . . . . . . . . . . 38
DGND . . . . . . . . . . . . . . . . . . . . . 19
Dimensions. . . . . . . . . . . . . . . . . . . 25
display . . . . . . . . . . . . . . . . . . . . . 19
disposal . . . . . . . . . . . . . . . . . . . . 67
E earthing
installation . . . . . . . . . . . . . . . . . 27
wiring diagram . . . . . . . . . . . . . . . 28
EMC . . . . . . . . . . . . . . . . . . . . . . 23
Emergency Stop methods . . . . . . . . . . . 22
enclosure rating . . . . . . . . . . . . . . . . 18
encoder
interface . . . . . . . . . . . . . . . . . . 40
master-slave interface . . . . . . . . . . . 50
encoder emulations . . . . . . . . . . . . . . 45
Equipment description . . . . . . . . . . . . . 11
error messages . . . . . . . . . . . . . . . . 60
external fusing . . . . . . . . . . . . . . . . . 18
F Fault-finding . . . . . . . . . . . . . . . . . . 68
Fieldbus interface . . . . . . . . . . . . . . . 52
forming . . . . . . . . . . . . . . . . . . . . . 55
G Glossary . . . . . . . . . . . . . . . . . . . . 70
ground symbol . . . . . . . . . . . . . . . . . 26
Grounding system . . . . . . . . . . . . . . . 19
H hardware requirements. . . . . . . . . . . . . 36
humidity . . . . . . . . . . . . . . . . . . . . 67
I inputs
analog setpoint. . . . . . . . . . . . . . . 41
DIGI-IN 1/2 . . . . . . . . . . . . . . . . . 42
Enable . . . . . . . . . . . . . . . . . . . 44
NSTOP. . . . . . . . . . . . . . . . . . . 42
PSTOP. . . . . . . . . . . . . . . . . . . 42
installation
hardware . . . . . . . . . . . . . . . . . . 26
software . . . . . . . . . . . . . . . . . . 36
Interfaces. . . . . . . . . . . . . . . . . . . . 37
K key operation. . . . . . . . . . . . . . . . . . 58
L LED display . . . . . . . . . . . . . . . . . . 58
limit-switch inputs . . . . . . . . . . . . . . . 42
M maintenance . . . . . . . . . . . . . . . . . . 67
master-slave . . . . . . . . . . . . . . . . . . 50
motor
interface . . . . . . . . . . . . . . . . . . 38
motor choke, connection example . . . . . . . 30
mounting . . . . . . . . . . . . . . . . . . . . 24
mounting position . . . . . . . . . . . . . . . 18
multi-axis system, connection example . . . . 30
N nameplate . . . . . . . . . . . . . . . . . . . 11
NSTOP, interface . . . . . . . . . . . . . . . 42
O Operating systems . . . . . . . . . . . . . . . 36
options . . . . . . . . . . . . . . . . . . . . . 12
outputs
BTB/RTO. . . . . . . . . . . . . . . . . . 44
DIGI-OUT 1/2 . . . . . . . . . . . . . . . 43
P package supplied . . . . . . . . . . . . . . . 11
packaging . . . . . . . . . . . . . . . . . . . 67
parameterization . . . . . . . . . . . . . . . . 57
PC connection . . . . . . . . . . . . . . . . . 47
PC interface cable . . . . . . . . . . . . . . . 47
pollution level. . . . . . . . . . . . . . . . . . 18
PROFIBUS interface . . . . . . . . . . . . . . 53
PSTOP, interface . . . . . . . . . . . . . . . 42
PSU 24V
20A. . . . . . . . . . . . . . . . . . . . . 64
5A . . . . . . . . . . . . . . . . . . . . . 63
pulse/direction, interface . . . . . . . . . . . . 48
R regen circuit . . . . . . . . . . . . . . . . . . 20
regen resistor
dimensions. . . . . . . . . . . . . . . . . 65
external interface. . . . . . . . . . . . . . 39
techn. data . . . . . . . . . . . . . . . . . 20
resolver
interface . . . . . . . . . . . . . . . . . . 39
ROD, interface . . . . . . . . . . . . . . . . . 45
RS232/PC, interface . . . . . . . . . . . . . . 47
S safety instructions . . . . . . . . . . . . . . . . 5
SERCOS interface . . . . . . . . . . . . . . . 54
setpoint inputs . . . . . . . . . . . . . . . . . 41
Setup software . . . . . . . . . . . . . . . . . 35
SETUP.EXE . . . . . . . . . . . . . . . . . . 36
Shield connection . . . . . . . . . . . . . . . 32
shielding
installation . . . . . . . . . . . . . . . . . 27
wiring diagram . . . . . . . . . . . . . . . 28
site . . . . . . . . . . . . . . . . . . . . . . . 27
site altitude . . . . . . . . . . . . . . . . . . . 18
SSI, interface. . . . . . . . . . . . . . . . . . 46
stacking height . . . . . . . . . . . . . . . . . 67
Standards . . . . . . . . . . . . . . . . . . . . 6
Status display . . . . . . . . . . . . . . . . . 58
storage . . . . . . . . . . . . . . . . . . . . . 67
storage duration . . . . . . . . . . . . . . . . 67
storage temperature . . . . . . . . . . . . . . 67
supply connection, interface . . . . . . . . . . 37
supply voltage . . . . . . . . . . . . . . . . . 18
Switch on/off behaviour . . . . . . . . . . . . 21
Symbols . . . . . . . . . . . . . . . . . . . . . 7
system components, summary. . . . . . . . . 16
T technical data . . . . . . . . . . . . . . . . . 17
tightening torques, connectors . . . . . . . . . 18
transport . . . . . . . . . . . . . . . . . . . . 67
Transport temperature . . . . . . . . . . . . . 18
U use as directed . . . . . . . . . . . . . . . . . 9
servo amplifier . . . . . . . . . . . . . . . 10
setup software . . . . . . . . . . . . . . . 35
V ventilation
installation . . . . . . . . . . . . . . . . . 27
techn. data . . . . . . . . . . . . . . . . . 18
W warning messages . . . . . . . . . . . . . . . 61
wiring . . . . . . . . . . . . . . . . . . . . . . 27
wiring diagram . . . . . . . . . . . . . . . . . 28
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SERVOSTAR®
400 Installation manual 73
Kollmorgen 07/03 Appendix
Sales and Service
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