SERVOSTAR® 601...620
Digital Servo Amplifier
Product Manual
Edition 07/2007
Valid for Hardware Revision 05.10
Keep all manuals as a product component
during the life span of the product.
Pass all manuals to future users / owners
of the product.
File sr601_e.***
Download from Www.Somanuals.com. All Manuals Search And Download.
Danaher Motion
07/2007
Contents
Page
About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hints for the online edition (PDF format) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Abbreviations used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
European Directives and Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
American Directives and Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Asian Directives and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CE conformance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Conformance with UL and cUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Package supplied. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Part number scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
The SERVOSTAR 600 family of digital servo amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Recommended torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ambient conditions, ventilation, mounting position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Conductor cross-sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Control for motor holding brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Grounding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Regen circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Switch-on and switch-off behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Behavior in standard operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Behavior in the event of an error (with standard setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Stop/Emergency Stop Function to EN 60204. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Stop: Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Emergency Stop: Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Implementation of the Stop Category 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Implementation of the Stop Category 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Implementation of the Stop Category 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Shock-hazard protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Leakage current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Residual-current circuit breakers (FI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Isolating transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SERVOSTAR® 601...620 Product Manual
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Contents
07/2007
Danaher Motion
Page
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Guide to mechanical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Guide to electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Technical data for connecting cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Shielding connection to the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Motor connector with shieldplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Components of a servo system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pin assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Connection diagram (overview) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Connection to various mains supply networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Mains supply connection (X0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
24V auxiliary supply (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
DC bus link (X7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Motor connection with brake (X9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.10 External regen resistor (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.11 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Resolver (X2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Sine Encoder 5V with BISS (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Sine Encoder with EnDat 2.1 or HIPERFACE (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Sine Encoder without data channel (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Incremental encoder / sine encoder with Hall (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Incremental Encoder (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.12 Electronic Gearing, Master-slave operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Connection to encoders with 24 V signal level (X3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Connection to a sine-cosine encoder (X1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connection to a SSI encoder (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.12.5.1 Step/Direction with 5 V signal level (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.12.5.2 Step/Direction with 24 V signal level (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.13 Encoder emulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.13.1 Incremental encoder output - A quad B (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.13.2 SSI output (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.14 Digital and analog inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Analog inputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Analog outputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Digital inputs (X3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Digital outputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.15 RS232 interface, PC connection (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.16 CANopen Interface (X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4
SERVOSTAR® 601...620 Product Manual
Download from Www.Somanuals.com. All Manuals Search And Download.
Danaher Motion
07/2007
Contents
Page
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Setup software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Software description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Hardware requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Operating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Quickstart Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9.3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Unpacking, Mounting and Wiring the Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Minimum Wiring for Drive Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Important Screen Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Motor (synchronous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Save Parameters and Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Jogging the Motor (Speed Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Additional Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Multi-axis systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Node address for CAN-bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Baud rate for CAN-bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Example of connections for multi-axis system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Key operation / LED display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Key operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Status display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Standard menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Extended menu structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Removing faults/warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.1 Option -AS-, restart lock for personal safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Signal diagram (sequence) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connection diagram (principle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Application example category 1 according to EN954-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10.1.8.1 Control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10.1.8.2 Mains supply circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Application example category 3 according to EN954-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.1.9.1 Control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.1.9.2 Mains supply circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.1.9.3 Flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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Contents
07/2007
Danaher Motion
Page
10.2 Expansion Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Guide to installation of expansion cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Expansion card -I/O-14/08- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.2.2.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.2.2.2 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.2.2.3 Light emitting diodes (LEDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.2.2.4 Select motion task number (Sample) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.2.2.5 Connector assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10.2.2.6 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Expansion cards -PROFIBUS-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.2.3.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.2.3.2 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.2.3.3 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Expansion card -SERCOS- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.2.4.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.2.4.2 Light emitting diodes (LEDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.2.4.3 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.2.4.4 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10.2.4.5 Modifying the station address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10.2.4.6 Modifying the baud rate and optical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Expansion card -DEVICENET- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.2.5.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.2.5.2 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.2.5.3 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.2.5.4 Combined module/network status-LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.2.5.5 Setting the station address (device address). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.2.5.6 Setting the transmission speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
10.2.5.7 Bus cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Expansion card -ETHERCAT- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.2.6.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.2.6.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.2.6.3 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Expansion card -SYNQNET- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
10.2.7.1 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
10.2.7.2 NODE ID Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
10.2.7.3 Node LED table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
10.2.7.4 SynqNet Connection, Connector X21B/C (RJ-45). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
10.2.7.5 Digital inputs/outputs, connector X21A (SubD 15-pin, socket) . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
10.2.7.6 Connection diagram digital inputs/outputs, connector X21A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Expansion module -2CAN-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
10.2.8.1 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
10.2.8.2 Front View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
10.2.8.3 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
10.2.8.4 Connector assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
10.2.8.5 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
10.3 Special Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Power Supply SINCOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Terminating adapter for encoder cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Hall Dongle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
11.1 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
11.2 Order numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Servo amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Expansion cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Special accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
11.3 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6
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General
1
General
1.1
About this manual
This manual describes the digital servo amplifiers of the SERVOSTAR® 600 series
(standard version, 1.5 to 20 Amps nominal current). Servoamplifiers of the SERVOSTAR 640/670
series are described in additional manuals.
SERVOSTAR 601 is sold in Europe only
A more detailed description of the expansion cards which are currently available and the digital
connection to automation systems can be found on the accompanying CD-ROM in Acrobat-Reader
format (system requirements: WINDOWS with Internet browser, Acrobat Reader) in several lan-
guage versions.
Technical data and dimensional drawings of accessories such as cables, regen resistors, mains
supplies, etc., can be found in the accessories manual.
You can print 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 in handling electrostatically
sensitive components.
Unpacking:
Installation :
Setup :
only by electrically qualified personnel.
only by electrically qualified personnel
only by personnel with extensive knowledge of electrical
engineering / drive technology
1.2
Hints for the online edition (PDF format)
Bookmark:
Table of contents and index are active bookmarks.
Table of contents and index in the text:
The lines are active cross references. Click on the desired line and the appropriate page is indi-
cated.
Page/chapter numbers in the text:
Page/chapter numbers with cross references are active. Click at the page/chapter number to reach
the indicated target.
1.3
Symbols used
Danger to personnel
Danger to maschinery,
general warning
Important
notes
from electricity and its
effects
see page
l
special emphasis
ð p.
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General
1.4
07/2007
Danaher Motion
Abbreviations used
The abbreviations used in this manual are explained in the table below.
Abbrev.
AGND
AS
Meaning
Analog ground
Restart Lock, option
BTB/RTO
CAN
Ready to operate
Fieldbus (CANopen)
CE
Communité Européenne (EC)
Clock signal
CLK
COM
DGND
DIN
Serial interface for a PC-AT
Digital ground
German Institute for industrial Standards
Magnetic storage (diskette, hard disk)
Electrically erasable programmable memory
Electromagnetic compatibility
Electromagnetic interference
European standard
Disk
EEPROM
EMC
EMI
EN
ESD
Electrostatic discharge
F-SMA
IEC
Fiber Optic Cable connector according to IEC 60874-2
International Electrotechnical Commission
Insulated Gate Bipolar Transistor
Incremental Interface
IGBT
INC
ISO
International Standardization Organization
Light-emitting diode
LED
MB
Megabyte
NI
Zero pulse
NSTOP
PELV
PGND
PSTOP
PWM
RAM
Rregen (RB)
RBext
Limit-switch input for CCW rotation (left)
Protected low voltage
Ground for the interface
Limit-switch input for CW rotation (right)
Pulse-width modulation
Volatile memory
Regen resistor
External regen resistor
RBint
Internal regen resistor
RES
Resolver
ROD 426 (EEO) A quad B encoder
PLC
SRAM
SSI
Programmable logic controller
Static RAM
Synchronous serial interface
Underwriters Laboratory
AC voltage
UL
VAC
VDC
VDE
XGND
DC voltage
Verein deutscher Elektrotechniker
Ground for the 24V supply
8
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Safety
2
Safety
2.1
Safety Instructions
l
Only properly qualified personnel are permitted to perform activities such as transport,
installation, setup and maintenance. Properly qualified persons are those who are fami-
liar with the transport, assembly, installation, setup and operation of the product, and
who have the appropriate qualifications for their job. The qualified personnel must
know and observe:
—
—
—
IEC 60364 or DIN VDE 0100
IEC 60664 or DIN VDE 0110
national accident prevention regulations or BGV A3
l
l
Check the Hardware Revision Number of the product (see product label). This revision
number must match the Hardware Revision Number on the cover page of the manual.
Read this documentation before carrying out installation and setup. 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 (on the name-
plate and in the documentation).
l
The servo amplifiers contain electrostatically sensitive components which may be da-
maged by incorrect handling. Ground yourself before touching the servo amplifier by
touching any unpainted metal surface. Avoid contact with highly insulating materials
(artificial fabrics, plastic film etc.). Place the servo amplifier on a conductive surface.
l
l
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 per-
sonal injury or material damage.
Do not open or touch the equipment during operation. Keep all covers and cabinet
doors closed during operation. Touching the equipment is allowed during installation
and commissioning for properly qualified persons only. Otherwise, there are deadly ha-
zards, 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.
Surface can reach temperatures above 80°C.
l
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 un-
doing 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
Bus link and wait until it has fallen below 40V.
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Safety
2.2
07/2007
Danaher Motion
Use as directed
l
The servo amplifiers are components which are built into electrical equipment or machines,
and can only be used as integral components of such equipment.
l
The manufacturer of the machine must generate a hazard analysis for the machine, and take
appropriate measures to ensure that unforeseen movements cannot cause injury or damage to
any person or property.
l
The SERVOSTAR 600 family of servo amplifiers can be connected directly to symmetrically
earthed (grounded) three-phase industrial mains supply networks [TN-system, TT-system with
earthed (grounded) neutral point, not more than 5000 rms symmetrical amperes, 480VAC ma-
ximum].
The servo amplifiers must not be operated directly on power supply networks >230V without
an earth (ground) or with an asymmetrical earth (ground).
l
Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo amplifier
may not exceed 1000V (peak value).
Transient overvoltages (< 50µs) between the outer conductors may not exceed 1000V.
Transient overvoltages (< 50µs) between outer conductors and housing may not exceed
2000V.
l
l
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 600 family of servo amplifiers is only intended to drive specific brushless
synchronous 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 bus link voltage of the servo amplifier.
l
The servo amplifiers may only be operated in a closed switchgear cabinet, taking into account
or cooling may be necessary to prevent enclosure ambient from exceeding 45°C (113°F).
l
l
Use only copper wire. Wire size may be determined from EN 60204 (or table 310-16 of the
NEC 60°C or 75°C column for AWG size).
We only guarantee the conformance of the servo amplifiers with the standards for industrial
Motion.
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-AS-.
Safety instructions
10
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07/2007
Standards
3
Standards
3.1
European Directives and Standards
Servo amplifiers are components that are intended to be incorporated into electrical plant and
machines for industrial use. When the servo amplifiers are built into machines or plant, the amplifier
must not be used until it has been established that the machine or equipment fulfills the require-
ments of the EC Machinery Directive (98/37/EC), the EC EMC Directive (89/336/EEC) and the EC
Low Voltage Directive 73/23/EEC.
Standards to be applied for conformance with the EC Machinery Directive (98/37/EC):
EN 60204-1 (Safety and Electrical Equipment in Machines)
EN 12100
(Safety of Machines)
The manufacturer of the machine must generate a hazard analysis for the machine,
and must implement appropriate measures to ensure that unforeseen movements
cannot cause injury or damage to any person or property.
Standards to be applied for conformance with the EC Low Voltage Directive (73/23/EEC):
EN 60204-1 (Safety and Electrical Equipment in Machines)
EN 50178
(Electronic Equipment in Power Installations)
EN 60439-1 (Low Voltage Switchgear Combinations)
Standards to be applied for conformance with the EC EMC Directive (89/336/EEC):
EN 61000-6-1 / EN 61000-6-2 (Interference Immunity in Residential & Industrial Areas)
EN 61000-6-3 / EN 61000-6-4 (Interference Generation in Residential & Industrial Areas)
The manufacturer of the machine/plant is responsible for ensuring that it meets the limits required
by the EMC regulations. Advice on the correct installation for EMC (such as shielding, grounding,
treatment of connectors and cable layout) can be found in this documentation.
The machine/plant manufacturer must check whether other standards or EC
Directives must be applied to the machine/plant.
3.2
3.3
American Directives and Standards
Chapter in process
Asian Directives and Standards
Chapter in process
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Standards
07/2007
Danaher Motion
3.4
Approvals
3.4.1
CE conformance
Conformance with the EC EMC Directive 89/336/EEC and the Low Voltage Directive 73/23/EEC is
mandatory for the supply of servo amplifiers within the European Community. Product standard EN
61800-3 is applied to ensure conformance with the EMC Directive. The Declaration of Conformity
form can be found on our website (download area).
Concerning noise immunity the servo amplifier meets the requirements to the 2nd environmental
category (industrial environment). For noise emission the amplifier meets the requirement to a prod-
uct of the category C3.
Warning!
This product can cause high-frequency interferences in non industrial
environments which can require measures for interference suppression.
The servo amplifiers have been tested in a defined configuration, using the system components that
are described in this documentation. Any divergence from the configuration and installation
described in this documentation means that you will be responsible for carrying out new measure-
ments to ensure conformance with regulatory requirements. The standard EN 50178 is applied to
ensure conformance with the Low Voltage Directive.
3.4.2
Conformance with UL and cUL
This servo amplifier is listed under UL file number E217428.
UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S. and Cana-
dian standard (in this case UL 840 and UL 508C).
This standard describes the fulfilment by design of minimum requirements for electrically operated
power conversion equipment, such as frequency converters and servo amplifiers, which is intended
to eliminate the risk of fire, electric shock, or injury to persons, being caused by such equipment.
The technical conformance with the U.S. and Canadian standard is determined by an independent
UL (cUL) inspector through the type testing and regular check-ups.
Apart from the notes on installation and safety in the documentation, the customer does not have to
observe any other points in direct connection with the UL (cUL)-certification of the equipment.
UL 508C
UL 508C describes the fulfilment by design of minimum requirements for electrically operated power
conversion equipment, such as frequency converters and servo amplifiers, which is intended to
eliminate the risk of fire being caused by such equipment.
UL 840
UL 840 describes the fulfilment by design of air and insulation creepage spacings for electrical
equipment and printed circuit boards.
12
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Danaher Motion
07/2007
Handling
4
Handling
4.1
Transport
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Only by qualified personnel in the manufacturer’s original recyclable packaging
Avoid shocks
Temperature
Humidity
–25 to +70°C (-13...158°F), max. 20K/hr rate of change
max. 95% relative humidity, no condensation
The servo amplifiers contain electrostatically sensitive components which can be da-
maged 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.
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If the packaging is damaged, check the unit for visible damage. In this case, inform the shipper
and the manufacturer.
4.2
4.3
Packaging
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Cardboard box, can be recycled
Dimensions:
SERVOSTAR 601...610
SERVOSTAR 614 / 620
(HxWxD) 125x415x350 mm
(HxWxD) 170x415x350 mm
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Labeling : nameplate outside at the box
Storage
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Storage only in the manufacturer’s original recyclable packaging
Max. stacking height 8 cartons
Storage temperature -25 to +55°C, max. rate of change 20°C / hour
Storage humidity
Storage duration
5 ... 95% relative humidity, no condensation
Less than 1 year without restriction.
More than 1 year: capacitors must be re-formed before setting up and operating the servo am-
plifier. To do this, remove all electrical connections and apply single-phase 230V AC for about
30 minutes to the terminals L1 / L2.
4.4
4.5
Maintenance
The instruments do not require any maintenance, opening the instruments invalidates the warranty.
Cleaning : — if the casing is dirty: clean with Isopropanol or similar
do not immerse or spray
— if there is dirt inside the unit it must be cleaned by the manufacturer
— dirty protective grill on fan must be cleaned with a dry brush
Disposal
In accordance to the WEEE-2002/96/EG-Guidelines we take old devices and accessories back for
professional disposal, if the transport costs are taken over by the sender. Send the devices to:
Danaher Motion GmbH
Wacholderstr. 40-42
D-40489 Düsseldorf
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Package
07/2007
Danaher Motion
5
Package
5.1
Package supplied
—
SERVOSTAR 6xx
—
mating connectors X3, X4, X0A, X0B, X7, X8
The mating SubD connectors and motor connector X9 are not part of the package!
—
—
—
Assembly, Installation and Setup Instructions (product manual)
Online documentation on CD-ROM
Setup software DRIVE.EXE on CD-ROM
Accessories: (must be ordered separately; description see accessories manual)
—
—
AC synchronous servomotor (linear or rotary)
motor cable (pre-assembled), or both motor connectors separately, with motor cable as a
cut-off length
—
feedback cable (pre-assembled or both feedback connectors separately,
with feedback cable as length
—
—
—
—
—
motor choke 3YL for cable length above 25m
external regen resistor BAR(U)
to 6 servo amplifiers from one PC
—
power cable, control cables, fieldbus cables (as lengths)
5.2
Nameplate
The nameplate depicted below is attached to the side of the servo amplifier.
The information described below is printed in the individual fields.
Servo amplifier type
Serial number
Comments
Enclosure Rating
Danaher Motion GmbH
Wacholderstr. 40-42
D-40489 Düsseldorf
Customer Support
U
C
®
L
US
Europe Tel. +49 (0)203 / 99790
Italy Tel. +39 (0)362 / 594260
North America Tel. +1 540 633 3400
E217428
LISTED
IND. CONT. EQ.
1VD4
www.DanaherMotion.com
Typenbezeichnung
Model Number Ser. Nr
Ser. No. Bemerkung
Comment
Spannungsversorgung
Power Supply Nennstrom
Nom. Current Schutzart
Encl.Rating
Umgebungstemp.
Ambient temp.
Hardware
Revision
example
example
Output current
in S1 operation
max. ambient
temperature
Electrical supply
Installed load
Hardware Revision
14
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5.3 Part number scheme
07/2007
Package
S 6 0 6 0 0 - S E*
Family
Expansions
S6
S600
NA
DN
PB
SE
SN
EC
IO
no expansion
DeviceNet
PROFIBUS
SERCOS
SynqNet
Current rating
01
03
06
10
1P
14
20
1A rms
3A rms
6A rms
ETHERCAT
10A rms
10/30A rms
14A rms
20A rms
I/O-Expansion
electr. option
Voltage rating
230...480V
0
1
no option
AS option
0
* additional coding defines customer specific specials.
Comparison (without expansion) device name -> part number
Device Name
Part Number
S60100-NA
S60300-NA
S60600-NA
S61000-NA
S61P00-NA
S61400-NA
S62000-NA
SERVOSTAR 601
SERVOSTAR 603
SERVOSTAR 606
SERVOSTAR 610
SERVOSTAR 610-30
SERVOSTAR 614
SERVOSTAR 620
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Technical description
07/2007
Danaher Motion
6
Technical description
6.1
The SERVOSTAR 600 family of digital servo amplifiers
Standard version
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6 current ratings (1.5 A -Europe only-, 3 A , 6 A , 10 A , 14 A, 20 A)
3 instrument widths : 70 mm for 1.5A up to 10A rated current
100 mm for 14A rated current
120 mm for 20A rated current
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Wide range of rated voltage (3x208V –10% to 3x480V +10%
Shield connection directly at the servo amplifier
2 analog setpoint inputs
)
Integrated CANopen (default 500 kBaud), for integration into CAN bus systems and for
setting parameters for several amplifiers via the PC-interface of one amplifier
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Integrated RS232, electrically isolated, integrated pulse-direction interface
Synchronous servomotors, linear motors and asynchronous motors can be used
Electrical supply
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Directly off grounded 3 phase system,
230V-10% ... 480V+10%, 50 Hz,
208V-10% ... 480V+10%, 60 Hz
TN-system or TT-system with grounded neutral point, max. 5000 rms symmetrical amperes.
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B6 rectifier bridge, directly off 3-phase earthed (grounded) supply system, integral power input
filter and inrush circuit
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Single-phase supply (e.g. for setup) is possible
Fusing: (e.g. fusible cutout) provided by the user
Shielding:
All shielding connections directly on the amplifier
Output stage: IGBT- module with isolated current measurement
Regen circuit: with dynamic distribution of the regen power between several
amplifiers on the same DC bus link circuit. Internal regen resistor as
standard, external regen resistors if required
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DC bus link voltage 260 — 900 VDC, can be switched in parallel
Interference suppression filter for the supply input (to category 3) is integrated
Interference suppression filter for the 24V aux. supply (to category 3) is integrated
Integrated safety
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Safe electrical separation to EN 50178 between the power input / motor connections and the
signal electronics, provided by appropriate insulation/creepage distances and complete electri-
cal isolation
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Soft-start, overvoltage recognition, short-circuit protection, phase-failure monitoring
Temperature monitoring of servo amplifier and motor
(when using our motors with our pre-assembled cables)
16
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07/2007
Technical description
Auxiliary supply voltage 24VDC
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Electrically isolated, internal fusing (3.15 AT), from an external 24VDC psu, e.g. with insulating
transformer
Operation and parameter setting
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With our user-friendly software for setup through the serial interface of a PC
Direct operation by means of two keys on the servo amplifier and a 3-character LED display for
status display in case there is no PC available
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Fully programmable via RS232 interface
Completely digital control
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Digital current controller (space vector pulse-width modulation, 62.5 µs)
digital speed controller adaptable to most different load conditions (65µs or 250 µs)
Integral position controller with adaptation possibilities for customer needs (250 µs)
Pulse direction interface integrated for connection of a servomotor to a stepping motor
control
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Evaluation of the resolver signals and sine-cosine signals of a high-resolution encoder
Encoder simulation (incremental or SSI)
Auxiliary functions
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2 analog monitor outputs
4 programmable digital inputs (normally, two are defined as limit-switch inputs)
2 programmable digital outputs
Freely programmable combinations of all digital signals
Options/Expansions
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Third party expansion cards (ModBus, FireWire, LightBus etc. - contact distributors for further
information)
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Technical description
6.2 Technical data
07/2007
Danaher Motion
SERVOSTAR
Rated data
DIM
601 603 606 610 610-30 614 620
3 x 230V-10% ... 480V+10%, 50 Hz
V~
V~
Rated supply voltage (grounded system)
3 x 208V-10% ... 480V+10%, 60 Hz
Rated installed load for S1 operation
Rated DC bus link voltage
kVA
V=
1
2
4
7
7
10
14
290 - 675
10
Arms
Arms
kHz
—
1.5
3
3
6
6
10
14
28
20
40
Rated output current (rms value, ± 3%)
Peak output current (max. ca. 5s, ± 3%)
Clock frequency of the output stage
Technical data for regen circuit
Overvoltage protection threshold
Max. load inductance
12
20
30 (2s)
8 (16 with VDCmax=400V)
ð p.22
V
450...900
mH 150
75
12
40
25
4
24
4
15
12
2
Min. load inductance
mH
25
7.5
2.5
Form factor of the output current
(at rated data and min. load inductance)
Bandwidth of subordinate current con-
troller
—
1.01
kHz
V
> 1.2
5
Residual voltage drop at rated current
Quiescent dissipation, output stage dis-
abled
W
15
Dissipation at rated current (incl. power
supply losses, without regen dissipation)
Inputs
W
30
40
60
90
90
160 200
Setpoint 1/2, resolution 14bit/12bit
Common-mode voltage max.
Input resistance to AGND
V
V
±10
±10
20
kW
V
Digital inputs
according to IEC 61131
according to IEC 61131
DC max. 30, AC max. 42
500
Digital outputs, open collector
V
V
BTB/RTO output, relay contacts
mA
V
Aux. power supply, electrically isolated
without brake
24 (-0% +15%)
1 (max. 16)
A
Aux. power supply, electrically isolated
with brake (consider voltage loss!)
Min./max. output current, brake
Connections
V
24 (-0% +15%)
3 (max. 16)
A
A
0,15 / 2
Control signals
—
—
—
—
—
—
Combicon 5.08 / 18 pole , 2,5mm²
Power signals
Power Combicon 7.62 / 4x4 + 1x6-pole, 4mm²
SubD 9pole (socket)
Resolver input
Sine-cosine encoder input
PC-interface, CAN
SubD 15pole (socket)
SubD 9pole (plug)
Encoder simulation, ROD (EEO) / SSI
Mechanical
SubD 9pole (plug)
Weight
kg
4
5
7.5
Height without connectors
Width
mm
mm
mm
275
265
70
100 120
Depth without connectors
18
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6.2.1 Recommended torque
07/2007
Technical description
Connector
Recommended torque
X3, X4
0.5 to 0.6 Nm (4.43 to 5.31 in lb)
0.5 to 0.6 Nm (4.43 to 5.31 in lb)
3.5 Nm (31 in lb)
X0A, X0B, X7, X8, X9
Ground bolt
6.2.2
Fusing
Internal Fusing
Circuit
internal fuse
Auxiliary supply 24V
Regen resistor
3.15 AT (FRx-3)
electronic
External fusing
Fusible cutouts or similar
(Fuse UL time delay)
SERVOSTAR
601/ 603
SERVOSTAR
606/ 610
SERVOSTAR
614/ 620
AC supply
FN1/2/3
6 AT (FRx-6)
10 AT (FRx-10)
20 AT (FRx-25)
24V supply FH1/2/3
Regen resistor
max. 12 AF (max. FRx-12)
10 AT (FRS-10)
FB1/2
6 AT (FRS-6)
10 AT (FR10-10)
(x = S or S-R for 480V applications
x = N or N-R for 230V applications)
6.2.3
Ambient conditions, ventilation, mounting position
Storage, hints
ð p.13
Transport, hints
Supply voltage tolerances
Input power
ð p.13
min 3x 230V-10% AC / max 3x 480V+10%, 50 Hz
min 3x 208V-10% AC / max 3x 480V+10%, 60 Hz
Aux. power supply
Ambient temperature in operation
Humidity in operation
Site altitude
24 VDC (-0% +15%), check voltage drop
0 to +45°C (32 to 113°F) at rated data
+45 to +55°C (113 to 131°F) with power derating
2.5% / K
rel. humidity 85%, no condensation
up to 1000m a.m.s.l. without restriction
1000 — 2500m a.m.s.l. with power derating
1.5%/100m
Pollution level
Vibrations
Pollution level 2 to EN60204/EN50178
Class 3111 according to IEC 721-3-3
max. 45 dB(A)
Noise emission
Enclosure protection
Mounting position
Ventilation
IP 20
forced convection by built-in fan
Make sure that there is sufficient forced ventilation within the switchgear cabinet.
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Technical description
07/2007
Danaher Motion
6.2.4
Conductor cross-sections
NEC 60°C or 75°C column), we recommend for single-axis systems:
SERVOSTAR 601-610: 1.5 mm² (14awg) 600V,105°C (221°F),
AC connection
SERVOSTAR 614/620: 4 mm²
(12awg) twisted
600V,105°C (221°F),
shielded for
SERVOSTAR 601-610: 1.5 mm² (14awg)
SERVOSTAR 614/620: 4 mm² (12awg)
DC bus link
lengths>20cm
600V,105°C (221°F),
shielded,
Motor cables
SERVOSTAR 601-610: 1-1.5 mm² (14awg)
SERVOSTAR 614/620: 2.5 mm² (12awg)
up to 25 m length*
capacitance <150pF/m
600V,105°C (221°F),
shielded,
Motor cables
SERVOSTAR 601-606: 1 mm²
(14awg)
25 to 100 m length*,
with motor choke 3YL
SERVOSTAR 610-620: 2.5 mm² (12awg)
capacitance <150pF/m
Resolver, thermostat-mo- 4x2x0.25 mm² (22awg) twisted pairs, shielded,
tor, max.100m length* capacitance <120pF/m
Encoder, thermostat-motor, 7x2x0,25 mm² (22 awg) twisted pairs, shielded,
max.50m length* capacitance <120pF/m
Setpoints, monitors, AGND 0.25 mm² (22awg) twisted pairs, shielded
Control signals, BTB,
0.5 mm² (20awg)
DGND
min. 0.75 mm² (18awg), 600V,105°C (221°F), shielded,
Holding brake (motor)
+24 V / XGND
check voltage drop
max. 2.5 mm² (12awg), check voltage drop
For multi-axis systems, please note the special operating conditions in your installation.
* Danaher Motion North America delivers cables up to 39m length.
* Danaher Motion Europe delivers cables up to the maximum length.
6.3
LED display
During operation of the amplifier via the keys on the front panel, the parameter and function num-
20
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07/2007
Technical description
6.4 Control for motor holding brake
A 24V / max. 2A holding brake in the motor can be controlled directly by the servo amplifier.
Check voltage drop, measure the voltage at brake input and check brake function
(brake and no brake).
This function does not ensure personnel safety!
The brake function must be enabled through the BRAKE parameter (setting: WITH BRAKE). In the
diagram below you can see the time and functional relationships between the ENABLE signal,
speed setpoint, speed and braking force.
During the internal ENABLE delay time of 100ms (DECDIS) the speed setpoint of the servo ampli-
fier is internally driven down a 10ms ramp to 0. The brake output is switched on when the speed
5rpm (VELO) is reached or after 5s (EMRGTO) the latest.
The rise (tbrH) and fall (tbrL) times of the holding brake which is built into the motors are different
for the various types of motor (see motor manual).
A safe (for personnel) operation of the holding brake requires an additional “make” (n.o.) contact in
the brake circuit and a suppressor device (varistor) for the recommended brake circuit diagram :
SERVOSTAR
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Technical description
6.5 Grounding system
07/2007
Danaher Motion
AGND — ground for analog inputs/outputs, internal analog/µC ground
DGND — ground for digital inputs/outputs, optically isolated
XGND — ground for external 24V aux. voltage, optically and inductively isolated
PGND — ground for encoder simulation, RS232, CAN, optically isolated
6.6
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. The regen circuit (thresholds) are adjusted to the supply
voltage with the help of the setup software.
Our customer service can help you with the calculation of the regen power which is required. A
Internal regen resistor
SERVOSTAR 601/603
SERVOSTAR 606-620
66 W
33 W
External regen resistor
SERVOSTAR 601-620
33 W
Functional description
1.- Individual amplifiers, not coupled through the DC bus link (DC+, DC-)
The circuit starts to respond at a DC bus link voltage of 400V, 720V or 840V (depending on
the supply voltage).
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 regen circuit will be switched off.
At the next internal check of the DC bus link voltage (after a few ms) an overvoltage will be
detected and the servo amplifier will be switched off with the error message “Overvoltage
2.- Several servo amplifiers coupled through the DC bus link circuit (DC+, DC-)
Thanks to the built-in regen circuit, several amplifiers (even with different current ratings) can
be operated off a common DC bus link. This is achieved by an automatic adjustment of the
regen thresholds (which vary, because of tolerances). The regen energy is distributed
equally among all the amplifiers.
The combined power of all the amplifiers is always available, as continuous or peak power.
The switch-off takes place as described under 1. (above) for the servo amplifier with the
lowest switch-off threshold (resulting from tolerances). The RTO (BTB) contact of this ampli-
Technical Data
The technical data depend on the used servo amplifier type and on the mains voltage. See table on
the next page.
22
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07/2007
Technical description
Regen circuit: technical data
SERVOSTAR
Supply
voltage
Rated data
DIM
601 - 603
606 - 620
Upper switch-on level of regen circuit
Switch-off level of regen circuit
Overvoltage F02
V
V
400 - 430
380 - 410
450
V
Continuous power of regen circuit (RBint
)
W
kW
kW
kW
W
80
0.25
2.5
200
0.75
5
3 x 230 V
3 x 400 V
3 x 480 V
Continuous power of regen circuit (RBext) max.
Pulse power, internal (RBint max. 1s)
Pulse power, external (RBext max. 1s)
External regen resistor
5
33
Upper switch-on level of regen circuit
Switch-off level of regen circuit
Overvoltage F02
V
720 - 750
680 - 710
800
V
V
Continuous power of regen circuit (RBint
)
W
kW
kW
kW
W
80
0.4
8
200
1.2
16
Continuous power of regen circuit (RBext) max.
Pulse power, internal (RBint max. 1s)
Pulse power, external (RBext max. 1s)
External regen resistor
16
33
Upper switch-on level of regen circuit
Switch-off level of regen circuit
Overvoltage F02
V
840 - 870
800 - 830
900
V
V
Continuous power of regen circuit (RBint
)
W
kW
kW
kW
W
80
0.5
200
1.5
21
Continuous power of regen circuit (RBext) max.
Pulse power, internal (RBint max. 1s)
Pulse power, external (RBext max. 1s)
External regen resistor
10.5
21
33
Suitable external regen resistors can be found in our accessories manual.
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Technical description
07/2007
Danaher Motion
6.7 Switch-on and switch-off behavior
This chapter describes the switch-on and switch-off behavior of the SERVOSTAR and the steps
required to achieve operational stopping or emergency stop behavior that complies with standards.
The servo amplifier’s 24 V supply must remain constant. The ASCII commands
ACTFAULT (error response) and STOPMODE (ENABLE signal response) dictate
how the drive will behave.
Behavior (see also ASCII reference in the online help of the
STOPMODE
ACTFAULT
setup software)
0 (default)
1
0
Motor coasts to a standstill in an uncontrolled manner
Motor is braked in a controlled manner
1 (default)
Behavior during a power failure
The servo amplifiers use an integrated circuit to detect if one or more input phases (power supply
feed) fail. The behavior of the servo amplifier is set using the setup software: Under “Response to
Loss of Input Phase” (PMODE) on the Basic Setup screen, select:
l
Warning if the higher-level control system is to bring the drive to a standstill: Warning n05 is
output if an input phase is missing, and the motor current is limited to 4 A. The servo amplifier
is not disabled. The higher-level control system can now selectively end the current cycle or
start bringing the drive to a standstill. Therefore, the error message “MAINS BTB, F16" is out-
put on a digital output of the servo amplifier and evaluated by the control system, for instance.
l
Error message if the servo amplifier is to bring the drive to a standstill: Error message F19 is
output if an input phase is missing. The servo amplifier is disabled and the BTB contact opens.
Where the factory setting is unchanged (ACTFAULT=1), the motor is braked using the set
“EMERGENCY STOP RAMP”.
Behavior when undervoltage threshold is reached
If the undervoltage threshold is undershot in the DC bus link (the threshold value depends on the
type of servo amplifier), the error message “UNDERVOLTAGE, F05" is displayed. The drive
response depends on the ACTFAULT/STOPMODE setting.
Behavior with enabled “holding brake” function
Servo amplifiers with an enabled holding brake function have a special procedure for switching off
electronic circuits, the general rule applies that there is a possibility of the internal “holding brake”
module failing. Bringing a motor to a standstill using a holding brake in a way that is personnel safe
also requires an electromechanical “make” contact for the holding equipment and a suppressor
device for the brake.
Behavior of the optional restart lock -AS-
With the personnel safe restart lock –AS-, the drive can be secured on standstill using its internal
electronics so that even when power is being supplied, the drive shaft is protected against uninten-
tional restart. The chapter “Personnel safe restart lock -AS-” describes how to use the restart lock
24
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Technical description
6.7.1 Behavior in standard operation
The behavior of the servo amplifier always depends on the current setting of a number of different
parameters (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see online help). The diagram
below illustrates the correct functional sequence for switching the servo amplifier on and off.
DC bus link
Motor speed
Power Stage
Enable (internal)
Devices which are equipped with a selected “Brake” function use a special sequence for
The -AS- option can be used to switch off the drive via a positive-action (approved by the Trade
Liability Association) safety relay, so that personnel safety is ensured at the drive shaft (ð p.91).
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Danaher Motion
6.7.2 Behavior in the event of an error (with standard setting)
The behavior of the servo amplifier always depends on the current setting of a number of different
parameters (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see online help). The diagram
shows the startup procedure and the procedure that the internal control system follows in the event
of one or more electrical supply phases failing, assuming that the standard parameter settings
apply.
(F16/F19 = error messages Mains BTB /input phase, F05 = error message Undervoltage)
Even if there is no intervention from an external control system (in the example, the ENABLE signal
remains active), the motor is immediately braked using the emergency stop ramp if an input phase
error is detected and assuming that no changes have been made to the factory setting
(ACTFAULT=1).
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Technical description
6.8
Stop/Emergency Stop Function to EN 60204
secured on standstill (torque-free) using its internal electronics so that even when
power is being supplied, the drive shaft is protected against unintentional restart.
6.8.1
Stop: Standards
The Stop function is used to shut down the machine in normal operation. The Stop functions are
defined by EN 60204 (VDE 0113), paragraphs 9.2.2 and 9.2.5.3.
Category 0:
Shut-down by immediate switching-off of the energy supply to the
drive machinery (i.e. an uncontrolled shut-down);
Category 1:
A controlled shut-down , whereby the energy supply to the drive
machinery is maintained to perform the shut-down, and the energy
supply is only interrupted when the shut-down has been completed;
Category 2:
A controlled shut-down, whereby the energy supply to the drive
machinery is maintained.
The parameters “STOPMODE” and “ACTFAULT” must be set to 1 in order to
implement the stop categories. If necessary, change the parameters via the
terminal screen of the setup software and store the data in the EEPROM.
The Stop Category must be determined by a risk evaluation of the machine. In addition, suitable
means must be provided to guarantee a reliable shut-down.
Category 0 and Category 1 Stops must be operable independently of the operating mode, whereby
a Category 0 Stop must have priority. Stop functions must be implemented by disconnection of the
appropriate circuitry, and have priority over assigned start functions.
If necessary, provision must be made for the connection of protective devices and lock-outs. If
applicable, the Stop function must signal its status to the control logic. A reset of the Stop function
must not create a hazardous situation.
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6.8.2 Emergency Stop: Standards
The emergency Stop function is used for the fastest possible shut-down of the machine in a dan-
gerous situation. The Emergency Stop function can be triggered by the actions of a single person. It
must be fully functional and available at all times. The user must not have to work out how to oper-
ate this mechanism.
The Emergency Stop function is defined by EN 60204 (VDE 0113), paragraph 9.2.5.4.
In addition to the requirements for Stop, the emergency Stop must fulfil the following requirements:
l
emergency stop must have priority over all other functions and controls in all operating situa-
tions;
l
the energy supply to any drive machinery that could cause dangerous situations must be swit-
ched off as fast as possible, without causing any further hazards (e.g. by using mechanical lat-
ching devices that do not require an external supply of energy, by counter-current braking in
Stop Category 1);
l
the reset must not initiate a restart.
If necessary, provision must be made for the additional connection of emergency stop devices (see
EN 60204, "Requirements for emergency stop devices").
The Emergency Stop must be effective as a stop of either Category 0 or Category 1.
The Emergency Stop Category must be determined by a risk evaluation of the machine.
Category 0
Only hard-wired, electromechanical components may be used for the Category 0 Emergency Stop
function. It must not be triggered using switching logic (hardware or software), by transferring com-
mands via a communication network, or via a data link.
The drive must be shut down using an electromechanical circuit. If the connected servo motor has
an integrated brake, this must always be controlled by an electromechanical circuit as well.
Category 1
With the Category 1 Emergency Stop function, there must be absolute certainty in terms of the
power supply for the machine drives being switched off (i.e., secured) using electromechanical com-
ponents. Additional Emergency Stop equipment may be connected. Bringing the motor to a stand-
still by interrupting the mains supply and using controlled electronic braking. The 24 V supply for the
servo amplifier must remain constant. The issue of which circuit should be used is highly dependent
on the requirements of the application at hand.
Usually a brake in a servo motor only has the function of a holding brake. To ensure an emergency
stop function, the braking torque that is required must be checked. If the holding brake fulfills the
dynamic requirements, it must be taken into acount that this application will cause increased wear.
The parameters “STOPMODE” and “ACTFAULT” must be set to 1 in order to
implement the stop categories. If necessary, change the parameters via the
terminal screen of the setup software and store the data in the EEPROM.
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Technical description
6.8.3 Implementation of the Stop Category 0
Bringing the motor to a standstill by immediately switching off the amplifier power supply
(STOPMODE & ACTFAULT parameters set to 1). The switching sequence is precisely deter-
mined by this circuit in order to avoid undesirable fault messages and servo amplifier failures.
It is not possible to achieve a Category 0 shut-down with the servo amplifier alone, since hard-wired
electromechanical components are compulsory for this type of disconnection.
A brake that is built into the motor must have an additional electromechanical control circuit, as well
as the control through the SERVOSTAR 600, in order to meet Category 0.
Usually a brake in a servo motor only has the function of a holding brake. To ensure an emergency
stop function, the braking torque that is required must be checked. If the holding brake fulfills the
dynamic requirements, it must be taken into acount that this application will cause increased wear.
Circuit suggestion
(with EMERGENCY STOP Category 0, control function with contactor relays)
SERVOSTAR
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Danaher Motion
6.8.4 Implementation of the Stop Category 1
Bringing the motor to a standstill by interrupting the mains supply and using controlled electronic
braking (STOPMODE & ACTFAULT parameters set to 1). The 24 V supply for the SERVOSTAR
must remain constant.
The drive is braked in a controlled manner during the stopping (disabling) procedure. If the speed
output stage is disabled.
As soon as two separate time periods (set at the time relay) have elapsed, the mains supply and
the holding brake are electrically isolated.
Should an internal SERVOSTAR 600 fault occur, the motor is forced to a standstill
once K20 drops out.
Circuit suggestion
(with EMERGENCY STOP Category 1, control function with contactor relays)
SERVOSTAR
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Technical description
6.8.5 Implementation of the Stop Category 2
The machine receives an operational stop (disable) command and brakes the drive using the set
braking ramp (STOPMODE & ACTFAULT parameters set to 1).
The drive is braked in a controlled manner during the stopping (disabling) procedure. If the speed
output stage is disabled. In this case, there is no interruption of the electrical supply.
If the electrical supply is switched off, not only will the controlled braking procedure be performed,
but the mains supply and the holding brake will also be electrically isolated following a time period
set at the time relay.
Circuit suggestion
(with EMERGENCY STOP Category 1, control function with contactor relays)
SERVOSTAR
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6.9
Shock-hazard protection
Leakage current
6.9.1
Leakage current via the PE conductor results from the combination of equipment and cable leakage
currents. The leakage current frequency pattern comprises a number of frequencies, whereby the
residual-current circuit breakers definitively evaluate the 50Hz current. For this reason, the leakage
current cannot be measured using a conventional multimeter.
As a rule of thumb, the following assumption can be made for leakage current on our low-capacity
cables at a mains voltage of 400 V, depending on the clock frequency of the output stage:
Ileak = n x 20mA + L x 1mA/m at 8kHz clock frequency at the output stage
I
leak = n x 20mA + L x 2mA/m at a 16kHz clock frequency at the output stage
(where I
=leakage current, n=number of amplifiers, L=length of motor cable)
leak
At other mains voltage ratings, the leakage current varies in proportion to the voltage.
Example:
2 x servo amplifiers + a 25m motor cable at a clock frequency of 8kHz:
2 x 20mA + 25m x 1mA/m = 65mA leakage current.
Since the leakage current to PE is more than 3.5 mA, in compliance with EN50178
the PE connection must either be doubled or a connecting cable with a
cross-section >10mm² must be used. Use the PE terminals (X0A and X0B) or the PE
bolt in order to fulfil this requirement.
The following measures can be used to minimise leakage currents.
— Reduce the length of the engine cable
— Avoid mains asymmetries (with an isolating transformer)
6.9.2
Residual-current circuit breakers (FI)
In conformity with DIN IEC 60364-4-41 – Regulations for installation and EN 60204 – Electrical
equipment of machinery, residual-current circuit-breakers (called FI below) can be used provided
the requisite regulations are complied with.
The SERVOSTAR 600 is a 3-phase system with a B6 bridge. Therefore, FIs which are sensitive
to all currents must be used in order to detect any d.c. fault current. Refer to chapter 6.9.1 for the
rule of thumb for determining the leakage current.
Rated residual currents in the FI
Protection against "indirect contact" (personal fire protection) for stationary and mo-
10 -30 mA
bile equipment, as well as for "direct contact".
Protection against "indirect contact" (personal fire protection) for stationary equip-
50 -300 mA
ment
Recommendation: In order to protect against direct contact (with motor cables
shorter than 5 m) we recommend that each servo amplifier be protected
individually using a 30mA residual-current circuit-breaker which is sensitive to all
currents.
If you use a selective FI circuit-breaker, the more intelligent evaluation process will prevent spurious
tripping of the circuit-breakers.
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6.9.3 Isolating transformers
07/2007
Technical description
If protection against indirect contact is absolutely essential despite a higher leakage current, or if an
alternative form of shock-hazard protection is sought, the SERVOSTAR 600 can also be operated
via an isolating transformer.
A ground-leakage monitor can be used to monitor for short circuits.
We would advise you to keep the length of wiring between the transformer and the
servo amplifier as short as possible.
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This page has been deliberately left blank.
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Mechanical Installation
7
Mechanical Installation
7.1
Important notes
l
Protect the servo amplifier from impermissible stresses. In particular, do not let any
components become bent or any insulation distances altered during transport and handling.
Avoid contact with electronic components and contacts.
l
l
l
Ensure that there is an adequate flow of cool, filtered air into the bottom of the switchgear cabi-
Take care that the servo amplifier and motor are earthed (grounded) properly. Do not use
painted (non-conductive) mounting plates.
Don't mount devices, which produce magnetic fields, directly beside the servo amplifier. Strong
magnetic fields could directly affect internal components. Install devices which produce mag-
netic field with distance to the servo amplifiers and/or shield the magnetic fields.
7.2
Guide to mechanical installation
The following notes should assist you to carry out the mechanical installation in a sensible
sequence, without overlooking anything important.
Site
The site must be free from conductive or corrosive materials.
Check that the ventilation of the servo amplifier is unimpeded
Ventilation
Assembly
Assemble the servo amplifier and power supply, filter and choke close
together on the conductive, grounded mounting plate in the cabinet.
Earth (ground) the mounting plate, motor housing and CNC-GND of the controls.
Notes on connection techniques are on page 42
Grounding
Shielding
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7.3 Assembly
07/2007
Danaher Motion
Material : 2 or 4 hexagon socket screws to DIN 912, M5
Tool required : 4 mm Allen key
SERVOSTAR
601-610
SERVOSTAR
601-610
SERVOSTAR
620
SERVOSTAR
614
SERVOSTAR 600
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Electrical Installation
8
Electrical Installation
8.1
Important notes
l
Check the combination of servo amplifier and motor. Compare the rated voltage and current of
l
Make sure that the maximum permissible rated voltage at the terminals L1, L2, L3 or +DC,
–DC is not exceeded by more than 10% even in the most unfavorable case
(see EN 60204-1 Section 4.3.1). An excessive voltage on these terminals can lead to
destruction of the regen circuit and the servo amplifier.
l
l
Route power and control cables separately. We recommend a separation of at least 200mm.
This improves the interference immunity required by EMC regulations. If a motor power cable
is used which includes cores for brake control, the brake control cores must be
l
l
Install all shielding with large areas (low impedance), with metallised connector housings or
shield connection clamps where possible. Notes on connection techniques can be found on
Feedback lines may not be extended, since thereby the shielding would be interrupted and the
signal processing could be disturbed.
l
l
The cable between servo amplifier and regen resistor must be shielded.
l
l
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.
It is permissible to alter the servo amplifier settings by using the setup software.
Any other alterations will invalidate the warranty.
Never disconnect the electrical connections to the servoamplifier while it is live. In
unfavorable 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 bus voltage at the DC
bus link pins (+DC/-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.
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8.2 Guide to electrical installation
The following notes should assist you to carry out the electrical installation in a sensible sequence,
without overlooking anything important.
Cable selec-
tion
Grounding
Earth (ground) the mounting plate, motor housing and CNC-GND of the controls.
Shielding
Notes on connection techniques are on page 42
Route power leads and control cables separately
Wiring
Wire the BTB/RTO contact in series into the safety loop
— Connect the digital control inputs to the servo amplifier
— Connect up AGND (also if fieldbuses are used)
— Connect the analog setpoint, if required
— Connect up the feedback unit (resolver and/or encoder)
— Connect the encoder emulation, if required
— Connect the motor cables, connect shielding to EMI connectors at both ends
— Use motor chokes (3YL) for lead lengths >25m
— Connect the external regen resistor (with fusing) if required
— Final check of the implementation of the wiring,
Final check
— according to the wiring diagrams which have been used.
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Electrical Installation
8.3
Wiring
Important notes
8.3.1
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 sensible or
necessary, depending on the application of the equipment.
We provide further know-how through training courses (on request).
Warning !
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 setup.
The ground symbol
X
, 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 surface area between the unit indicated and the mounting plate in
the switchgear cabinet.
This connection is for the effective grounding of HF interference, and must not be
confused with the PE- symbol W (a protective measure to EN 60204).
Use the following connection diagrams:
Overview
: page 47
: page 49
: page 50
: page 51ff
Mains power
Motor
Feedback
Electronic Gearing / Master Slave
Master-Slave
Pulse-Direction
Encoder Emulation:
ROD (A quad B)
SSI
: page 58
: page 61
: page 63
: page 64
: page 65ff
: page 69
: page 70
: page 85
: page 94
Digital/Analog I/Os
RS232 / PC
CAN Interface
Multi-axis systems, example
Restart lock option -AS-
Expansion cards:
I/O-14/08
: page 101
: page 102
: page 104
: page 105
: page 108
: page 110
: page 112
PROFIBUS
SERCOS
DeviceNet
EtherCat
SynqNet
-2CAN-
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8.3.2 Technical data for connecting cables
Further information on the chemical, mechanical and electrical characteristics of the cables can be
obtained from our customer service.
Observe the restrictions in the chapter "Conductor cross-sections" on page 20.
To reach the max. permitted cable length, you must use cable material that
matches the capacitance requirements listed below.
Insulation material
Sheathing
PUR (polyurethane, code 11Y)
Core insulation
PETP (polyesteraphtalate, code 12Y)
Capacitance
Motor cable
less than 150 pF/m
less than 120 pF/m
RES-/Encoder-cable
Technical data
For a detailed description of cable types and how to assemble them, please refer to the accessories
manual.
Motor cables longer than 25m with motor choke 3YL only.
8.3.3
Shielding connection to the front panel
Remove the outer covering of the cable
and the shielding braid from the cores
for the required length. Secure the cores
with a cable tie.
Remove the outer covering of the cable
over a length of about 30mm, without
damaging the shielding braid.
Pull a cable tie through the slot in the
shielding rail (front panel) of the servo
amplifier.
Use the cable tie to clamp the shielding
braid of the cable firmly to the shielding
rail.
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8.3.4 Motor connector with shieldplate
The motor is connected to the SERVOSTAR 600 by a Power Combicon connector (X9). You can
obtain the connector kit from us (connector, housing, shield plate, rubber bushes, installation mate-
The cable material depends on the motor that is used. Please refer to the installation manual for the
corresponding motor series. Please take note that the connector can accept a maximum conductor
cross-section of 4mm².
First push the rubber sleeve onto the
cable, and then strip off about 70mm
of the outer covering, without damag-
ing the shielding.
Carefully separate the shielding braid
from the cores.
Twist the shielding braid into a pigtail
and tie it to the sleeve with the wire.
Shorten the brake cores to 55mm
and the power cores to 45mm.
Fold back the overhanging length of
the shielding pigtail to face forwards.
Strip off the ends of the cores for
about 10mm. This length can vary,
depending on the type of bootlace
ferrule that is used.
Apply bootlace ferrules to the con-
ductors. Place the shield plate in the
bottom half of the connector housing.
Place the cable in the strain relief, so
that the folded shielding pigtail lies on
the shield plate, but the tie-wire is not
clamped inside.
Tighten up the screws, without crush-
ing the cable.
Place the connector in the housing.
Take care that the tongue of the
shield plate sits in the PE clamp.
Wire up the connector according to
tighten up the clamping screws. Take
care that the insulation is not trapped
underneath. Close the housing.
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8.4
Components of a servo system
PC
Control / PLC
I/O
Option -AS-
24V supply
Fuses
Regen resistor
(optional)
Drive cut-out
Motor
Terminals
Motor choke
(optional)
Cables drawn bold are shielded. Electrical ground is drawn with dash-dotted lines.
Optional devices are connected with dashed lines to the servo amplifier. The
required accessories are described in our accessories manual.
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Electrical Installation
8.7 Connection diagram (overview)
SERVOSTAR 600
ð p.65
ð p.53ff
ð p.66
ð p.52
ð p.67
ð p.50
ð p.68
ð p.50
ð p.63
ð p.64
ð p.58
ð p.61
ð p.49
ð p.70
ð p.49
ð p.69
ð p.49
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8.8
Power supply
8.8.1
Connection to various mains supply networks
This page illustrates all the possible connection variations for different electrical supply networks.
An isolating transformer is always required for 400...480V mains networks without
earth(ground) and for networks with asymmetrical earth(ground).
208V with 60Hz only
SERVOSTAR
230...480V with 50Hz or 60Hz
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
SERVOSTAR
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Electrical Installation
8.8.2 Mains supply connection (X0)
—
—
Directly to earthed (grounded) 3~ supply, integrated EMI filter
SERVOSTAR 600
8.8.3
24V auxiliary supply (X4)
—
—
—
Electrically isolated, external 24VDC supply, e.g. with insulating transformer
Integrated EMI filter for the 24V auxiliary supply
SERVOSTAR 600
8.8.4
DC bus link (X7)
Can be connected in parallel. A patented circuit distributes the regen power among all the amplifiers
Only servo amplifiers with mains supply from the same mains (identical mains
supply voltage) may be connected by the DC bus link.
The sum of the rated currents for all of the servo amplifiers connected in parallel
to an SERVOSTAR 600 must not exceed 40A.
Use unshielded single cores (2.5mm²) with a max. length of 200 mm. Use shielded
cables for longer lengths. - A.4.031.1/21,25
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8.9
Motor connection with brake (X9)
Lead length £ 25m
SERVOSTAR 600
Lead length >25m
For lead lengths above 25m the choke box 3YL must be wired into the motor lead,
close to the amplifier.
SERVOSTAR 600
8.10
External regen resistor (X8)
Remove the plug-in link between the terminals X8/1 (-RB) and X8/2 (+Rbint).
SERVOSTAR 600
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8.11 Feedback
07/2007
Electrical Installation
Every closed servo system will normally require at least one feedback device for sending actual
values from the motor to the servo drive. Depending on the type of feedback device used, informa-
tion will be fed back to the servo amplifier using digital or analog means.
SERVOSTAR 600 supports the most common types of feedback device whose functions must be
assigned with the parameters
FBTYPE
(screen page FEEDBACK), primary Feedback
(screen page POSITION), secondary Feedback
(screen page GEARING), secondary Feedback
EXTPOS
GEARMODE
in the setup software. Scaling and other settings must always be made here.
Commu-
Speed
Position- electr.
Configuration
One Feedback
Location ASCII Parameter
tation
control
control
X
gearing
motor
motor
FBTYPE
X
X
X
X
FBTYPE
Two Feedbacks
EXTPOS
GEARMODE
X
externally
X
For a detailed description of the ASCII parameters, please refer to the online help of the setup soft-
ware.
The table below provides an overview of the supported feedback types, their corresponding param-
eters and a reference to the relevant connection diagram in each case. On each of these, the pin
assignment shown on the encoder side relates to the Danaher Motion motors.
Wiring
Primary feedback type
Connector
FBTYPE
diagram
ð p.52
ð p.53
ð p.54
ð p.54
ð p.55
ð p.56
ð p.56
ð p.57
-
Resolver
X2
X1
X1
X1
X1
X1
X1
X5
-
0, 3
20*
SinCos Encoder BISS
SinCos Encoder ENDAT
SinCos Encoder HIPERFACE
SinCos Encoder w/o data channel
SinCos Encoder + Hall
RS422 5V + Hall
3, 4
2, 3
6, 7 (16*)
11*
12*
RS422 5V
8*, 9*
10*
Sensorless (w/o feedback)
* Can only be set on the terminal screen of the setup software
** RS422 means “incremental encoder AquadB”.
Hints for combining primary with secondary feedback systems for position
control/electr. gearing can be found from page 58.
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8.11.1 Resolver (X2)
07/2007
Danaher Motion
contact in the motor is connected via the resolver cable to X2 and evaluated there.
If cable lengths of more than 100 meters are planned, please contact our customer service.
FBTYPE: 0, 3
SubD9
SERVOSTAR 600
12pol.round
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Electrical Installation
8.11.2 Sine Encoder 5V with BISS (X1)
Wiring of a single-turn or multi-turn sine-cosine encoder with BISS interface as a feedback system
(firmware revision from 6.68). During start-up of the servo amplifier the parameters stored in the
encoder eeprom are uploaded, after that phase only the sine/cosine signals are used.
The thermostat contact in the motor is connected via the encoder cable to X1 and evaluated there.
All signals are connected using our pre-assembled encoder connection cable.
Encoder types with a power consumption of more than 150mA can also be connected using our
If cable lengths of more than 50m are planned, please consult our customer service.
Frequency limit (sin, cos): 250 kHz
FBTYPE 20
SERVOSTAR 600
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8.11.3 Sine Encoder with EnDat 2.1 or HIPERFACE (X1)
Wiring of a single-turn or multiturn sine-cosine encoder as a feedback system. Preferred types are
ECN1313 and EQN1325.
The thermostat contact in the motor is connected via the encoder cable to the SERVOSTAR 600
and evaluated there. All signals are connected using our pre-assembled encoder connection cable.
Encoder types with a power consumption of more than 150mA can also be connected using our
If lead lengths of more than 50m are planned, please consult our customer service.
Frequency limit (sin, cos): 250 kHz
Encoder with EnDat: FBTYPE 3, 4
Encoder with HIPERFACE: FBTYPE 2, 3
SubD1
17pol.round
SERVOSTAR 600
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Electrical Installation
8.11.4 Sine Encoder without data channel (X1)
Wiring of a sine-cosine encoder without data channel as standard feedback system. Every time the
24V auxiliary voltage is switched on, the amplifier needs start-up information for the position control-
ler (parameter value MPHASE). Depending on the feedback type either wake&shake is executed or
the value for MPHASE is read out of the amplifier's EEPROM.
Encoder types with a power consumption of more than 150mA can also be connected using our
The thermostat contact in the motor is connected via the encoder cable to X1 and evaluated there.
If lead lengths of more than 50m are planned, please consult our customer service.
Frequency limit (sin, cos): 250 kHz
Encoder type
SinCos 5V
FBTYPE Remarks
6
7
MPHASE from EEPROM
SinCos 5V
MPHASE with wake & shake
Resolver+SinCos5V
16
Commutation with Resolver, speed&position with Encoder
Don't use this feedback type with vertical load (hanging load).
SERVOSTAR 600
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8.11.5 Incremental encoder / sine encoder with Hall (X1)
Encoder types (incremental or sine/cosine) that do not provide definitive information on commuta-
tion, can be used as a complete feedback system using an additional Hall dongle.
In this case, an adapter is used for interfacing and adapting the signals (Hall dongle, ð p. 90). This
adapter is also used to connect encoders known as ComCoders.
Encoder types with a power consumption of more than 150mA can also be connected using our
If you plan to use a cable longer than 25m, please contact our application department.
Frequency limit (A, B): 250 kHz
RS422 with Hall: FBTYPE 12
Encoder with Hall: FBTYPE 11
SERVOSTAR 600
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8.11.6 Incremental Encoder (X5)
07/2007
Electrical Installation
An incremental encoder can be used as standard motor feedback.
Every time the 24V auxiliary voltage is switched on, the amplifier needs start-up information for the
position controller (parameter value MPHASE). Depending on the feedback type either wake&shake
is executed or the value for MPHASE is read out of the amplifier's EEPROM.
If lead lengths of more than 50m are planned and for questions concerning the power supply of the
encoder, please consult our customer service.
AGND and DGND (connector X3) must be joined together !
Frequency limit: 1.5 MHz
Encoder type
RS422 5V
FBTYPE
Remarks
9
8
MPHASE from EEPROM
MPHASE with wake & shake
RS422 5V
Don't use this feedback type with vertical load (hanging load).
SubD 9
SERVOSTAR 600
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8.12 Electronic Gearing, Master-slave operation
In the case of the “electronic gearing” functionality (see setup software and description of
GEARMODE parameter), the servo amplifier is controlled by a secondary feedback device as a
slave.
It is possible to set up master/slave systems, use an external encoder as a setpoint encoder or con-
nect the amplifier to a stepper motor control.
The amplifier is parameterized using the setup software (electronic gearing).
Primary Feedback: adjust on screen page "Feedback" (FBTYPE)
Secondary Feedback: adjust on screen pages "Position" and "Gearing" (EXTPOS, GEARMODE)
Master-/Slave adjustment
Master: adjust encoder emulation on screen page "ROD/SSI/Encoder" (ENCMODE)
Slave: adjust on screen pages "Position" and "Gearing" (EXTPOS, GEARMODE)
The following types of external encoder can be used:
Wiring
secondary Feedback type
Connector
GEARMODE
diagram
ð p.59
ð p.59
ð p.60
ð p.61
ð p.62
ð p.62
Incremental Encoder 5V
Incremental Encoder 24V
Sine/Cosine Encoder
SSI Encoder
X5
X3
X1
X5
X5
X3
3, 5*, 13*, 15*
0, 2*, 10*, 12*
6, 8*, 9*, 16*
7*, 17*
Pulse and Direction 5V
Pulse and Direction 24V
4, 14*
1, 11*
* adjustable via terminal screen of the setup software
The follwing table shows the allowed feedback combinations:
Secondary Feedback for Position control/Following
Sine Encoder
(X1)
Increment. Enco- Pulse&Direct.
SSI Encoder
Primary Feedback
der5V/24V (X5/X3) 5V/24V (X5/X3) (X5)
EXTPOS = 1,2,3 EXTPOS = 1,2,3
GEARMODE = GEARMODE =
EXTPOS = 1,2,3 EXTPOS = 1,2,3
GEARMODE =
GEARMODE =
7,17
Resolver (X2)
FBTYPE = 0
6,8,9,16
0,2,3,5,10,12,13,15 1,4,11,14
FPGA = 0
FPGA = 0
FPGA = 0
FPGA = 1
ENCMODE = 0 ENCMODE = 0
EXTPOS = 1,2,3
ENCMODE = 0
ENCMODE = 2
EXTPOS = 1,2,3 EXTPOS = 1,2,3
GEARMODE =
GEARMODE =
GEARMODE =
7,17
Sine Encoder (X1)
-
0,2,3,5,10,12,13,15 1,4,11,14
FBTYPE = 2,4,6,7,20
FPGA = 1
FPGA = 1
FPGA = 1
ENCMODE = 0
EXTPOS = 1,2,3
GEARMODE =
ENCMODE = 0
EXTPOS = 1,2,3
GEARMODE =
ENCMODE = 2
Encoder & Hall (X1)
-
-
-
0,2,3,5,10,12,13,15 1,4,11,14
-
FBTYPE = 11,12
FPGA = 1
FPGA = 1
ENCMODE = 0
ENCMODE = 0
RS422 Encoder (X5)
-
-
-
FBTYPE = 8,9
EXTPOS = 1,2,3
GEARMODE =
EXTPOS = 1,2,3 EXTPOS = 1,2,3
GEARMODE =
GEARMODE =
7,17
Sensorless
FBTYPE = 10
0,2,3,5,10,12,13,15 1,4,11,14
FPGA = 0
FPGA = 0
FPGA = 1
ENCMODE = 0
ENCMODE = 0
ENCMODE = 2
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8.12.1
07/2007
Electrical Installation
Connection to a SERVOSTAR master, 5 V signal level (X5)
You can link several SERVOSTAR amplifiers together in master-slave operation.
Up to 16 slave amplifiers can be controlled by the master via the encoder output. The connector X5
must be used.
Frequency limit: 1,5 MHz, slew rate tv £ 0,1 µs
SERVOSTAR 600
SERVOSTAR 600
AGND and DGND (connector X3) must be joined together !
Connection to encoders with 24 V signal level (X3)
8.12.2
This interface can be used to operate the SERVOSTAR as a slave, mastered by an encoder with
24 V signal level (master-slave operation). The digital inputs DIGITAL-IN 1 and 2 at connector X3
must be used. Frequency limit: 250 kHz, slew rate tv £ 0,1 µs
SERVOSTAR 600
AGND and DGND (connector X3) must be joined together !
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8.12.3 Connection to a sine-cosine encoder (X1)
You can operate the SERVOSTAR as a slave, mastered by a sine-cosine encoder (master-slave
operation). The connector X1 must be used.
Encoder types with a power consumption of more than 150 mA can also be connected using our
Frequency limit: 250 kHz
AGND and DGND (connector X3) must be joined together !
SERVOSTAR 600
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8.12.4 Connection to a SSI encoder (X5)
You can set up the SERVOSTAR 600 as a slave following a synchronous serial absolute-encoder
(master-slave operation). This application uses the SubD connector X5.
If lead lengths of more than 50 m are planned and for questions concerning the power supply of the
encoder, please consult our customer service.
Frequency limit: 1,5MHz
SERVOSTAR 600
AGND and DGND (connector X3) must be joined together!
8.12.5
Connection to stepper motor controllers (step and 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 gear-
ing). 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 setpoint inputs are out of action.
Observe the frequency limit!
Using an A quad B encoder provides better EMC noise immunity.
Speed profile and signal diagram
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8.12.5.1 Step/Direction with 5 V signal level (X5)
Connection of the servo amplifier to a stepper-motor controller with 5 V signal level. The connector
X5 must be used.
Frequency limit: 1,5 MHz
AGND and DGND (connector X3) must be joined together !
SERVOSTAR 600
8.12.5.2
Step/Direction with 24 V signal level (X3)
Connection of a servo amplifier to a stepper-motor controller with 24 V signal level. The digital
inputs DIGITAL-IN 1 and 2 at connector X3 must be used.
Frequency limit: 250 kHz
AGND and DGND (connector X3) must be joined together !
SERVOSTAR 600
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Electrical Installation
8.13
Encoder emulations
8.13.1
Incremental encoder output - A quad B (X5)
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. Incremental-encoder compatible pulses
are generated from this information. Pulses are output on the SubD-connector X5 as two signals, A
and B, with 90° phase difference and a zero pulse.
The resolution (lines before quadrature) can be changed with the RESOLUTION parameter:
Encoder function
Feedback system
Resolver
Resolution
Zero position
(ENCMODE)
one per revolution
(only if A=B=1)
256...4096
ROD (1)
256...524288
(28 ... 219)
22...27
one per revolution
(only if A=B=1)
Encoder
analog pass through
ROD interpolation (3) Encoder
TTL lines per sine line from X1 to X5
You can also adjust and store the position of the zero pulse within one mechanical turn
(parameter NI-OFFSET).
The drivers are supplied from an internal supply voltage. PGND must always be
connected to the controls. The max. admissible cable length is 10 m.
Connections and signal description for incremental-encoder interface :
Default count direction: upwards when the motor shaft is rotating clockwise (looking at the shaft
end).
SERVOSTAR 600
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8.13.2 SSI output (X5)
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Danaher Motion
The SSI interface (synchronous serial absolute-encoder simulation) is part of the delivered pack-
age. Select the encoder function SSI (screen page “Encoder”). In the servo amplifier, the position of
the motor shaft is calculated from the cyclically absolute signals from the resolver or encoder. This
information is used to create a position output in a format that is compatible with the standard
SSI-absolute-encoder format. 24 bits are transmitted.
SINGLE TURN selected: The upper 12 bits are fixed to ZERO, the lower 12 bits contain the posi-
tion information. For 2-pole resolvers, the position value refers to the position within one turn of the
motor, for 4-pole resolvers it is within half a turn, and for 6-pole resolvers it is within a third of a turn.
Exception: If an encoder with a commutation track is used as the feedback unit, then the upper 12
bits are set to 1 (data invalid!) until a homing run is performed.
MULTI TURN selected: The upper 12 bits contain the number of motor turns, the lower 12 bits con-
tain the position information.
The signal sequence can be output in Gray code (standard) or in binary code (parameter
SSI-CODE). The servo amplifier can be adjusted to the clock frequency of your SSI-evaluation with
the SSI-TAKT parameter (200 kHz or 1.5MHz and inverted).
Drivers are supplied from internal supply voltage. PGND must always be
connected.
Connection and signal description for SSI interface :
Default count direction: upwards when the motor shaft is rotating clockwise (looking at the shaft
end).
SERVOSTAR 600
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8.14
Digital and analog inputs and outputs
Analog inputs (X3)
8.14.1
The servo amplifier is equipped with two differential inputs for analog setpoints which are
programmable. AGND (X3/1) must always be joined to the CNC-GND of the controls as a ground
reference.
Technical characteristics
—
—
—
—
—
—
Differential-input voltage max. ± 10 V
Resolution 1.25 mV
Ground reference AGND, terminal X3/1
Input resistance 20 kW
Common-mode voltage range for both inputs 10 V
Update rate 62.5 µs
SERVOSTAR 600
Input Analog-In 1 (terminals X3/4-5)
Differential input voltage max. 10 V, resolution 14-bit, scalable
Standard setting : speed setpoint
Input Analog-In 2 (terminals X3/6-7)
Differential input voltage max. 10 V, resolution 12-bit, scalable
Standard setting : torque setpoint
Application examples for setpoint input Analog-In 2:
—
—
—
adjustable external current limit
reduced-sensitivity input for setting-up/jog operation
pre-control / override
Fixing the direction of rotation
Standard setting : clockwise rotation of the motor shaft (looking at the shaft end)
—
—
Positive voltage between terminal X3/4 (+ ) and terminal X3/5 ( - ) or
Positive voltage between terminal X3/6 (+ ) and terminal X3/7 ( - )
To reverse the direction of rotation, swap the connections to terminals X3/4-5 and. X3/6-7 or
change the ROT. DIRECTION parameter in the “Speed controller” screen.
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8.14.2 Analog outputs (X3)
07/2007
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Technical characteristics
—
—
—
—
—
Reference ground is analog-GND (AGND, terminal X3/1 and X3/10)
Output resistance 2.2 kW
Output voltage ±10 V
Resolution 10 bit.
Update rate 62.5 µs
SERVOSTAR 600
Programmable analog outputs Analog-Out 1 / Analog-Out 2
The terminals X3/8 (Analog-Out 1) or X3/9 (Analog-Out 2) can have the following analog signals
assigned to them:
Standard setting :
Analog-Out 1 : Tachometer voltage nact (speed)
The output delivers ±10V at the preset limit speed.
Analog-Out 2 : Current actual value Iact (torque)
The output delivers ± 10V at the preset peak current Ipeak (effective r.m.s. value).
You can use the terminals X3/8 (Analog-Out 1) or X3/9 (Analog-Out 2) to output converted analog
values for digital measurements which are contained in the servo amplifier.
You can find a list of pre-programmed functions on the "Analog I/O" screen of our setup software.
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8.14.3 Digital inputs (X3)
07/2007
Electrical Installation
All digital inputs are electrically isolated through optocouplers.
Technical characteristics
—
—
—
—
Reference ground is digital-GND (DGND, terminal X3/18)
Inputs at X3 meet PLC standards (IEC 61131-2 Type 1)
High: 11...30V / 2...11mA, Low -3...+5V / <1 mA
Update rate: 250µs
SERVOSTAR 600
ENABLE input
The output stage of the servo amplifier is activated by the enable signal
(terminal X3/15, input 24V, active-high).
In the inhibited state (low signal) the motor which is attached does not have any torque.
Programmable digital inputs :
You can use the digital inputs PSTOP / NSTOP / DIGITAL-IN1 and DIGITAL-IN2 to initiate
preprogrammed functions that are stored in the servo amplifier.
You can find a list of pre-programmed functions on the "digital I/O" screen of our setup software.
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
switched off and on again (to reset the amplifier software).
Limit-switches PSTOP / NSTOP
Terminals X3/13 and X3/14 are normally programmed for the connection of limit switches. If these
inputs are not needed for the connection of limit switches, then they are programmable for other
input functions.
Limit-switch positive/negative (PSTOP / NSTOP, terminals X3/13 and X3/14), high level in normal
operation (fail-safe for a cable break).
A low signal (open) inhibits the corresponding direction of rotation, the ramp function remains
effective.
DIGITAL-IN 1 / DIGITAL-IN 2
The digital inputs on terminal X3/11 (DIGITAL-IN 1) or terminal X3/12 (DIGITAL-IN 2) can be logi-
cally combined in a pre-programmed function.
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8.14.4 Digital outputs (X3)
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Technical characteristics
—
—
—
Reference ground is digital-GND (DGND, terminal X3/18)
All digital outputs are floating
DIGITAL-OUT1 and 2
BTB/RTO
: Open-Collector, max. 30 VDC, 10 mA
: Relay output, max. 30 VDC or 42 VAC, 0.5 A
: 250 µs
—
Update rate
SERVOSTAR 600
Ready-to-operate contact BTB/RTO
Operational readiness (terminals X3/2 and X3/3 ) is signaled by a floating relay contact.
The contact is closed when the servo amplifier is ready for operation, the 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 switch-off of the output
stage (if the BTB contact is open, the output stage is disabled -> no power).
A list of the error messages can be found on page 88.
Programmable digital outputs DIGITAL-OUT 1 / 2:
You can use the digital outputs DIGITAL-OUT1 (terminal X3/16) and DIGITAL-OUT2 (terminal
X3/17) to output messages from pre-programmed functions that are stored in the servo amplifier.
You can find a list of pre-programmed functions on the "digital I/O" screen of our setup software.
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
switched off and on again (to reset the amplifier software).
Evaluate the outputs via inverting interface relays (see connection diagram), for example
Phönix DEK-REL-24/I/1 (turn-on delay 6 ms, turn-off delay 16ms).
The described logic in the online help of the setup software refers to the output of
the inverting interface relays. Consider the delay of the applied relay !
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Electrical Installation
8.15 RS232 interface, PC connection (X6)
The setting of the operating, position control, and motion-block parameters can be carried out with
an ordinary commercial PC.
Connect the PC interface (X6) of the servo amplifier while the supply to the equipment is
switched off via a normal commercial 3-core null-modem cable to a serial interface on the PC.
Do not use a null-modem link cable!
The interface is electrically isolated through an optocoupler, and is at the same potential as the
CANopen interface.
The interface is selected and set up in the setup software.
With the optional expansion card -2CAN- the two interfaces for RS232 and CAN, which otherwise
SERVOSTAR 600
Interface cable between the PC and servo amplifiers of the SERVOSTAR 600 series:
(View : looking at the face of the built-in SubD connectors, this corresponds to the solder side of the
SubD sockets on the cable)
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8.16 CANopen Interface (X6)
07/2007
Danaher Motion
The interface for connection to the CAN bus (default 500 kBaud). The integrated profile is based on
the communication profile CANopen DS301 and the drive profile DS402. The following functions are
available in connection with the integrated position controller:
Jogging with variable speed, reference traverse (zeroing), 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 electrically isolated by
optocouplers, and is at the same potential as the RS232 interface. The analog setpoint inputs can
still be used.
With the optional expansion card -2CAN- the two interfaces for RS232 and CAN, which otherwise
AGND and DGND (connector X3) must be joined together !
SERVOSTAR 600
CAN bus cable
To meet ISO 11898 you should use a bus cable with a characteristic impedance of 120 W. The
maximum 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 are not to
be taken as assured limits:
Cable data:
Characteristic impedance
Cable capacitance
100-120 W
max. 60 nF/km
159.8 W/km
Lead resistance (loop)
Cable length, depending on the transmission rate
Transmission rate (kbaud)
max. cable length (m)
1000
500
20
70
250
115
Lower cable capacitance (max. 30 nF/km) and lower lead resistance
(loop, 115 W/km) make it possible to achieve greater distances.
(Characteristic impedance 150 5W Þ terminating resistor 150 5W).
For EMC reasons, the SubD connector housing must fulfill the following conditions:
—
—
metal or metallised housing
provision for cable shielding connection in housing, large-area connection
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Setup
9
Setup
9.1
Important notes
Only professional personnel with extensive knowledge in the fields of electrical/
drive technology are allowed to setup the servo amplifier.
The procedure for setup is described as an example. Depending on the application,
a different procedure may be sensible or necessary. In multi-axis systems, setup each servo ampli-
fier individually.
The manufacturer of the machine must generate a hazard analysis for the machine,
and take appropriate measures to ensure that unforeseen movements cannot
cause injury or damage to any person or property.
Check that all live connecting elements are protected from accidental contact.
Deadly voltages can be present, up to 900V.
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 after switching off the supply power.
Heat sinks and front panels of the amplifier can reach a temperature of up to
80°C(176°F) in operation. Check (measure) the heat sink temperature. Wait until the
heat sink has cooled down below 40°C (104°F) before touching it.
If the servo amplifier has been stored for longer than 1 year, then the DC bus link
capacitors 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 230VAC to the
terminals L1 / L2. This will re-form the capacitors.
Further information on setup :
The adaptation of parameters and the effects on the control loop behavior are
described in the online help of the setup software.
The setup of the expansion card (if present) is described in the corresponding
manual on the CD-ROM.
We can provide further know-how through training courses (on request).
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Setup
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Danaher Motion
9.2
Setup software
General
9.2.1
This chapter describes the installation of the setup software DRIVE.EXE for the SERVOSTAR 600
digital servo amplifiers.
We offer training and familiarization courses on request.
9.2.1.1
Use as directed
The setup software is intended to be used for setting up and storing the operating parameters for
the SERVOSTAR 600 series of servo amplifiers. The attached servo amplifier can be setup with the
assistance of the software - during this process the drive can be controlled directly by the service
functions.
Only professional personnel who have the relevant expertise described on page 7
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.
9.2.1.2
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 setup software provides the communication between SERVOSTAR 600 and the PC.
You will find the setup software on the accompanying CD-ROM and at our web site.
With very little effort you can alter parameters and instantly observe the effect on the drive, since
there is a continuous (online) connection to the amplifier.
Simultaneously, important actual values are read out from the amplifier and displayed on the PC
monitor (oscilloscope function).
Any interface modules (expansion cards) which may be built into the amplifier are automatically rec-
ognized, and the additional parameters which are required for position control or motion-block defi-
nition are made available.
Sets of data can be stored on data media (archived) and loaded again. Sets of data which are
stored on data media can be printed.
We supply you with motor-specific default sets of data for the most common 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.
An extensive online help with integrated description of all variables and functions supports you in
each situation.
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Setup
9.2.1.3
Hardware requirements
The PC interface (X6, RS232) of the servo amplifier is connected to the serial interface of the PC by
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
:
:
:
:
Pentium® I or higher
Operating system
Graphics adapter
Drives
WINDOWS 95(c) / 98 / 2000 / ME / NT 4.0 / XP
Windows compatible, color
hard disk with at least 10 MB free space
CD-ROM drive
Main memory
Interface
:
:
at least 8MB
one free serial interface (COM1...COM10)
9.2.1.4
Operating systems
WINDOWS 95(c) / 98 / 2000 / ME / NT / XP
DRIVE.EXE is executable under WINDOWS 95(c) / 98 / 2000 / ME / XP and WINDOWS NT 4.0.
The HTML help system is not available under WINDOWS 95a and 95b.
WINDOWS FOR WORKGROUPS 3.xx, DOS, OS2 Unix, Linux
DRIVE.EXE is not executable under WINDOWS 3.xx, DOS, OS2, Unix and Linux.
In emergency, operation is possible through an ASCII terminal emulation (without user-interface).
Interface settings : 9600 bps, no parity, no handshake
9.2.2
Installation under WINDOWS 95 / 98 / 2000 / ME / NT / XP
The CD-ROM includes an installation program for the setup software.
Installation
Autostart function activated:
Insert the CD-ROM into a free drive. A window with the start screen opens. There you find a link to
the setup software DRIVE.EXE. Click it and follow the instructions.
Autostart function deactivated:
Insert the CD-ROM into a free drive. Click on START (task bar), then on Run. Enter the program
call: x:\index.htm (x = correct CD drive letter).
Click OK and proceed as described above.
Connection to the serial interface of the PC
Connect the interface cable to a serial interface on your PC and the PC interface (X6) of the
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Setup
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Danaher Motion
9.3
Quickstart Guide
Preparation
9.3.1
9.3.1.1
Unpacking, Mounting and Wiring the Servo Amplifier
1. Unpack servo amplifier and accessories
2. Observe safety instructions in the manuals
3. Mount the servo amplifier as described in chapter 7.3
4. Wire the servo amplifier as described in chapter 8.3 or apply the minimum wiring for drive testing
as described in chapter 9.3.1.3
5. Install the software as described in chapter 9.2
9.3.1.2
Documents
You need access to these documents (located on the product CD-ROM, you can download the
latest editions from our website):
l
l
l
Product Manual (this manual)
CANopen Communication Profile Manual
Accessories Manual
Depending on the installed expansion card you need one of these documents:
l
l
l
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PROFIBUS DP Communication Profile Manual
DeviceNet Communication Profile Manual
SERCOS Communication Profile Manual
EtherCat Communication Profile Manual (in process)
You need Acrobat Reader to read the PDFs, an installation link is on every screen of the product
CD-ROM.
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Setup
9.3.1.3 Minimum Wiring for Drive Test
This wiring does not fulfill any requirements to safety or functionality of your
application, it just shows the required wiring for drive testing without load.
Motor-Feedback
ENC
RES
PC
CAN
X3 2
3
Power ON
Enable
15
18
24V ON
X4
1
3
+
-
2
24V DC
Power
Motor
Motor-Power
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Setup
9.3.2
07/2007
Danaher Motion
Connect
l
Connect the interface cable to a serial interface on your PC and to the serial interface X6 of the
servo amplifier. USB to serial converter can be used optionally.
l
l
Switch on the 24 V power supply for the servo amplifier.
Wait about 30 seconds, until the front display of the servo amplifier displays the current classe
(e.g.
for 3 amps). If the power supply voltage is switched on, too, a leading P is display-
for Power, 3 amps).
ed (e.g.
If a fault code (
) or a warning (
) or a status message (./_ / E/S) appears
problem.
Double-Click the DRIVE.EXE icon on your Windows desktop to start the software.
You can work offline or online with .
Work ONLINE now. Select the interface where the servo am-
plifier is connected to.
The software tries to communicate with the
drive and to upload the parameters. If it's
not successful, you receive this error mes-
sage.
- wrong interface chosen
- wrong connector chosen at the servo amplifier
Frequent causes:
- interface is used by another software
- 24 V auxiliary voltage for the servo amplifier not working
- interface cable broken or wrong wiring
Click OK to remove the error message. Detect and remove the error source. Restart the software.
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Setup
If communication works, parameters are transmitted from the servoamplifier to the computer.
Then you see the start screen.
Make sure, that the amplifier is
disabled (Input HW-Enable
connector X3 pin 15 must be
0 V or open)!
9.3.3
Important Screen Elements
Help Function
The Online-Help gives detailed information to all parameters the servo amplifier can work with.
Key F1
Starts Online Help for the actual screen page.
Starts Online Help with table of contents.
Menu Bar ? or
Online HTML Help
Tool Bar
Save to EEPROM,
required if you changed parameters.
Reset (coldstart),
required if you changed important configuration parameters.
Operation Mode, use Digital Velocity mode for drive testing.
Disable and Enable of the amplifier's output stage via software.
Status Bar
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Setup
9.3.4
07/2007
Danaher Motion
Basic Setup
On the start screen click "Basic Setup" button.
Regen Resistor: Change only if you use an external regen resistor. Most applications don't need
an external regen resistor
max. Mains Voltage: Select the nominal mains AC voltage
Mains Phase Missing: You can select either warning "n05" or error "F19" in case of phase loss.
The setting "F19" disables the output stage, "n05" is just a message.
Units: Acceleration, Velocity, Position
Select usable units for your application referring to the moved load.
Leave all other fields unchanged.
Click OK. On the start screen click "Motor" button.
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9.3.5 Motor (synchronous)
07/2007
Setup
Press function key F12 (Software Disable) before changing motor parameters.
Motor Type: Select Synchronous Motor. If you use a linear motor or an induction motor, please
contact our support department.
Number-Name: Click the list to start uploading the motor parameter table, which is stored in the
servo amplifier. Search and select the connected motor. If your motor is not listed, please contact
our support department.
Leave all other fields unchanged.
Click OK.
If your motor has a built-in brake, click Yes,
otherwise "No".
If Software Enable is active, a warning ap-
pears. You can proceed, but after the ampli-
fier is restarted, you must check whether the
holding brake configuration is correct.
Click OK.
Parameters are uploaded to the amplifier's
RAM now (takes some seconds). When this is
done, you have to accept the changed config-
uration with "Yes" or to discard the changes in
the appearing screen.
If you click "Yes", the parameters are saved in
the EEPROM and the amplifier makes a
coldstart (reset). This takes some seconds.
On the start screen, click "Feedback" button.
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Setup
9.3.6
07/2007
Danaher Motion
Feedback
Press F12 (disable) before changing feed-
back parameters.
Feedback Type:
Select the feedback type used.
Leave all other fields unchanged.
If Software Enable is active, a warning appears.
The configuration change cannot be performed.
Click OK on the warnings, press F12 (SW dis-
able) and start the Feedback procedure again.
If everything was ok, the same procedure (pa-
rameter upload) that has been described for the
motor selection starts.
If you click "Yes", the parameters are saved in
the EEPROM and the amplifier makes a
coldstart (reset). This takes some seconds.
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Setup
9.3.7 Save Parameters and Restart
You are going to finish setup and you have changed several basic parameters. Depending on the
parameters you changed, two possible reactions can occur:
Configuration parameters changed
A warning appears, that you have to restart the amplifier. This is called "coldstart". Click "YES". The
parameters are saved to the amplifier's EEPROM automatically and a reset command restarts the
amplifier (takes a few seconds). For example, this happens after motor or feedback selection.
Other parameters changed
No warning appears. Parameters are saved in the volatile RAM only. Save the parameters to the
EEPROM of the servo amplifier manually by clicking the symbol
of the amplifier is not necessary.
in the tool bar. A coldstart
Reset the amplifier
You can reset the amplifier manually (e.g. in case of an error). Click the icon
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Setup
9.3.8
07/2007
Danaher Motion
Jogging the Motor (Speed Control)
Be aware that the actual position of the load permits the subsequent moving
operations. The axis could move to the hardware limit-switch or the mechanical
stop. Make sure that a jerk or a fast acceleration of the load cannot cause any
damage.
l
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Switch on the power supply for the drive.
Hardware-Enable: +24 VDC to Enable [connector X3 pin 15].
l
Software-Enable: Click the "Enable" button
on the start screen or use key
combination Shift+F12. Now, the front display shows an E and the current rating (e.g.
for Enable, 3 amps).
l
Click the icon "Oscilloscope"
l
Select Service-Mode "Speed F6", then click "Parameter" button
l
Enter a safe speed. The sign defines the direction of movement.
Observe the "safe reduced speed" requirements for your application!
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l
Click OK.
Start the service function ("Start" button or press F6).
Click OK on the warning notice.
Opmode is switched to "0" and the output stage is enabled automatically. The symbol's color
changes to green as long as the function is active.
l
l
The function is active until you click the "Stop" button or press F9.
The output stage can be disabled by pressing function key F12.
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Setup
9.3.9
Status
Actual warnings and errors are listed on the Status screen, which can be accessed on the start
screen by clicking the "Status" button. This button monitors the current status of the amplifier and
can appear with different text.
The Reset button can be used to clear some actual error messages. A description of errors/warn-
Now you have setup and tested the basic functions of the drive successfully.
9.3.10
Monitor
Click the icon "Monitor"
The Monitor screen shows all
important electrical and me-
chanical actual values
9.3.11
Additional Setup Parameters
Detailed information on all setup functions can be found in the Online Help systemand and the inte-
grated command reference.
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9.4
07/2007
Danaher Motion
Multi-axis systems
Using a special multilink cable, you can connect up to six servo amplifiers together and to your PC :
Cable type -SR6Y- (for 4 amplifiers) or -SR6Y6- (for 6 amplifiers).
Cable -SR6Y-
PC
X6
CAN
COMx
RS232
Add.:
04
Add.:
01
Add.:
02
Add.:
03
Baud rate identical for all amplifiers,
see table below.
With the PC connected to just one servo amplifier you can now use the setup software to select all
four / six amplifiers through the preset station addresses and set up the parameters.
9.4.1
9.4.2
Node address for CAN-bus
During setup it makes sense to preset the station addresses for the individual amplifiers and the
Baud rate for CAN-bus
After changing the station address and baud rate you must turn the 24V auxiliary
supply of the servo amplifier off and on again.
Coding of the baud rate in the LED display :
Coding
Baud rate in kbit/s
Coding
Baud rate in kbit/s
0
1
2
3
4
10
20
5
6
250
333
500
666
800
1000
50
7
100
125
8
9
10
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9.5
07/2007
Danaher Motion
Key operation / LED display
In this chapter the two possible operation menus and the use of the keys in the front panel are
shown. Normally, the SERVOSTAR 600 only places the standard menu at your disposal. If you
want to attend the amplifier via the detailed menu, you must keep the right key pressed while
switching on the 24V-supply.
9.5.1
Key operation
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 :
enter a number, return function name
9.5.2
Status display
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9.6
07/2007
Danaher Motion
Error messages
Errors which 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). If a motor-holding brake is installed, it will be
activated.
Number
Designation
Explanation
E / S / A / P
Status Messages
Status Message
Status Message
Status messages, no error, see p. 86
Updating the startup configuration
Programming mode
. . .
-
Heat sink temperature too high
limit is set by manufacturer to 80°
Overvoltage in DC bus link
F01*
F02*
Heat sink temperature
Overvoltage
limit depends on the electrical supply voltage
Message from the position controller
Cable break, short-circuit, short to ground
Undervoltage in DC bus link
F03*
F04
Following error
Feedback
F05*
F06
Undervoltage
limit is set by manufacturer to 100V
Motor temperature too high or temp. sensor defect
limit is set by manufacturer to 145°C
Motor temperature
F07
F08*
F09
F10
F11
F12
F13*
F14
F15
F16*
Internal voltage supply Internal amplifier supply voltages are out of tolerance
Overspeed
Motor runs away, speed is too high
Checksum error
EEPROM
Flash-EPROM
Brake
Checksum error
Cable break, short-circuit, short to ground
Motor phase missing (cable break or similar)
Internal temperature too high
Motor phase
Internal temperature
Output stage
I²t max.
Fault in the power output stage
I²t maximum value exceeded
Supply BTB/RTO
2 or 3 phases missing in the mains supply feed
Error in the analog-digital conversion, normally caused by
extreme electromagnetic interferences.
Regen circuit faulty or incorrect setting
A phase is missing in the mains supply power feed
(can be switched off for 2-phase operation)
Slot error (hardware fault on expansion card)
Software error on the expansion card
For 40/70 amps type only
F17
F18
F19*
A/D converter
Regen
Supply phase
F20
F21
F22
F23
F24
F25
Slot fault
Handling error
Earth short circuit
CAN-bus off
Warning
Severe CAN bus communication error
Warning is displayed as fault
Commutation error
Commutation error
Homing error (machine has driven onto hardware limit
switch)
F26
F27
F28
Limit switch
AS
Operational error with -AS- , input for AS-Enable and EN-
ABLE have been set at the same time
External position profile generator created a step, that ex-
ceeded the maximum value
External Trajectory
F29
F30
F31
F32
Slot Fault
depends on expansion card, see online help
Timeout emergency stop
Emergency timeout
Macro
Macro program error
System Error
system software not responding correctly
* = These error messages can be cancelled by the ASCII command CLRFAULT, without executing a reset. If
only these errors are present, and the RESET button or the I/O-function RESET is used, the CLRFAULT com-
mand is also all that is carried out.
More information to the messages can be found in the ASCII Object Reference
(Online Help), see parameter ERRCODE. Hints for removal can be found in section
"Trouble-Shooting" of the online help.
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9.7 Warning messages
07/2007
Setup
Faults which occur, but which do not cause a switch-off of the amplifier output stage (BTB/RTO
contact remains closed), are indicated in the LED display on the front panel by a coded warning
number.
Number
Designation
Explanation
E / S / A / P Status Messages
Status messages, no error, see p. 86
Updating the startup configuration
. . .
Status Message
Status Message
I²t
-
Programming mode
n01
n02
n03*
n04*
n05
n06*
n07*
n08
n09
n10*
n11*
I²t threshold exceeded
Regen power
S_fault
Reached preset regen power limit
Exceeded preset following error limit
Response monitoring (fieldbus) has been activated
Mains supply phase missing
Response monitoring
Supply phase
SW limit switch 1
SW limit switch 2
Motion task error
No reference point
PSTOP
Underrun software limit switch 1
Overrun software limit switch 2
A faulty motion task was started
No reference point (Home) set at start of motion task
PSTOP limit-switch activated
NSTOP
NSTOP limit-switch activated
Only for ENDAT or HIPERFACE® :
discrepancy between motor number saved in the en-
coder and the amplifier, motor default values loaded
24V supply of the I/O expansion board is missing
SinCos commutation (wake & shake) not completed, will
be canceled when amplifier is enabled and wake &
shake carried out
Motor default values
loaded
n12
n13*
n14
Slot warning
SinCos feedback
n15
n16
Table error
Fault according to speed/current table INXMODE 35
Summarized warning for n17 to n31
The mode synchronization SYNCSRC is selected but
the drive isn’t in synchronies cycle
Summarized warning
n17
n18
n19
Fielbus Synchronization
Multiturn overrun
Using Multiturn encoder feedback, an overrun over the
maximum number of resolutions was detected
Motion task ramps are
limited
Range overflow on motion task data
n20
n21
Wrong GMT data
PLC program error
max. motor temperatur
reached
Wrong "Graphical Motion Task" data
For details see plc code
The user can shut down the process before the tempera-
ture eror will interrupt the process immediately
reserved
n22
n23...n31
n32
reserved
firmware beta version
Firmware is an unreleased beta version
* = These warning messages lead to a controlled shut-down of the drive (braking with the emergency ramp)
More information to the messages can be found in the ASCII Object Reference
(Online Help), see parameter STATCODE. Hints for removal can be found in section
"Trouble-Shooting" of the online help.
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Setup
9.8
07/2007
Danaher Motion
Removing faults/warnings
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.
Detailled hints for removal of faults can be found in the Online help chapter
"Trouble-Shooting".
Our customer service can give you further assistance with problems.
Measures to remove the cause of
Fault
possible causes
the fault
— wrong cable used
— use null-modem cable
— plug cable into the correct
sockets on the servo amplifier
and PC
HMI message:
communication
fault
— cable plugged into wrong position
in servo amplifier or PC
— wrong PC interface selected
— servo amplifier not enabled
— break in setpoint cable
— select correct interface
— apply enable signal
— check setpoint cable
— correct motor phase sequence
— check brake control
— check mechanism
— motor phases swapped
motor does not
rotate
— brake not released
— drive is mechanically blocked
— no. of motor poles set incorrectly
— feedback set up incorrectly
— gain too high (speed controller)
— set no. of motor poles
— set up feedback correctly
— reduce Kp (speed controller)
motor oscillates — shielding in feedback cable is broken — replace feedback cable
— AGND not wired up
— join AGND to CNC-GND
— increase Irms or Ipeak
— Irms or Ipeak is set to low
drive reports
(keep within motor data !)
— shorten setpoint ramp +/-
following error
— setpoint ramp is too long
— Irms/Ipeak set too high
motor overheat-
ing
— reduce Irms/Ipeak
— Kp (speed controller) too low
— Tn (speed controller) too high
— increase Kp (speed controller)
— use motor default value for
Tn (speed controller)
drive too soft
— PID-T2 too high
— reduce PID-T2
— T-Tacho too high
— reduce T-Tacho
— Kp (speed controller) too high
— Tn (speed controller) too low
— reduce Kp (speed controller)
— use motor default value for
Tn (speed controller)
drive runs
roughly
— PID-T2 too low
— increase PID-T2
— T-Tacho too low
— increase T-Tacho
— offset not correctly adjusted for
analog setpoint provision
— AGND not joined to the CNC-GND
of the controls
— adjust setpoint-offset (analogI/O)
axis drifts at
setpoint = 0V
— join AGND and CNC-GND
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Expansions / Accessories
10
Expansions / Accessories
10.1
Option -AS-, restart lock for personal safety
A frequently required application task is the protection of personnel against the restarting of drives.
This can not be achieved by an electronic inhibit, but must be implemented with mechanical ele-
ments (positively driven relay contacts).
To get round this problem, up to now either the main contactor in the mains supply line was
switched off, or another contactor was used to disconnect the motor from the servo amplifier.
The disadvantages of this method are :
—
—
—
the DC bus link has to be charged up again at restart
wear on the contacts of the contactors, caused by switching under load
extensive wiring required, with additional switching components
The -AS- option avoids these disadvantages. A safety relay in the servo amplifier is activated either
by the PLC or manually. Positively driven contacts provide a safe disconnection of the servo ampli-
fier, the setpoint input of the servo amplifier is inhibited, and a signal is sent to the safety circuit.
The suggested circuits (ð p. 95) fulfills safety category 1 (EN 954-1) or category 3 with additional
safety relay (e.g. PNOZ of PILZ company).
Advantages of the -AS- option
—
—
—
—
the DC bus link remains charged up, since the mains supply line remains active
only low voltages are switched, so there is no contact wear
very little wiring is required
the functionality and the personnel safety when using the circuit recommendations
in this documentation have been approved by the Trade Liability Association.
Moving single axes or axis-groups in setting-up operation
In setting-up operation, people will frequently be within the danger zone of the machinery. Axes will
normally be moved under the control of permission switches. An additional switch-off of the unused
axes, by means of the restart lock, increases the safety margin and avoids the repeated switching
of main contactors or motor contactors.
Switching off grouped axes with separate working areas
Even when several SERVOSTAR 600 are operating off a common mains supply and DC bus link, it
is possible to set up groups for separate working areas. These groups can then be switched off sep-
arately for personnel safety.
10.1.1
Safety instructions
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l
The monitoring contacts (KSO1/2) for each amplifier with an -AS- option must be looped
into the control circuit. This is vital, so that a malfunction of the internal safety relay or
a cable break can be recognized.
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l
If the -AS- option is automatically activated by a control system (KSI1/2), then make
sure that the output of the control is monitored for possible malfunction. Can be used
to prevent a faulty output from activating the -AS- option while the motor is running.
It is vital to keep to the following functional sequence when the -AS- option is used:
1. Brake the drive in a controlled manner (speed setpoint = 0V)
2. When speed = 0 rpm, disable the servo amplifier (enable = 0V)
3. If there is a suspended load, apply an additional mechanical block to the drive
4. Activate the -AS- option
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Expansions / Accessories
10.1.2 Use as directed
07/2007
Danaher Motion
The -AS- restart lock is exclusively intended to provide safety for personnel, by preventing the
restart of a system. To achieve this personnel safety, the wiring of the safety circuits must meet the
safety requirements of EN60204, EN12100 and EN 954-1.
The -AS- restart lock must only be activated,
—
when the motor is no longer rotating (setpoint = 0V, speed = 0rpm, enable = 0V).
Drives with a suspended load must have an additional safe mechanical blocking
(e.g. by a motor-holding brake).
—
when the monitoring contacts (KSO1/2) for all servo amplifiers are wired into the control
signal loop.
The -AS- restart lock may only be controlled by a CNC if the control of the internal safety relay is
arranged for redundant monitoring.
The -AS- restart lock must not be used if the drive is to be made inactive for the following reasons :
1.
-
-
cleaning, maintenance and repair operations
long inoperative periods
In such cases, the entire system should be disconnected from the supply by the personnel,
and secured (main switch).
2.
-
emergency-stop situations
In an emergency-stop situation, the main contactor is switched off
(by the emergency-stop button).
10.1.3
Block diagram
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10.1.4 Functional description
07/2007
Expansions / Accessories
An additional connector (X10) is mounted on the front panel of the SERVOSTAR 600. The coil con-
nections and a make (n.o.) contact of a safety relay are made available through 4 terminals on this
connector.
The 24VDC safety relay in the servo amplifier (approved) is controlled externally. All the relay con-
tacts have positive action.
Two contacts switch off the driver supply of the output stage in the servo amplifier, and short the
internal setpoint signal to AGND (0 V).
The make (n.o.) contact used for monitoring is looped into the control circuit.
If the safety relay is not energized, then the monitoring contact is open and the servo amplifier is
ready for operation.
If the drive is electronically braked, the servo amplifier is disabled and the motor-holding brake is
on, then the safety relay is energized (manually or by the controls).
The supply voltage for the driver circuit of the output stage is switched off in a safe manner, the
internal setpoint is shorted to 0V, and the monitoring contact bridges the safety logic in the control
circuit of the system (monitoring of protective doors etc.)
Even if the output stage or driver is destroyed, it is impossible to start the motor.
If the safety relay itself is faulty, then the monitoring contact cannot bridge the safety logic of the
system. Opening the protective devices will then switch off the system.
10.1.5
Signal diagram (sequence)
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The functioning of the restart lock must be tested during setup, after every
alteration in the wiring of the system, or after exchanging one or more components
of the system.
1.
2.
3.
4.
5.
6.
Stop all drives, with setpoint 0V, disable drives, mechanically block any suspended loads
Activate the -AS- option.
Open protective screens (but do not enter hazardous area)
Pull off the X10 connector from an amplifier: the mains contactor must drop out
Reconnect X10. Switch on mains contactor again.
Repeat steps 4 and 5 for each individual servo amplifier.
10.1.7
Connection diagram (principle)
SERVOSTAR 600
Application examples for category 1 see chapter 10.1.8.
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10.1.8
Application example category 1 according to EN954-1
Flowchart for stop and emergency stop category 0.
10.1.8.1
Control circuit
10.1.8.2
Mains supply circuit
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10.1.9
Application example category 3 according to EN954-1
Flowchart for stop and emergency stop category 1.
10.1.9.1
Control circuit
10.1.9.2
Mains supply circuit
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10.1.9.3 Flow chart
07/2007
Expansions / Accessories
t(K30t)
t(K10t) / t(K20t)
24V
AS Relais
ON
OFF
K1
K10t / K20t
K30t / Enable
Speed
t(K30t) ³ 500ms
t(K10t) and t(K20t) ensure that the drive remains active until the axis has come to a standstill. This
time depends on the application and must exceed the deceleration ramp.
The drive must have been brought to a safe standstill by the time t(K10t) and
t(K20t) have elapsed. After this point, active braking with the servo amplifier is no
longer possible.
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10.2
Expansion Cards
Information about availability and order numbers can be found on p. 117
10.2.1
Guide to installation of expansion cards
l
l
Use a suitable screwdriver to lever off the cover of the option slot.
Take care that no small items (such as screws) fall into the open option slot.
l
Push the expansion card carefully into the provided guide rails of the slot, without twi-
sting it.
l
l
Press the expansion card firmly into the slot, until the front cover touches the fixing
lugs. This ensures that the connectors make good contact.
Screw the screws on the front cover into the threads in the fixing lugs.
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10.2.2
Expansion card -I/O-14/08-
This chapter describes the I/O-expansion card -I/O-14/08-. It only describes the additional features
that the expansion card makes available for the SERVOSTAR 600.
The -I/O-14/08- provides you with 14 additional digital inputs and 8 digital outputs. The functions of
the inputs and outputs are fixed. They are used to initiate the motion tasks that are stored in the
servo amplifier and to evaluate signals from the integrated position control in the higher-level
control.
The functions of the inputs and signal outputs correspond exactly to the functions that can be
assigned to the digital-I/O on connector X3 of the SERVOSTAR 600.
The 24VDC supply for the expansion card is taken from the controller. All inputs and outputs are
electrically isolated from the servo amplifier by optocoupler.
10.2.2.1
10.2.2.2
Front view
Technical data
Control inputs
Signal outputs
24 V / 7 mA, PLC-compatible
24 V / max. 500 mA, PLC-compatible
24 V (18 ... 36 V) / 100 mA plus total current of the out-
puts (depends on the input wiring of the controls)
The 24 VDC voltage has to be supplied by an elec-
trically isolated power supply, e.g. with insulating
transformer.
Supply inputs, to IEC 1131
Fusing (external)
Connectors
4 AT
MiniCombicon, 12-pole, coded on PIN1 and 12 respec-
tively
Data – up to 50m long : 22 x 0.5mm², unshielded,
Supply – 2 x 1mm², check voltage drop
Cables
Waiting time between 2 motion tasks depends on the response time of the control system
Addressing time (min.)
4 ms
2 ms
Starting delay (max.)
Response time of digital outputs
max. 10 ms
10.2.2.3
10.2.2.4
Light emitting diodes (LEDs)
Two LEDs are mounted next to the terminals on the expansion card. The green LED signals that
the 24 V auxiliary supply is available for the expansion card. The red LED signals faults in the out-
puts from the expansion card (overload, short-circuit).
Select motion task number (Sample)
Motion task no.
binary 1010 1110
decimal 174
A7
1
A6
0
A5
1
A4
0
A3
1
A2
1
A1
1
A0
0
128
-
32
-
8
4
2
-
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Connector X11A
Pin
1
Dir
In
In
In
In
In
In
In
In
Function
A0
Description
Motion task no., LSB
Motion task no., 21
Motion task no., 22
Motion task no., 23
Motion task no., 24
Motion task no., 25
Motion task no., 26
Motion task no., MSB
2
A1
3
A2
4
A3
5
A4
6
A5
7
A6
8
A7
Polls the reference switch. If a digital input on the basic unit is
used as a reference input, then the input on the I/O expansion
card will not be evaluated.
9
In
In
Reference
Clear the warning of a following error (no3) or the response
monitoring (n04).
10
FError_clear
The following task, that is defined in the motion task by “Start
with I/O” is started. The target position of the present motion task
11
12
In
In
Start_MT Next must be reached before the following task can be started.
The next motion block can also be started by an appropriately
configured digital input on the basic unit.
Start of the setup mode "Jog Mode" with a defined speed. After
selecting the function, you can enter the speed in the auxiliary
Start_Jog v=x variable “x”. The sign of the auxiliary variable defines the direc-
tion. A rising edge starts the motion, a falling edge cancels the
motion.
Connector X11B
Continues the motion task that was previously interrupted.
The motion task can also be continued by an appropriately con-
figured digital input on the basic unit.
1
In
MT_Restart
Start of the motion task that has the number that is presented,
bit-coded, at the digital inputs (A0 to A7).
2
In
Start_MT I/O The digital function with the same name, in the basic unit, starts
the motion task with the address from the digital inputs on the
basic unit.
When the target position for a motion task has been reached (the
InPosition window), this is signaled by the output of a HIGH-sig-
3
Out
InPos
nal.
A cable break will not be detected
The start of each motion task in an automatically executed se-
quence of motion tasks is signaled by an inversion of the output
signal. The output produces a Low signal at the start of the first
Next-InPos
motion task of the motion task sequence.
4
5
Out
Out
The form of the message can be varied by using ASCII com-
mands.
PosReg0
FError
Can only be adjusted by ASCII commands.
A LOW signal indicates that the position has gone outside the
acceptable following error window.
6
7
Out
Out
Out
Out
Out
PosReg1
PosReg2
PosReg3
PosReg4
PosReg5
24VDC
The preset function of the corresponding position register is indi-
cated by a HIGH-signal.
8
9
10
Can only be adjusted by ASCII commands.
auxiliary supply voltage
11 Supply
12 Supply
I/O-GND
Digital-GND for the controls
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10.2.3
Expansion cards -PROFIBUS-
This chapter describes the PROFIBUS expansion card for the SERVOSTAR 600.
Information on the range of functions and the software protocol can be found in the manual
"Communication profile PROFIBUS DP". The PROFIBUS expansion card has two 9-pin Sub-D
sockets wired in parallel.
The supply voltage for the expansion card is provided by the servo amplifier.
10.2.3.1
Front view
10.2.3.2
10.2.3.3
Connection technology
Cable selection, cable routing, shielding, bus connector, bus termination and transmission times are
described in the “Installation guidelines for PROFIBUS-DP/FMS” from PNO, the PROFIBUS User
Organization.
Connection diagram
SERVOSTAR 600
AGND and DGND (connector X3) must be joined together !
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10.2.4
Expansion card -SERCOS-
This chapter describes the SERCOS expansion card for SERVOSTAR 600.
Information on the range of functions and the software protocol can be found in the manual
"IDN Reference Guide SERCOS".
10.2.4.1
Front view
10.2.4.2
Light emitting diodes (LEDs)
indicates whether SERCOS telegrams are being correctly received. In the final Communi-
RT
cation Phase 4 this LED should flicker, since cyclical telegrams are being received.
indicates that SERCOS telegrams are being transmitted. In the final Communication
Phase 4 this LED should flicker, since cyclical telegrams are being transmitted.
TT
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.
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.
ERR
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 parameter for the cable length.
10.2.4.3
Connection technology
For the fiber optic cable connection, only use SERCOS components to the SERCOS Standard IEC
61491.
Receive data
The fiber optic cable carrying receive data for the drive in the ring structure is connected to X13 with
an F-SMA connector.
Transmit data
Connect the fiber optic cable for the data output to X14 with an F-SMA connector.
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10.2.4.4
Connection diagram
Layout of the SERCOS bus system in ring topology, with optical fibre cables (schematic).
AGND and DGND (connector X3) must be joined together !
Modifying the station address
10.2.4.5
The drive address can be set to a value between 0 and 63. With address 0, the drive is assigned
as an amplifier in the SERCOS ring. There are various ways to set the station address:
Keys on the front of the servo amplifier
Setup software
The address can also be modified in the setup software. For additional information, please refer to
the “Setup software” online help. Alternatively, enter the command ADDR # in the “Terminal”
screen, where # is the new address of the drive.
10.2.4.6
Modifying the baud rate and optical power
If the baud rate is not set correctly, communication is not possible. The SBAUD # parameter can be
used to set the baud rate, where # is the baud rate.
If the optical power is not set correctly, errors occur in telegram transmission and the red LED on
the drive lights up. During normal communication, the green send and receive LEDs flash, giving
the impression that the relevant LED is on. The SLEN # parameter can be used to specify the opti-
cal range for a standard 1 mm² glass fibre cable, where # is the length of the cable in metres.
SBAUD
2 Mbaud
SLEN
Very short connection
2
4
0
4 Mbaud
8 Mbaud
16 Mbaud
1…< 15
15…< 30
³ 30
Length of the connection with a 1 mm² plastic cable
Length of the connection with a 1 mm² plastic cable
Length of the connection with a 1 mm² plastic cable
8
16
Setup software
The parameters can be modified in the setup software, “SERCOS” screen. For additional informa-
tion, please refer to the “Setup software” online help. Alternatively, the commands SBAUD # and
SLEN # can be entered in the “Terminal” screen.
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10.2.5
Expansion card -DEVICENET-
This section describes the DeviceNet expansion card for SERVOSTAR 600.
Information on the range of functions and the software protocol can be found in our manual
“DeviceNet Communication Profile”.
10.2.5.1
Front view
10.2.5.2
10.2.5.3
Connection technology
Cable selection, cable routing, shielding, bus connector, bus termination and transmission times are
all described in the “DeviceNet Specification, Volume I, II”, published by ODVA.
Connection diagram
SERVOSTAR 600
AGND and DGND (connector X3) must be joined together !
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10.2.5.4
Combined module/network status-LED
LED
off
Meaning
The device is not online.
-
-
The device has not yet finished the Dup_MAC_ID test.
The device is possibly not yet switched on.
The device is operating as normal, is online, and the connections have been estab-
lished. The device has been assigned to a master.
green
The device is operating as normal, is online, but the connections have not been estab-
lished.
-
The device has passed the Dup_MAC_ID test and is online, but the
connection to other nodes have not been established.
This device has not been assigned to a master.
blinking
green
-
-
Missing, incomplete or wrong configuration.
blinking
red
An error that can be cleared and/or at least one I/O connection are in a waiting state.
-
-
An error has occurred that cannot can be cleared; it may be necessary to
replace the device.
red
Communication device failure. The device has detected a fault that
prevents communication with the network (for instance, a MAC ID appears
twice or BUSOFF).
10.2.5.5
Setting the station address (device address)
The station address for the servo amplifier can be set in three different ways:
l
l
l
Set the rotary switches at the front of the expansion card to a value between 0 and 63. Each
switch represents a decimal figure. For example, to set the address for the drive to 10, set
MSD to 1 and LSD to 0.
Set the rotary switches at the front of the expansion card to a value higher than 63. Now you
can set up the station address by using the ASCII commands DNMACID x, SAVE, COLD-
START, whereby “x” stands for the station address.
Set the rotary switches at the front of the expansion card to a value higher than 63. Now you
can set up the station address by using the DeviceNet Object (Class 0x03, Attribute 1). This is
normally carried out with the help of a DeviceNet software setup tool. You must save the para-
meters in non-volatile memory (Class 0x25, Attribute 0x65) and then restart the drive after set-
ting/altering the address.
10.2.5.6
Setting the transmission speed
The DeviceNet transmission speed can be set in three different ways:
l
Set the rotary switch for Baud rate (at the front of the option card) to a value between
0 and 2. 0 = 125 kbit/s, 1 = 250 kbit/s, 2 = 500 kbit/s.
l
Set the rotary switch for Baud rate (at the front of the option card) to a value higher than 2.
Now you can set the Baud rate by using the terminal commands DNBAUD x, SAVE, COLD-
START, whereby “x” stands for 125, 250 or 500 .
l
Set the rotary switch for Baud rate (at the front of the option card) to a value higher than 2.
Now you can set the Baud rate by using the DeviceNet Object (Class 0x03, Attribute 2) to a
value between 0 and 2. This is normally carried out with the help of a DeviceNet software se-
tup tool. You must save the parameters in non-volatile memory (Class 0x25, Attribute 0x65)
and then restart the drive after altering the baud rate.
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10.2.5.7 Bus cable
07/2007
Expansions / Accessories
To meet ISO 898, a bus cable with a characteristic impedance of 120 W should be used. 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 are not to be taken
as assured limits.
General characteristic
Specification
Bit rates
125 kbit, 250 kbit, 500 kbit
500 meters at 125 kBaud
Distance with larger
bus connections
250 meters at 250 kBaud
100 meters at 500 kBaud
Number of nodes
64
Signal environment
Modulation
CAN
Basic bandwidth
Coupling medium
DC-coupled differential transmit/receive operation
500 V (option: optocoupler on the transceiver's node side)
Shunt C = 5pF
Isolation
Typical differential input im-
pedance (recessive state)
Min. differential input imped-
ance (recessive state)
Shunt R = 25KW (power on)
Shunt C = 24pF + 36 pF/m of the permanently attached stub cable
Shunt R = 20KW
-25 V to +18 V (CAN_H, CAN_L)
The voltages for CAN_H and CAN_L refer to the ground pin of the
transceiver. The voltage is higher than that on the V-terminal by
the amount of the forward voltage drop of the Schottky diode. This
voltage drop must be < 0.6 V.
Absolute max.
voltage range
Grounding:
The DeviceNet network must only be grounded at one point, to avoid ground loops. The circuitry for
the physical layer in all devices are referenced to the V-bus signal. The ground connection is made
via the power supply for the bus system. The current flowing between V- and ground must not flow
through any device other than the power supply.
Bus topology:
The DeviceNet medium utilizes a linear bus topology. Termination resistors are required at each
end of the connecting cable. Stub cables are permitted up to a length of 6 meters, so that at least
one node can be connected.
Termination resistors:
DeviceNet requires a termination at each end of the connecting cable.
These resistors must meet the following requirements: 120 W, 1% metal-film, 1/4 W
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10.2.6
Expansion card -ETHERCAT-
This section describes the EtherCat expansion card for SERVOSTAR 600. Information on the range
of functions and the software protocol can be found in the EtherCat documentation. This expansion
card enables the servo amplifier to be connected to the EtherCat network via RJ-45 connectors (IN
and OUT ports).
10.2.6.1
10.2.6.2
Front view
LEDs
LED
Function
flickering = Booting Error
blinking = Invalid Configuration
single flash = Unsolicited State Change
double flash = Watchdog Timeout
off = No Error
ERROR
on = Device is in state OPERATIONAL
blinking = Device is in state PRE-OPERATIONAL
single flash = Device is in state SAFE-OPERATIONAL
off = Device is in state INIT
RUN
on = linked, but not active at X20A (in)
flickering = linked and active at X20A (in)
off = not linked at X20A (in)
ACT IN
on = linked, but not active at X20B (out)
ACT OUT flickering = linked and active at X20B (out)
off = not linked at X20B (out)
10.2.6.3
Connection diagram
AGND and DGND (connector X3) must be joined together !
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10.2.7
Expansion card -SYNQNET-
This section describes the SynqNet expansion card for SERVOSTAR 600. Information on the range
of functions and the software protocol can be found in the SynqNet documentation.
10.2.7.1
Front view
LED2 LED1 LED4 LED3
10.2.7.2
10.2.7.3
NODE ID Switch
With these hexadecimal switches you can set the main and low significant bytes of the Node ID
seperately. SynqNet does not require an address for correct operation in the network, however in
some machines this can be a convenient way of identifying build options to the application program.
Node LED table
LED#
Name
Function
ON = receive valid (IN port)
OFF= not valid, power off, or reset.
ON = network cyclic
LED1, green
LINK_IN
LED2, yellow
LED3, green
LED4, yellow
CYCLIC
BLINK = network not cyclic
OFF = power off, or reset
ON = receive valid (OUT port)
OFF = not valid, power off, or reset
ON = repeater on, network cyclic
BLINK = repeater on, network not cyclic
OFF = repeater off, power off, or reset
LINK_OUT
REPEATER
10.2.7.4
SynqNet Connection, Connector X21B/C (RJ-45)
Connection to the SynqNet network via RJ-45 connectors (IN and OUT ports) with integrated LEDs.
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10.2.7.5
Digital inputs/outputs, connector X21A (SubD 15-pin, socket)
Inputs (In): 24V (20...28V), opto-isolated, one high-speed input (Pin 4)
Outputs (Out): 24V, opto-isolated, Darlington driver
Pinout connector X21A (SubD 15 pin)
Pin Type Description
1
2
In
+24V
power supply
Out NODEALARM
Out OUT_01
indicates a problem with the node
digital output
3
4
In
In
In
In
In
In
IN_00 (fast)
IN_04
capture input (fast)
digital input
5
6
IN_01
digital input
7
HOME
POSLIM
GND
reference switch
limit switch, positive direction
power supply
8
9
10
11
12
13
14
15
Out OUT_00
Out OUT_02
digital output
digital output
In
In
In
In
IN_02
digital input
IN_03
digital input
NEGLIM
NODEDISABLE
limit switch, negative direction
disables Node
10.2.7.6
Connection diagram digital inputs/outputs, connector X21A
AGND and DGND (connector X3) must be joined together !
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10.2.8
Expansion module -2CAN-
Connector X6 of the SERVOSTAR 6xx is assigned to the signals for the RS232 interface and the
CAN interface. It is therefore not the standard pin assignment for these interfaces, and a special
cable is required to be able to use both interfaces simultaneously.
The -2CAN- expansion module provides the interfaces on separate Sub-D connectors. The two
CAN connectors are wired in parallel. A termination resistor (120 W) for the CAN bus can be
switched into circuit if the SERVOSTAR 6xx is at the end of the bus.
10.2.8.1
Installation
The modul must be placed onto the option slot after levering off the cover of the option slot:
l
l
l
l
Screw the distance pieces into the fixing lugs of the option slot.
Place the expansion module onto the option slot.
Screw the screws into the threads of the distance pieces.
Plug the Sub-D9 socket into connector X6 on the SERVOSTAR 600
10.2.8.2
Front View
10.2.8.3
Connection technology
Standard shielded cables can be used for the RS232 and CAN interfaces.
If the servo amplifier is the last device on the CAN bus, then the switch for the bus
termination must be set to ON.
Otherwise, the switch must be set to OFF (condition as delivered).
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10.2.8.4 Connector assignments
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Danaher Motion
RS232
CAN1=CAN2
X6A Pin
Signal
Vcc
X6B=X6C Pin
Signal
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
RxD
TxD
CAN-Low
CAN-GND
GND
CAN-High
10.2.8.5
Connection diagram
AGND and DGND (connector X3) must be joined together !
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10.3
Special Accessories
10.3.1
Power Supply SINCOS
The extended power supply enables the
operation of encoder systems at con-
nector X1 with a power consumption of
up to 400 mA DC. This power supply is
switched between X1 and the encoder
and supplied by SERVOSTAR 600.
to servo amplifier
(max. 2 m)
The connection between the amplifier
and the power supply requires a 1:1 pro-
tected data cable with a maximum
length of 2 m (see ordering information,
The encoder is connected to the power
supply using the normal encoder con-
nection cable (max. 50 m).
to feedback
(max. 50 m)
Technical Data
Output voltage
5 V DC (-5%…+5%)
Output current
max. 400 mA DC
IP20
Protection type
Ambient temperature
Type of mounting
0…+55°C
Mounting rail
max. 2 m
Cable length (amplifier -> mains supply)
Cable length (mains supply -> encoder)
max. 50 m
10.3.2
Terminating adapter for encoder cables
Encoders that do not have integrated terminating resistors can be connected to X1 with our stan-
The terminating resistors increase noise immunity. The adapter (approx. 200 mm long) is con-
nected to the servo amplifier (X1).
SERVOSTAR® 601...620 Product Manual
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Expansions / Accessories
10.3.3 Hall Dongle
07/2007
Danaher Motion
Encoder types that do not provide definitive information on commutation, can be used as a com-
plete feedback system using an additional Hall dongle.
Encoders with analog signals are connected to the dongle, digital encoders are connected to con-
The connection between the amplifier and the dongle requires a 1:1 protected data cable with a
Encoders that require a supply current of more than 150 mA can be operated using the extended
X1.2
X1.3
to Encoder
to Hall feedback
(analog signals)
X1.1
to SERVOSTAR, X1
114
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Appendix
11
Appendix
11.1
Glossary
C
Clock
Clock signal
Common-mode voltage
The maximum amplitude of a disturbance (on both
inputs) which a differential input can eliminate
CONNECT- modules
Modules built into the servo amplifier, with integrated
position control, which provide special versions of the
interface for the connection to the higher-level control
Continuous power of regen circuit
Counts
Mean power which can be dissipated in the regen circuit
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 bus link
Disable
Rectified and smoothed power voltage
Removal of the enable signal (0V or open)
Enable signal for the servo amplifier (+24V)
Maximum value for speed normalization at 10V
CANopen, PROFIBUS, SERCOS etc.
E
F
Enable
Final speed
Fieldbus interface
GRAY-code
Holding brake
G
H
Special method of representing binary numbers
Brake in the motor, which can only be used when the
motor is at a standstill
I
I²t threshold
Input drift
Monitoring of the actually required r.m.s. current
Temperature and age-dependent alteration of an analog
input
Incremental encoder interface
Position signaling by 2 signals with 90° phase
difference, not an absolute position output
Ipeak, peak current
Irms, effective current
Kp, P-gain
The effective value of the peak current
The r.m.s. value of the continuous current
Proportional gain of a control loop
K
L
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
Monitor output
Motion-block
Output of an analog measurement
Data packet with all the position control parameters
which are required for a motion task
Multi-axis system
Natural convection
Optocoupler
Machine with several independently driven axes
Free movement of air for cooling
N
O
Optical connection between two electrically
independent systems
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Appendix
07/2007
Danaher Motion
P
P-controller
Phase shift
Control loop with purely proportional behavior
Compensation for the lag between the electromagnetic
and magnetic fields in the motor
PID-controller
Control loop with proportional, integral and
differential behavior
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
Resolver-digital converter
Conversion of the analog resolver signals into
digital information
Reversing mode
Ring core
Operation with a periodic change of direction
Ferrite rings for interference suppression
Incremental position output
ROD-Interface
Servo amplifier
S
Control device for regulating the position of a
servomotor
Setpoint ramps
Short to ground
Limits for the rate of change of the speed setpoint
Electrically conductive connection between a
phase and PE (protective earth (ground))
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
Supply filter
Cyclic-absolute, serial position output
Device to divert interference on the power supply
cables to PE
T
Z
T-tacho, tachometer time constant
Filter time constant in the speed feedback
of the control loop
Tachometer voltage
Thermostat
Voltage proportional to the actual speed
Temperature-sensitive switch built into the
motor winding
Tn, I-integration time
Zero pulse
Integral section of a control loop
Output once per turn from incremental encoders,
used to zero the machine
116
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Appendix
11.2
Order numbers
The order numbers of accessories such as cables, regen resistors, mains supplies, etc., can be
found in the accessories manual.
11.2.1
Servo amplifiers
Article
EU order code
DE-89700
DE-89701
DE-89702
DE-89703
DE-102192
DE-90846
DE-89704
DE-90350
DE-90351
DE-90352
DE-90353
DE-102897
DE-91448
DE-90354
US order code
not available
S60300-NA
S60600-NA
S61000-NA
S610-3000-NA
S61400-NA
S62000-NA
not available
S60301-NA
S60601-NA
S61001-NA
S610-3001-NA
S61401-NA
S62001-NA
SERVOSTAR 601
SERVOSTAR 603
SERVOSTAR 606
SERVOSTAR 610
SERVOSTAR 610-30
SERVOSTAR 614
SERVOSTAR 620
SERVOSTAR 601-AS
SERVOSTAR 603-AS
SERVOSTAR 606-AS
SERVOSTAR 610-AS
SERVOSTAR 610-30-AS
SERVOSTAR 614-AS
SERVOSTAR 620-AS
*= NA means without built-in expansion card
11.2.2
Expansion cards
Article
EU order code
DE-103571
DE-90056
US order code
OPT-DN
OPT-PB
Expansion card DeviceNet
Expansion card PROFIBUS DP
Expansion card SERCOS
Expansion card -I/0-14/08-
Expansion card EtherCat
Expansion card SynqNet
Expansion module 2CAN
DE-90879
DE-90057
OPT-SE
OPT-EI
DE-108350
DE-200073
DE-101174
OPT-EC
OPT-SN
not available
11.2.3
Connectors
Article
EU order code
DE-90061
DE-90062
DE-92258
DE-92259
DE-90064
DE-90065
DE-90066
DE-101696
DE-106368
US order code
CON-S6X3
CON-S6X4
CON-S6X0A
CON-S6X0B
CON-S6X7
CON-S6X8
CON-S6X9
CON-S6X10
CON-S6X15
Connector X3
Connector X4
Connector X0A
Connector X0B
Connector X7
Connector X8
Connector X9
Connector X10
Connector X15
(I/O)
(24V)
(Mains)
(Mains)
(DC bus link)
(Regen-R)
(Motor)
(AS)
(DeviceNet)
11.2.4
Special accessories
Article
Power supply SINCOS
HALL Dongle
EU order code
DE-107712
DE-107351
US order code
in preparation
in preparation
Connection Cable, 1m
for X1-Hall Dongle or
for X1-Power Supply SINCOS
Termination Adapter SINCOS
DE-107730
DE-103692
in preparation
in preparation
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Appendix
This page has been deliberately left blank
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Sales and Service
We are committed to quality customer service. In order to serve in the most effective way,
please contact your local sales representative for assistance.
If you are unaware of your local sales representative, please contact us.
Europe
Danaher Motion Customer Support Europe
E-Mail [email protected]
Internet www.DanaherMotion.net
Tel.:
Fax:
+49(0)203 - 99 79 - 0
+49(0)203 - 99 79 - 216
North America
Danaher Motion Customer Support North America
Internet www.DanaherMotion.com
E-Mail
Phone: +1 - 540 - 633 - 3400
Fax: +1 - 540 - 639 - 4162
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