KOLLMORGEN www.DanaherMotion.com SERVOSTAR® S Installation Manual M-SS-001-01 Rev. T Firmware Version 6.3.
Version History Revision Date Description of Revision 0 1 2 3 4 5 6 7 8 9 -01/05/98 03/13/98 09/18/98 12/03/98 05/01/99 09/15/99 06/30/00 10/10/00 02/01/01 10 11 02/28/01 09/28/01 12 13 14 15 01/16/02 03/27/02 06/14/02 07/10/02 16 17 18 19 T 11/22/02 12/16/02 02/14/03 04/18/03 08/04 Preliminary issue for review Initial release of UCB hardware Added UCB features Cx and UCB position capability (restructure document) Additional position features added Restructured SERCOS interface, CD-ROM transition
Directives and Standards The SERVOSTAR S product series have been successfully tested and evaluated to meet UL/cUL 508C for both U.S. and Canadian markets. This standard describes the fulfillment by design of minimum requirements for electrically operated power conversion equipment, such as frequency converters and servo amplifiers, which is intended to eliminate the risk of fire, electric shock, or injury to persons, being caused by such equipment.
Safety Instructions Only qualified personnel are permitted to transport, assembly, commission, and maintenance this equipment. Properly qualified personnel are persons who are familiar with the transport, assembly, installation, commissioning and operation of motors, and who have the appropriate qualifications for their jobs. The qualified personnel must know and observe the standards and regulations of IEC 364 resp.
Danaher Motion Kollmorgen 08/04 Table of Contents Table of Contents 1 READ BEFORE INSTALLING.......................................................... 1 1.1 USE AS DIRECTED .................................................................................2 2 UNPACKING AND INSPECTING..................................................... 3 2.1 BUS MODULE MODEL NUMBERS ...........................................................3 2.2 SERVOSTAR S MODEL NUMBERS ................................................
Table of Contents 4.9.2 Specifications.....................................................................................34 Cable Lengths ....................................................................................35 Resolution and Accuracy ...................................................................35 Digital Encoder.......................................................................... 36 4.9.3.1. 4.9.3.2. 4.9.3.3. 4.9.4 4.9.5 Danaher Motion Kollmorgen Resolver Feedback Diagram.
Danaher Motion Kollmorgen 6.4.2.1. 6.4.2.2. 6.4.2.3. 6.4.2.4. 7 08/04 Table of Contents CP2 Initialization .............................................................................. 59 CP3 Initialization .............................................................................. 59 Operational Notes ............................................................................. 59 Equation Notes..................................................................................
Table of Contents 08/04 Danaher Motion Kollmorgen 8.1.10 Monitoring and Troubleshooting Tools ..................................... 80 8.1.11 Fault and Safety Detection......................................................... 81 8.1.12 General....................................................................................... 81 8.2 BUS MODULE .................................................................................... 82 8.2.1 Features .........................................................
Danaher Motion Kollmorgen 1 08/04 Read Before Installing READ BEFORE INSTALLING These installation steps are designed to lead you through the ® proper installation and setup of a SERVOSTAR S system. They were developed with the assumption that you have a fundamental understanding of basic electronics, computers, mechanics, and proper safety practices. However, you do not have to be an expert in motion control to install and operate the drive system.
Read Before Installing 1. 1.1 08/04 Danaher Motion Kollmorgen Using the Startup Wizard in MOTIONLINK: A. Configure the SERVOSTAR S for your particular motor, if this was not done at the factory. Refer to the MOTIONLINK Startup Wizard. B. Enable the system. Use As Directed The restrictions for proper use of a SERVOSTAR S system are: − The amplifiers are components that are built into electrical equipment or machines and can only be commissioned as integral components of such equipment.
Danaher Motion Kollmorgen 2 08/04 Unpacking and Inspecting UNPACKING AND INSPECTING Electronic components in this amplifier are design hardened to reduce static sensitivity. However, proper procedures should be used when handling. Remove all packing material and equipment from the shipping container. Be aware that some connector kits and other equipment pieces may be very small and can be accidentally discarded if care is not taken when unpacking the equipment.
Unpacking and Inspecting 2.
Danaher Motion Kollmorgen 3 08/04 Mounting MOUNTING For proper ventilation mount the SERVOSTAR S vertically. These products are designed for mounting in an electrical enclosure to protect them from physical and environmental damage. 3.1 Hardware Specifications 3.1.
Mounting 08/04 Amplifier Model Unit Weight lbs / kgs Mounting English (Metric) Hardware Applied Torque BUS Screw Size/Torque Connection Motor Screw Hardware Size/Torque Ground Screw Size/Torque Control Logic (AWG/ mm2) Motor Line (AWG/ mm2) Danaher Motion Kollmorgen Sx30 11.5 / 5.2 Sx55 14.3 / 6.5 Sx85 19.7 / 9.0 10-32 (M4) 20 lb-in (2.26 N-m.) 6-32 / 12lb-in (1.35 N-m.) 10-32 / 20 lb-in (2.26 N-m) M4 / 20 lb-in (2.26 N-m) M5/20 lb-in. Box Lug M5/20 lb-in. (2.26 N-m) 18/0.
Danaher Motion Kollmorgen Distance 08/04 Top/Bottom CK100 Kit C6 Mating Connectors C7 C8 Connector Screw Torque 3.1.3 Mounting 63.5 mm. (2.5 in.) Includes: C1, C2, C4, C7 (plus 2 ft of stranded bus ribbon), C8 Danaher Motion #: A-81014-002 Vendor Info: PCD ELFP02110 Danaher Motion #: A-81014-004 Vendor Info: PCD ELFP04110 Danaher Motion #: A-81014-003 Vendor Info: PCD ELFP03110 2.25 lb-in. (0.
Mounting 08/04 Danaher Motion Kollmorgen Product Model Control Specifications 100 Ω SN75173 Input Impedance RS 485 Line Receiver Type See Position Loop for features using this input. Note: A flyback diode is necessary for inductive loads connected across the 01 output. 3.2 Sx and PA Unit Outline Dimensions D E I J F C G A H B K Note: Fan (Sx85 Only) 8 M-SS-001-01 Rev.
Danaher Motion Kollmorgen 3.2.1 08/04 Mounting PHYSICAL DIMENSIONS 3.2.1.1. Inches Product Sx03/06 Sx10 Sx20 Sx30 Sx55 Sx85 PA08 PA14/28 PA50/75/85 A B C D E F G H I J K 10.39 10.39 10.39 10.39 11.89 11.87 10.39 10.39 11.89 9.921 9.921 9.921 9.921 11.10 11.07 9.921 9.921 11.10 0.24 0.24 0.24 0.24 0.24 0.40 0.24 0.24 0.24 2.91 3.54 4.67 5.59 6.30 7.27 2.50 4.90 6.53 1.969 1.969 1.969 2.953 4.00 4.00 1.969 1.969 4.000 0.49 0.79 1.35 1.32 1.13 1.64 0.24 1.46 1.22 0.228 0.228 0.228 0.
Mounting 3.3 08/04 Danaher Motion Kollmorgen PA – LM Units Dimensions in mm (in.) 56.9 [2.24] 185.4 [7.30] MAX. 175.5 [6.91] 26.2 [1.03] 3.1 [0.12] 52.1 [2.05] +15V -15V 158.8 [6.25] +8V 1 LOGI C 2 3 4 C5 147.3 [5.80] LOGIC POWER SUPPL Y LIN E INPUT LA N/C LC EAR TH 2x 5.8 [0.23] 10 M-SS-001-01 Rev.
Danaher Motion Kollmorgen 4 08/04 Wiring WIRING The environment into which any electronic control system is installed can effect its operation. Danaher Motion recommends that the SERVOSTAR system be operated and stored under the environmental conditions stated in the product specification tables. The system may be operated in higher temperature ambient conditions with a derating applied. Contact Danaher Motion C.2 Customer Support for derating information.
Wiring 4.2 08/04 Danaher Motion Kollmorgen Grounding System grounding is essential for proper performance of the drive system. A ground bus bar may be used as a single point ground for the system. Safety grounding should be provided to all pieces of the system from a star point. In addition to the safety grounding, a high frequency ground must be provided that connects the back panel to the enclosure and to earth ground.
Danaher Motion Kollmorgen 4.3.1 08/04 Wiring NON-INSULATED CABLE CLAMP Terminal Clamp and Sx Drive Clamp show how cable bonding is implemented using non-insulated metallic cable clamps. Cx From the drive Terminal Strip Bonded to Back Plane To Motor Terminal Clamp 4.3.2 Sx Drive Clamp ALTERNATIVE BONDING METHODS Another option is to use cable bonding clamps offered by Phoenix Contact (and others).
Wiring 08/04 Danaher Motion Kollmorgen Phoenix Contact - Side View and Phoenix Contact -Top View represent a side and top view of the SK device that clamps down on the shield of the cable. The Phoenix SK device is excellent for providing a low impedance path between cable shield and the back panel.
Danaher Motion Kollmorgen 08/04 Wiring To properly mount the filters, the enclosure should have an unpainted metallic surface. This allows for more surface area to be in contact with the filter housing and provides a lower impedance path between this housing and the back plane. The back panel, in turn, has a high frequency ground strap connection to the enclosure frame or earth ground. 4.4.
Wiring 08/04 Danaher Motion Kollmorgen The filters called out in the table above are used on a one-toone correspondence with the drive. If drives are paralleled off one filter, it needs to be sized. Drives can be ganged off one EMI filter as shown in the Sx Filter and Bonding Diagram. 4.4.2 MOTOR LINE FILTERING Motor filtering may not be necessary for CE compliance of SERVOSTAR systems. However, this additional filtering increases the reliability of the system.
Danaher Motion Kollmorgen 08/04 Wiring Common mode currents commonly occur from noise spikes created by the PWM switching frequency of the drive. The use of a ferrite or iron-powder core toroid places common mode impedance in the line between the motor and the drive. The use of a common mode choke on the motor leads increases signal integrity of encoder outputs and associated I/O signals. The following is a list of toroidal and ferrite cores used to make common mode chokes: Manufacturer Manuf.
Wiring 08/04 Danaher Motion Kollmorgen Clamp on cores illustrates the use of multiple turns through a clamp-on core. The more turns created, the more impedance is added to the line. Avoid putting the shield in a clamp-on core. It is undesirable to place an impedance in-line with the shield. The use of ribbon cable may be common in many cabinets. Some ferrite clamps are designed just for ribbon cable use. Clamp on cores Flat cable clamp used with ribbon cable 4.4.
Danaher Motion Kollmorgen 08/04 Wiring 1 Cabinet/Enclosure Back Plane Contactor, Fuses, Xformer, etc. Line CNC / PLC / Controller Controller I/O EMI Filter 6 230 / 120 Xformer EMI Filter 3 phase PA Sx Sx 7 Load 9 5 4 2 3 8 Routed to motors 4.5 Routed to motors System Interconnect The following sections provide connector information and the system connections up to the motor power and feedback connections.
Wiring 4.5.1 08/04 Danaher Motion Kollmorgen SX ELECTRICAL SPECIFICATIONS Product Model Sx03 Sx06 Sx10 Sx20 Main Input (BUS+ / BUS-) BUS (VDC) 125 to 360 260 to 360 Rated Power at DC (kW) 0.63-1.4 1.26-2.79 1.96-4.34 8.68 Continuous Power (kVA) at 165 VDC 0.55 1.1 1.6 N/A BUS Input (45° C (113° F) Ambient) Continuous Power (kVA) at 325 VDC 1.1 2.2 3.6 7.
Danaher Motion Kollmorgen Protective Functions Environment 4.5.
Wiring 08/04 Product Model Internal Fuses (amps) (±15 V/+8 V) Max. # of Drives Sourced SoftStart Protection Functions Environment 115 VAC Turn-Off Level (power-up) 115 VAC Turn-On Level (normal) 230 VAC Turn-Off Level (power-up) 230 VAC Turn-On Level (normal) Max. Surge Current (amps) during power application Max. Charge Time (sec) Fault Contact Rating (±15%) Fault Contact Closing Period (ms) Over Temperature trip Internal heat dissipation Operating temp. (°C/°F) Storage temp.
Danaher Motion Kollmorgen Product Model 115 VAC Turn-Off Level (powerup) 115 VAC Turn-On Level (normal) 230 VAC Turn-Off Level (powerup) 230 VAC Turn-On Level (normal) Max. Surge Current (amps) during power application Max. Charge Time (sec) Fault Contact Rating Fault Contact Closing Period (ms) OverTemperature trip Internal heat dissipation Operation temperature (°C/°F) Storage temperature (°C/°F) Ambient humidity (%) Atmosphere Altitude Vibration (g) SoftStart Protection Functions Environment 4.5.
Wiring 08/04 Danaher Motion Kollmorgen Product Model Capacitance (Farads) Application BUS Voltage (nominal) (VDC) Information VHYS (Regen turn-off) (VDC) VMAX (Regen turn-on) (VDC) ER-20 ER-21 External Regen Kits ER-22 ER-23 PA50 0.00392 a a PA75 0.00504 325 370 390 a a a a PA85 0.00504 a a a a *For guidance on application sizing of Regen Kits, see the SERVOSTAR S-Series Regeneration Requirements Application Note. 4.5.
Danaher Motion Kollmorgen 08/04 Wiring Note 3 A thermal overload relay is supplied in the regen resistor kit. The thermal overload relay is sized for the resistance and power rating of the resistor. The output contacts of the relay must be wired to drop power to the main power contactor during a fault condition, as shown in the drawing. Do not wire Logic Control power through the main power contactor.
Wiring 08/04 4.6.1 Danaher Motion Kollmorgen Note 15 Control logic input can be tapped directly off the main line input. If this source is used, the main line power is lost and all communication functions to the drive cease. Note 16 See the SERVOSTAR Sx Hardware Specifications and the BUS Module Hardware Specifications for spade terminal sizes. Note 17 This system is suitable for use on a circuit capable of delivering not more than 5000 ARMS (symmetrical) and 240 V maximum. BUS MODULES 4.6.1.1.
Danaher Motion Kollmorgen 08/04 Wiring 4.6.1.2.
28 M-SS-001-01 Rev.
Danaher Motion Kollmorgen 4.6.
Wiring 08/04 Danaher Motion Kollmorgen 4.7 Pin-out Connections 4.7.
Danaher Motion Kollmorgen 08/04 Wiring C3: User I/O Connector +24 V Input (Common Rail for return pins 8,9,10,11) 8 Remote Enable Input 9 Configurable Input(See IN1 variable) 10 Configurable Input (See IN2 variable) 11 Configurable Input (See IN3 variable) 12 Configurable Output (See O1 variable) 13 *Configurable Output (See ANOUT variable) * Internal DC common reference for ANOUT.
Wiring 4.7.2 08/04 Danaher Motion Kollmorgen TOP VIEW C7 C8 1 10 24V C7: MultiDrop Communications Type: 10 Pin (0.1 in x 0.1 in) female ribbon cable. Connector and cable are included in the optional CK100 kit. This connector functions only when using the R-S232 interface. It will NOT function using RS-485.
Danaher Motion Kollmorgen 08/04 Wiring Notes for DIP switch: The 10 position DIP switch is provided for drive configuration. The first 6 switches control communications parameters and are read only at power up. Any changes in these settings will require cycling the power. The other two switch functions (7, 8) control the motor operation and are monitored in realtime. The DIP switch provides the following functions: MultiDrop Address Select (switches 1 through 5) set the drive's address.
Wiring Danaher Motion Kollmorgen RESOLVER 0.45 X RATIO SINE HI SINE LO COS HI REF LO COS LO 13 12 11 10 9 8 7 6 5 4 3 2 1 25 24 23 22 21 20 19 18 17 16 15 1 4 C2 RESOLVER VERSION REF HI (SEE BELOW) MOTORS MUST HAVE INTEGRAL THERMAL PROTECTION OR EXTERNAL MOTOR OVERLOAD MUST BE USED. THERMOSTAT SWITCH MAY SEE +12 VOLTS AND 20 ma. RESOLVER FEEDBACK DIAGRAM MOTOR OVERLOAD PROTECTION 4.9.2 08/04 4.9.2.1. Specifications Resolver Requirements Type Control Transmitter Transformation Ratio 0.
Danaher Motion Kollmorgen 08/04 Wiring 4.9.2.2. Cable Lengths It is important to use properly shielded cable and to keep it away from other noise-radiating devices and cables. It is not recommended to run the feedback and motor cables in the same conduit. Danaher Motion has tested cable lengths up to 75 ft. (22.9 m). without degradation of performance. Performance may vary, however,depending on motor and resolver type.
Wiring 4.9.3 08/04 Danaher Motion Kollmorgen DIGITAL ENCODER The SERVOSTAR can use encoder feedback to monitor the motor shaft position. As opposed to a resolver, which is an absolute position feedback device, the encoder is an incremental device that indicates changes in position. The encoder resolution of the SERVOSTAR (and therefore the drive’s encoder equivalent output) is fixed because it is a hardware characteristic of the encoder device. The encoder interface includes three groups of wires: 1.
Danaher Motion Kollmorgen 08/04 Wiring 4.9.3.2. Cable Lengths The recommended cable length when using the SERVOSTAR to source the encoder is no longer than 50 ft. (15 m). Long encoder cables tend to have high DC resistance that may create significant loading effects in the supply lines to the encoder. Please consider this carefully when designing the system. An option that would allow the use of longer lengths implements a separate supply located at the motor to source the encoder.
Wiring 38 08/04 Danaher Motion Kollmorgen − No Hall signals exist if no power-up commutation signals are available. The SERVOSTAR can excite two phases and lock the shaft in place. It then approximates position of the locked shaft and uses only the incremental signals to commutate forward until the index is found. − Hall signals provide information representing the approximate location of the motor shaft (6 transitions per electrical cycle of the motor).
ENCODER/SINE ENCODER VERSION SERVOSTAR S Installation M-SS-001-01 Rev.
Wiring 08/04 Danaher Motion Kollmorgen 4.9.5.1.
Danaher Motion Kollmorgen 08/04 Wiring 4.9.5.2. Cable Lengths The recommended cable length when using the SERVOSTAR to source the encoder is no longer than 50 ft. (15 m) Long encoder cables tend to have high DC resistance that may create significant loading affects in the supply lines to the encoder. Consider this carefully when designing the system. An option that would allow the use of longer lengths would be to put a separate supply at the motor to source the encoder.
Wiring 4.10 08/04 Danaher Motion Kollmorgen Encoder Equivalent Output The SERVOSTAR provides a motor position output in the form of quadrature encoder signals eliminating the need for an additional position feedback device. The outputs are differential line drivers. There is an associated DC common output (C4: pin 3) that can connect to your port to keep common mode noise and voltage spikes minimized for device protection.
Danaher Motion Kollmorgen 08/04 Wiring 4.10.2 ENCODER SYSTEMS The output signal is the actual encoder feedback signal that is preconfigured (MENCRES) in the drive’s motor parameters. It can be scaled down by multiples of two (ENCOUTO: 1, 2, 4, 8, 16) and has a maximum frequency limit of 3 MHz. 4.10.3 SINE-ENCODER SYSTEMS This output signal is developed for a resolution that is determined by a divisor (SININTOUT: 128, 64, 32, 16, 8, 4, 2, 1) of the actual sine-encoder line resolution (MENCRES).
Wiring 08/04 Danaher Motion Kollmorgen 4.10.5 RECOMMENDED MANUFACTURERS’ LIST Schaffner Electronik AG Nordstrasse 11 CH-4708 Luterbach Switzerland Phone: 065 802 626 Fax: 065 802 641 North America Schaffner EMC Inc. 9-B Fadem Road Springfield, NJ 07081 Phone: 201 379-7778 Fax: 201 379-1151 Corcom World Headquarters 844 E. Rockland Rd.
Danaher Motion Kollmorgen 5 08/04 System Communication SYSTEM COMMUNICATION Communication with the SERVOSTAR is through either the serial port or on a SERCOS interface fiber-optic ring (SERCOS interface versions only). The serial port can transmit data at baud rates of 9600 or 19200 (DIP switch 6) in either RS-232 or RS-485 configurations. Multiple drives can be addressed simultaneously when daisy chained as described later in this section.
System Communication 5.2 08/04 Danaher Motion Kollmorgen Drive Communication Review and be familiar with this section completely before applying power to the system. Most drives are shipped from the factory already configured for a particular motor. This can be verified by applying logic power and monitoring the Status Display. A factory-configured drive will go through a power-up sequence flashing all segments of the display before settling out to a number indicating the mode of operation.
Danaher Motion Kollmorgen 5.2.
System Communication 5.3 08/04 Danaher Motion Kollmorgen Sending/Retrieving System Data The following chart describes the flow of data between the PC and the SERVOSTAR. When logic power is applied to the drive, it loads the variable parameters stored in EEPROM into the dynamic RAM for fast and easy access. You can read (and write) these variable parameters to (and from) the PC by one of several methods described in INITIAL STARTUP USER SETTING VARIABLE FILE (*.
Danaher Motion Kollmorgen 5.4.2 08/04 System Communication RUNNING THE PROGRAM Go to your Start/Programs listing and select SERVOSTAR MOTIONLINK from the menu (or click on the SERVOSTAR MOTIONLINK icon if loaded on the desktop). 5.5 Using MOTIONLINK MOTIONLINK gives you three methods to configure the drive. The first uses the Startup screen and is the easiest and most highly recommended approach. Its main purpose is for initial startups.
System Communication 08/04 Danaher Motion Kollmorgen Setting Drive Variable Parameters: Click the Drive button. This screen allows you to select a bus value that corresponds to the incoming line voltage. This selection actually determines the setting of the variable VBUS. Also included is a realtime monitoring of the DIP switch on top of the drive so you can verify the proper setting for the drive address, baud rate, and various other parameters. Click Exit to return to the Startup screen.
Danaher Motion Kollmorgen 5.5.2 08/04 System Communication MAIN MOTIONLINK SCREEN This screen appears the when you exit out of the Startup screen. All the screens mentioned in the method above can be accessed from this screen and should be used to make corrections in the current system configuration. Setting Drive Variable Parameters: From the Configure menu, click the Drive option. The same screen appears as described in MOTIONLINK Startup Wizard. Click Exit to return to Main MOTIONLINK Screen.
System Communication 08/04 Danaher Motion Kollmorgen Restoring Factory Variable Parameters: To restore the original factory variable parameters, pull down the Configure menu, select Motor, and select the motor family and motor model. Click the To Drive button to send the variable parameters to RAM and the RAM/E2 SAVE button to save to EEPROM. Restoring Custom Variable Parameters: This process assumes that you saved the custom variable parameters to a .SSV file, as described above.
Danaher Motion Kollmorgen 08/04 System Communication Saving Variable Parameters to EEPROM At the prompt, type SAVE. This will save the variable parameters stored in the RAM to the EEPROM. All of the variables listed in the VarCom Reference Guide indicate whether its contents can be saved to EEPROM. Saving Variable Parameters to .SSV file At the prompt, type DUMP.
System Communication 5.7 08/04 Danaher Motion Kollmorgen Power-Up Sequence Upon powering up, the SERVOSTAR performs a series of selftests. If the status display illuminates a solid number, no errors were found and the EEPROM has loaded its variable parameters (or loaded default values in case of invalid EEPROM data) into RAM. The Remote Enable switch on the I/O connector (C3) may now be energized, thus enabling the servo loops. 5.
Danaher Motion Kollmorgen 6 08/04 SERCOS Interface Setup SERCOS INTERFACE SETUP The SERVOSTAR S-Series drives come with SERCOS interface communication capability. It must be ordered from the factory with this option. The Encoder Equivalent Output D9 connector (C4) is replaced with two fiber-optic ports, transmitter (Tx) and receiver (Rx).
SERCOS Interface Setup 08/04 Danaher Motion Kollmorgen The maximum and minimum cable lengths may be calculated by dividing the maximum and minimum signal attenuations by the cable attenuation. The following table shows the cable lengths for 1 mm plastic fiber with an attenuation of 0.18 dBm/m: Length Maximum Minimum Cable Length Specifications Low Power 54.7 m - High Power 71.4 m 10.3 m Note: 1) Fiber optic cable attenuation is 0.18 dBm/m.
Danaher Motion Kollmorgen 6.3 08/04 SERCOS Interface Setup Connection The mating connector selected for the Tx and Rx ports follow the IEC 874-2 specification, which recommends an F-SMA type connector. A hand-tight connection is adequate. Danaher Motion offers 30, 60, and 100 cm plastic fiber optic cables with SERCOS interface compatible F-SMA connectors.
SERCOS Interface Setup 6.4.1 08/04 Danaher Motion Kollmorgen DRIVE CONFIGURATION Before you can begin the CPx (where x = 0,1,2,3,4) run-up process, the drive should be configured and tuned for the axis of operation. To accomplish this, follow the guidelines below: 1. Power down the drive. 2. Set the drive address to zero for single-axis operation. 3. Select a serial baud rate. 4. Connect a serial cable from the drive to a host. 5. Power up the drive 6. Install MOTIONLINK and communicate with the drive.
Danaher Motion Kollmorgen 08/04 SERCOS Interface Setup 6.4.2.1. CP2 Initialization IDN 18 contains a list of IDNs that must be written to the drive in CP2. The CP2 transition procedure (IDN 127) verifies the drive’s readiness to transition from CP2 to CP3 and checks whether each IDN listed within IDN 18 has been written by the master. If any IDN has been written with illegal values, then the drive will not allow a transition to CP3.
SERCOS Interface Setup 08/04 Danaher Motion Kollmorgen 6.4.2.4. Equation Notes 1. Cnts = the number of encoder (or resolver equivalent) counts per revolution. Where: Encoder counts = Encoder lines * 4. Resolver counts = 2^16 * MResPoles/2 2. CUCT = The control unit cycle time (IDN 1) in ms. 3. The units "CUCT/ms" is the number of CUCT periods per ms. For example, a 2 ms CUCT has 1/2 a CUCT per 1 ms. 4.
Danaher Motion Kollmorgen 7 08/04 System Operation SYSTEM OPERATION The SERVOSTAR has a seven-segment indicator, called a status display that indicates four types of states: Power-up, Steady State, Flashing State, and Momentary State. The decimal point directly relates to the global drive enable. DRIVE STATE Power-up Steady State (No Faults) Flashing State Momentary Fault Status Display DISPLAY APPEARANCE Momentarily illuminates all display segments (forming an 8) and the decimal point.
System Operation 7.1 08/04 Danaher Motion Kollmorgen Operational Modes The SERVOSTAR has the ability to assume different modes of operation. It is factory configured in OPMODE 1 (Analog Velocity Controller) but may be reconfigured. Not all commands and variables are active or meaningful in every OPMODE.
Danaher Motion Kollmorgen 7.2.1 08/04 System Operation ANALOG INPUT (ANIN) The position, velocity, or torque loop can receive its command from an analog voltage source and is selectable through the OPMODE variable. The analog input to the SERVOSTAR is differential. This means that the signals received at the two inputs are subtracted from each other to create a difference, which is then used to command the rest of the system.
System Operation 7.2.2 08/04 Danaher Motion Kollmorgen REMOTE ENABLE INPUT (REMOTE) The opto-isolated Remote Enable input (REMOTE) provides a hardware drive enable switch. This 12 VDC to 24 VDC input will disable or enable the power stage output to the motor. The signal must be customer supplied in order to get the drive to enable (in combination with other parameters; ACTIVE) and operate. Tapping the signal off the logic supply (C5) is not recommended.
Danaher Motion Kollmorgen 7.2.5 08/04 System Operation FAULT OUTPUT RELAY (RELAY, RELAYMODE) The SERVOSTAR provides a drive ready/drive up output in the form of a relay (RELAY) output. The relay (RELAY) output is controlled by the SERVOSTAR’s microprocessor. There is a software switch (RELAYMODE) that configures the relay (RELAY) output to act as a Drive Ready or Drive Up indicator: RELAYMODE = 0, the relay is closed when the drive is error free and ready to run. This is a Drive Ready configuration.
System Operation 7.3 08/04 Danaher Motion Kollmorgen Control loops This section describes the servo control loops, their characteristics, and how to configure them. 7.3.1 CORE PROCESSORS A 40 MHz embedded controller and a 40 MHz DSP controller are the heart of the SERVOSTAR. They use its internal operating system to monitor inputs, adjust outputs, communicate serially, maintain servo control, and monitor faults.
Danaher Motion Kollmorgen 08/04 System Operation 7.3.2.1. Current Loop Since current and torque are proportional in a permanent magnet (PM) motor, the current loop is often referred to as the torque loop. The function of the current loop is to regulate motor current as directed by a current command signal. The current command signal from the microprocessor can either come from a direct user input (OPMODE 2 & 3) or from the output of the velocity loop.
System Operation 08/04 Danaher Motion Kollmorgen The difference between actual and desired velocity is filtered through a compensator algorithm and fed to the commutation loop. The SERVOSTAR offers four velocity compensators (methods of regulating velocity) and are selectable through the COMPMODE variable. The four are: Proportional-Integral (PI), PseudoDerivative-Feedback with Feed-Forward (PDFF), Standard Pole Placement, and Extended Standard Pole Placement. 7.3.2.4.
Danaher Motion Kollmorgen 08/04 System Operation In this mode of operation, the drive can also accept an external load feedback signal through the C8 connector (DUALFB=1). This helps eliminate the positional inaccuracies due to gear backlash and poor coupling by positioning according to the load’s position (not the motor shaft’s position). The SERVOSTAR also operates in the position mode when the drive is in the hold position state (HOLD = 1). 7.3.
System Operation 08/04 Danaher Motion Kollmorgen 7.3.3.2. Analog Torque The SERVOSTAR can be often configured to operate as an analog torque loop controller (OPMODE 3). In this case, the current loop receives its input from the analog-to-digital (A/D) conversion system. After conversion, the input command signal is processed through an algorithm that adjusts the signal (ANOFF, ANDB, ANZERO), filters it (ANLPFHZ) and then scales it (ISCALE), before developing the current command (ICMD).
Danaher Motion Kollmorgen 7.3.4 08/04 System Operation CURRENT SAMPLING The current loop receives corrective feedback from the current sampling circuitry. The current sensors use closed-loop hall sampling techniques in all units. The current sample is used by the current loops to regulate the current in each of the three motor phases. Two phases (A and C) of the current signal are sampled by the microprocessor at a 16 kHz rate.
System Operation 7.4.2 08/04 Danaher Motion Kollmorgen MOTOR FOLDBACK This FoldBack algorithm is designed to provide motor protection in cases where the drive’s continuous current rating is above the motor’s continuous rating. This combination is often desired in applications where maximum peak motor torques is required. The possibility exists, however, that the drive could source current on a continuous basis indefinitely to the motor and would force it beyond its thermal capability.
Danaher Motion Kollmorgen 7.6.1 08/04 System Operation THE PROCESS 1. 2. 3. 4. 5. 6. 7. Disable the drive. Select the encoder initialization process by entering the instruction, INITMODE 2. Set the encoder initialization current using IENCSTART. Set this to the maximum allowed application current. Set the gain for the process using INITGAIN (typically 1000). Initialize the process by using ENCSTART. Enable the drive. Monitor the process by reading the status word, STATUS2, and the status of ACTIVE.
System Operation 7.7.1 08/04 Danaher Motion Kollmorgen THE PROCESS During calibration, the motor is either moved manually or under servo control (preferably under velocity control). Take the following steps: 1. Initialize the process by entering the instruction, SININIT (without parameters) 7.8 2. Move the motor in either direction. While moving the motor, query the status using SININIST. 3. The process is complete when SININIST returns a value of 3 (done) or 5 (fault).
Danaher Motion Kollmorgen 8 08/04 System Description SYSTEM DESCRIPTION The SERVOSTAR S is a digital servo motor amplifier that meets the needs of many servo applications such as machine tooling, packaging, electronic assembly, and document handling. It has been designed to be a multifaceted amplifier capable of driving Danaher Motion’s vast product lines of motors and their assorted feedback devices. The S-series of drives comes in standard packages of 3, 6, 10, 20, 30, 55, and 85 amps.
System Description − − − − − − − − − − − − 8.1.3 Danaher Motion Kollmorgen Automatic control loop tuning through the auto-tune feature (TUNE). Configurable application and system speed limits (VLIM, VOSPD, VMAX). Advanced control algorithms (COMPMODE): Proportional-Integral (GV, GVI). Pseudo-Derivative with feed forward (KV, KVI, KVFR). Standard Pole Placement (BW, MJ, LMJR, TF). Extended Standard Pole Placement (BW, MJ, LMJR, TF).
Danaher Motion Kollmorgen − − − − − − 8.1.4 System Description Dual-loop mode (DUALFB) capable of positioning from a load feedback (C8 input, PEXTOFF, PEXT, VEXT, XENDIR) device while controlling velocity and torque from the motor feedback (C2 input). PID position loop tuning (GP, GPD, GPI, ) with feed-forward acceleration gain input to both the velocity and current loops (GPAFR, GPAFR2), and feed-forward velocity gain input to the velocity loop (GPVFR).
System Description 8.1.6 08/04 Danaher Motion Kollmorgen FEEDBACK DEVICES Device zeroing mode that rotates the motor to an electrical null point (ZERO, IZERO). 8.1.6.1. Resolvers − − − − − 8.1.7 Variety of motor and resolver pole combinations (MPOLES, MRESPOLES). Resolver-zero offsetting (MPHASE). System accuracy better than 20 arc minutes (reduced when resolver pole count is increased).
Danaher Motion Kollmorgen 08/04 System Description − Interface through Danaher Motion’s MOTIONLINK or a dumb terminal. Differential analog input command (ANIN). − ±10 V at 14 bit resolution. ±10 V at 15 bit resolution below 4 V of input for slow speed operation using the Dual Gain feature (ANDG - SE units only). − Input signal filtering (ANLPFHZ). − Flexible analog input scaling (VSCALE, ISCALE, ANOFF, ANZERO, ANDB). SERCOS interface communications port (SERCOS interface versions only).
System Description − − − − − − 08/04 Danaher Motion Kollmorgen Extensive on-line help file (F1) designed to assist you in MOTIONLINK’s intuitive nature. A set of limits folders allowing you to manipulate the position, velocity, current, and filtering limits from one screen. An I/O screen for easy manipulation of the drive’s I/O, thermostat options, encoder output, and hardware position limits capabilities. A feedback device screen that provides realtime pictorial positioning information.
Danaher Motion Kollmorgen 08/04 System Description 8.1.11 FAULT AND SAFETY DETECTION − − − − − − − − − − − − General faults (ACKFAULT, STAT, STATUS). Configurable under-volt protection (UVMODE, UVTIME, UVRECOVER). Speed and current protection (VOSPD, VLIM, ACC, DEC, ILIM, ILIM2). Fatal and non-fatal error coding with text explanation to the host (ERR, FLTHIST, FLTCLR). A run-time counter (TRUN) that records the time the error occurred is also provided.
System Description 8.2 08/04 Danaher Motion Kollmorgen BUS Module The SERVOSTAR family includes a variety of BUS Modules that convert a single-phase logic voltage and a three-phase AC line into the drive’s DC logic power and main DC BUS. 8.2.1 FEATURES − − − − Converts single or three-phase AC main lines into a rectified DC BUS (check BUS Module Electrical Specifications table to verify specific BUS Module operation). The input consists of a 3φ diode bridge and BUS capacitors.
Danaher Motion Kollmorgen 9 08/04 Troubleshooting TROUBLESHOOTING Technical papers and publications about the SERVOSTAR and its associated applications, prepared by Danaher Motion’s engineering and technical resource staff, complete the information package necessary for you to become well versed with the product. The Product Support Package (PSP) CD-ROM contains technical content stored in an electronic .PDF format.
Troubleshooting 9.2 08/04 Danaher Motion Kollmorgen Error Codes In most cases, the SERVOSTAR communicates error codes with a text message via the serial port to the host. Some error codes are also transmitted to the Status Display. The same message is saved in the EEPROM under an error history log (FLTHIST, ERR) so that nothing is lost when power is removed. Not all errors reflect a message back to the host. In these cases, the no-message errors communicate to the Status Display only.
Danaher Motion Kollmorgen Status Disp. Fault Message 08/04 Troubleshooting Possible Cause Negative analog Failure in –12 V supply (regulated) supply fail J OverSpeed velocity ≥ VOSPD J1 OverSpeed Velocity ≥ 1.
Troubleshooting Error Message O1RST out of range DISSPEED out of range MENCTYPE out of range Communication error Not in proper COMPMODE EXT velocity param warning Vel loop design failed Invalid EEPROM Recording active Rec data not available EEPROM is empty Argument must be binary Burnin is active Burnin is not active Conflicts with ENCOUT Conflicts with VLIM Not available Drive is in Hold mode Limit Switch Hold Command Into Limit Drive is in Zero Mode Motor is Jogging Argument not divisible by 20 Encoder In
Danaher Motion Kollmorgen Error Message Use Lower Bandwidth Drive in Dual Feedback mode Drive is in Gear mode Functionality is occupied Warning: A/B Line not routed Warning: Limit sw not routed Move is pending Incorrect password Password protected Capture during homing Homing during capture Capture process not done Capture process not active Capture process not enabled ENCSTART while ACONFIG SERCOSinterface test failure 9.2.
Troubleshooting Display E103 E104 8 B 9.3 08/04 Fault Description Danaher Motion Kollmorgen Fatal NonFatal DSP load fail (during init) DSP alive failure (during init) Test LED Indexed position with zero velocity Flashing Steady Display Display Fault Monitoring System The SERVOSTAR’s microprocessor is constantly monitoring the status of many different components. In general, the philosophy of the SERVOSTAR is to latch all fault conditions so you can readily determine the source of the problem.
Danaher Motion Kollmorgen 08/04 Troubleshooting Bus OverVoltage An over-voltage condition shuts down the drive and displays a lower-case o in the status display. This fault will occur mostly during regen operation where the bus is raised to higher values than that produced by the power supply. Bus UnderVoltage An under-voltage condition shuts down the drive and displays a u in the status display. This fault normally occurs when the incoming line voltage drops out or a fault occurs in the power supply.
Troubleshooting 08/04 Danaher Motion Kollmorgen Non-volatile memory (EEPROM) Non-volatile memory (EEPROM)is also checked for integrity upon power-up. Any discrepancy in this data is noted with an e in the status display. After power up is successfully completed, any subsequent fault in the operation of the EEPROM is noted with an E in the status display. WatchDogs In addition, the SERVOSTAR incorporates a watchdog system to maintain software operation integrity.
Danaher Motion Kollmorgen 08/04 Appendix A APPENDIX A A.1 Motor Pinouts The SERVOSTAR S product family can be mated with a variety of motors. Cable sets (motor and feedback) can be purchased directly from Danaher Motion, which gives you a complete plug-n-play system. However, you may find it necessary to manufacture your own cable sets. This appendix provides pinout information between the drive’s power and feedback connections and the motor receptacles for most of Danaher Motion’s motor products. A.1.
Appendix A 08/04 SERVOSTAR Danaher Motion Kollmorgen DDR C2 Pin 1 Pin 2 Pin 3 (shield) Pin 4 Pin 5 Pin 6 (Shield ) Pin 14 (Shield ) Pin 15 Pin 16 Pin 13 Pin 25 Pin 12 (Shield ) RBHR Pin 3 Pin 7 Wire Color (from resolver to motor receptacle) Black Red Pin 8 Pin 4 Yellow Blue Red Black Pin 5 Pin 9 Pin 2 Pin 6 Yellow/White Red/White Blue Red Red / White Yellow / White Resolver Connector Wire Color Yellow Blue A.1.
Danaher Motion Kollmorgen SERVOSTAR C2 08/04 Appendix A SILVERLINE 0802 Encoder Receptacle Pin 3 Pin 6 0802 Wire Color Pin 1 Blue Pin 2 Blue / Black Pin 3 (shield) Pin 4 Pin 4 Green Pin 5 Pin 7 Green / Black Pin 6 (Shield ) Pin 7 & 8 Pin 10 Red Pin 9 Pin 12 Brown Pin 10 Pin 13 Gray Pin 11 Pin 14 White Pin 12 (Shield ) Pin 13 Pin 1 Yellow Pin 14 (Shield ) Pin 15 Pin 5 Violet Pin 16 Pin 8 Violet / Black Pin 18,19 & 20 Pin 9 Black Pin 22 ( see note 1 ) ( see note 1 ) Pin 23 ( see note 1 ) ( see note 1 ) P
Appendix A 08/04 Danaher Motion Kollmorgen A.1.4 SYSTEM CONNECTION DIAGRAM 94 M-SS-001-01 Rev.
Danaher Motion Kollmorgen 08/04 Appendix B APPENDIX B B.1 Digital Incremental Encoder Types The SERVOSTAR products include models designed for use with incremental digital encoders. Encoders are available in different configurations from a variety of manufacturers using different nomenclature and conventions, making this topic somewhat confusing. Encoders can be as simple as having only A and B output channels or as complex as 6 channels of outputs.
Appendix B 08/04 Danaher Motion Kollmorgen The 90º electrical phase shift between the two channels is referred to as quadrature-encoded. The encoder output appears as a frequency, but the pulse rate is dependent on the motor's rotational velocity, not time. Since the two channels are phase-shifted by 90º, there are actually four states available per electrical cycle of these signals. The SERVOSTAR is able to receive four counts for position feedback for one line of motion of the encoder.
Danaher Motion Kollmorgen 08/04 Appendix B Commutation Tracks The hall channels can be synthesized in the encoder or can be discrete devices integrated in the motor windings. Commutation tracks (hall channels) provide three digital channels that represent alignment to the A-phase, B-phase, and C-phase back EMF of the motor. An encoder with Hall channels must have the correct output for the given pole count of the motor as the Hall signals are referencing the motor's BEMF waveform.
Appendix B 08/04 Danaher Motion Kollmorgen B.1.2 SERVOSTAR ENCODER TYPES The idea of obtaining velocity or position information from the series of pulses generated from the encoder is not difficult to understand. Permanent magnet brushless DC servo motors require commutation. As stated earlier, commutation is simply the positioning of the electromagnetic fields in alignment with the permanent magnet fields such that optimal torque is produced.
Danaher Motion Kollmorgen 08/04 Appendix B MENCTYPES 3 & 4 MENCTYPES 1 & 2 Drive puts IENCSTART current through 2 phases and waits for motor to stop Perform MENCTYPE 3 & 4 algorithm Marker Channel Occur? Position is read by drive No Drive puts current through other phase. Wait for stop. Yes Establish new Commutation using MENCOFF Drive establishes commutation angle End End B.1.2.1 MENCTYPE 0 Incremental with A/B/I and Hall Channels MENCTYPE 0 is the most robust encoder system.
Appendix B 08/04 Danaher Motion Kollmorgen B.1.2.2 MENCTYPE 1 Encoders with A/B/I channels Some systems do not have hall channels, so this mode tells the SERVOSTAR not to expect them. The initialization process occurs in two steps. The first step is the 'wake-and-shake initialization process (see B.1.2.4 MENCTYPE 3 and B.1.2.5 MENCTYPE 4 for wake and shake details) which gets the commutation alignment initialized after power up. The second step occurs when the index pulse is seen.
Danaher Motion Kollmorgen B.1.2.4 08/04 Appendix B MENCTYPE 3 − − − Encoders with A and B channels only The simplest of encoders provide only an A and B Channel. MENCTYPE 3 configures the SERVOSTAR for these signals. These encoders provide no power-up information about where the motor is positioned, so this information is obtained through a special initialization process known as 'wake and shake'. When using MENCTYPE 3, initialization is required but it is triggered by the serial command, ENCSTART.
Appendix B B.1.2.5 08/04 MENCTYPE 4 − − − B.1.2.6 Danaher Motion Kollmorgen Encoders with A and B channels only The simplest of encoders provide only an A and B Channel. MENCTYPE 4 configures the SERVOSTAR for these signals. These encoders provide no power-up information about where the motor is positioned, so this information is obtained through a special initialization process known as 'wake and shake'.
Danaher Motion Kollmorgen 08/04 Appendix B B.1.3 COMMUTATION ACCURACY The accuracy of the commutation alignment within the drive affects the overall system efficiency. Misalignment also causes greater torque ripple. As a general estimator, the following equation holds: Kt effective = Kt Rated * Cosine (Alignment Error) Inaccuracy of commutation alignment can occur from multiple sources when using encoders.
Appendix B 08/04 Danaher Motion Kollmorgen B.1.2.2 MENCTYPE 1 and B.1.2.3 MENCTYPE 2 (A/B/I without Halls) require the marker to be aligned to the motor's BEMF waveform. Danaher Motion has not defined any particular alignment standard. Defining your own alignment standard could be beneficial. B.1.2.4 MENCTYPE 3 and B.1.2.5 MENCTYPE 4 (A/B only) require no alignment or adjustments. B.1.2.7 MENCTYPE 6 (A/B/I with Halls) requires the same alignment as B.1.2.
Danaher Motion Kollmorgen 08/04 Appendix B B.1.6 SYSTEM PHASING With so many signals coming from the encoder back to the drive and then the signals going to the motor, it can become quite frustrating to make sure that each signal is of the appropriate phase. Commutation shows the commutation phasing (PFB counts down) for: – Motors with shafts, counter-clockwise rotation viewing shaft end. – Motors without shafts, clockwise rotation viewing lead exit end.
Appendix B 08/04 Danaher Motion Kollmorgen B.1.7 TROUBLESHOOTING Several problems can occur with encoder-based systems. The most common problem is miswiring. The section on system phasing provides the necessary troubleshooting information. Miswired Hall channels can cause intermittent problems. With miswired Hall channels, the motor operates correctly sometimes, but will occasionally not operate correctly after cycling power. It is very important to physically verify the Hall effect channels.
Danaher Motion Kollmorgen 08/04 Appendix B Another common sense approach is to use differential transmission for the signals to provide the highest degree of noise immunity. Differential line drivers are required by the SERVOSTAR. The differential line signals follow the RS-485 format where pulses are sent up and down a 120 Ω cable. Termination is expected at both ends and the SERVOSTAR provides the required termination.
Appendix B 08/04 Danaher Motion Kollmorgen ENCSTART – Selects automatic or manual wake and shake initialization. HALLS - Read the states on the Hall channels. IENCSTART - Set the wake and shake initialize current level. MENCOFF - Tell the SERVOSTAR where the marker is relative to commutation angle 0. MENCRES - Tell the SERVOSTAR how many lines there are on the encoder. MENCTYPE - Tell the SERVOSTAR what encoder signals are present. MHINVA - Invert the active level of Hall channel A.
Danaher Motion Kollmorgen 3. 08/04 Appendix B Determine the Relationship Between Halls and Motor Phases Measure the motor phase voltages versus the Hall states on an oscilloscope to determine which motor phase matches which Hall sensor. If the zero crossings of the sine wave match the edges of the Hall sensor, this is a match. If the the Hall sensor is low during the positive peak of the sign wave, this follows the default polarity definition of the CD amp and you should set MHINVx=0.
Appendix B 08/04 Danaher Motion Kollmorgen 8. Confirm Proper Operation in the Application Conditions Tune the servo loop. Command agressive moves and the highest acceleration used by the application. Observe the peak value of DAC input required for forward and reverse motion. These values should be approximately the same (within about 10%). If desired/required, adjust MPHASE up or down to give equal peak DAC output in both directions 110 M-SS-001-01 Rev.
Danaher Motion Kollmorgen 08/04 Appendix C APPENDIX C C.1 Resistive Regeneration Shunt regeneration is required to dissipate energy that is pumped back into the DC bus during load deceleration. The loads need to be defined in terms of system inertia, maximum speed, and deceleration time. In addition, the duty cycle must be known. External Regen Resistor Dimensions are in mm (inches) White Black 26 Ω White SERVOSTAR S Installation Normally Closed Black M-SS-001-01 Rev.
Appendix C C.2 08/04 Danaher Motion Kollmorgen Customer Support Danaher Motion products are available world-wide through an extensive authorized distributor network. These distributors offer literature, technical assistance, and a wide range of models off the shelf for the fastest possible delivery. Danaher Motion sales engineers are conveniently located to provide prompt attention to customer' needs.