SERVOSTAR® S and SERVOSTAR® CD Installation Manual M-SS-001-0119 Firmware Version 6.3.
Record of Manual Revisions ISSUE NO.
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 following standards and regulations: IEC 364 resp.
Directives and Standards The SERVOSTAR S and SERVOSTAR CD product series have been successfully tested and evaluated to meet UL/cUL 508C for both U.S. and Canadian markets. This standard describes the fulfillment by design of minimum requirements for electrically operated power conversion equipment, such as frequency converters and servo amplifiers, which is intended to eliminate the risk of fire, electric shock, or injury to persons, being caused by such equipment.
Danaher Motion Kollmorgen Table of Contents Table of Contents READ BEFORE INSTALLING............................................................ 1 USE AS DIRECTED ................................................................................. 2 UNPACKING AND INSPECTING ...................................................... 3 BUS MODULE MODEL NUMBERS .......................................................... 3 SERVOSTAR S/CD MODEL NUMBERS ............................................... 4 MOUNTING........
Danaher Motion Kollmorgen Table of Contents Cx Regen Information......................................................................28 BUS Module Regen Information......................................................29 Kit Parts and Models .......................................................................30 WIRING DIAGRAMS .............................................................................31 Bus Module Simplified Schematic....................................................
Danaher Motion Kollmorgen Table of Contents RS-485 Connection .......................................................................... 49 Setting Drive Address ...................................................................... 49 SENDING/RETRIEVING SYSTEM DATA................................................. 50 MOTIONLINK INSTALLATION ........................................................... 51 Installing on PC...............................................................................
Danaher Motion Kollmorgen Table of Contents Servo Loop Description ...................................................................70 Current Loop ................................................................................70 Commutation Loop ......................................................................71 Velocity Loop...............................................................................71 Position Loop ..............................................................................
Danaher Motion Kollmorgen Table of Contents FIRMWARE UPGRADES ........................................................................ 96 APPENDIX A ........................................................................................ 97 MOTOR PINOUTS ................................................................................. 97 Motor Power Connections............................................................... 97 SR/CR RESOLVER Connection.......................................................
Danaher Motion Kollmorgen Table of Contents Determining Dissipated Power...................................................125 APPENDIX E ......................................................................................127 SERIES 5 UCB2 DIGITAL CONTROL BOARD .....................................127 PART NUMBER ...................................................................................127 SUMMARY OF NEW FEATURES ..........................................................
Danaher Motion Kollmorgen Read Before Installing READ BEFORE INSTALLING These installation steps are designed to lead you through the proper installation and setup of a SERVOSTAR® S or SERVOSTAR® CD system. They were developed with the assumption that you have a fundamental understanding of basic electronics, computers, mechanics, and proper safety practices. However, you do not have to be an expert in motion control to install and operate the drive system.
Danaher Motion Kollmorgen Read Before Installing 13. Install MOTIONLINK on the PC. Startup processes can cause motor motion. Be certain that all applicable safety precautions are taken to ensure that no harm to personal or machine can occur. 14. Using the Startup Wizard in MOTIONLINK: A. Configure the SERVOSTAR S or SERVOSTAR CD for your particular motor, if this was not done at the factory. Refer to the MOTIONLINK Startup Wizard. B. Enable the system.
Danaher Motion Kollmorgen 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 quite small and can be accidentally discarded if care is not observed when unpacking the equipment.
Danaher Motion Kollmorgen Unpacking and Inspecting SERVOSTAR S/CD Model Numbers Month Manufactured A - January B - February : : L - December Year Manufactured Unit Manufactured Manufacturing Location S 9 8 A-5 8 9 CR03000-2G204 Motor Winding SERVOSTAR® Amplifier Family S - S Series C - CD Series (Compact Drive) Motor Frame & Stack Length Feedback Motor Family R - Resolver E - Encoder B - Sine Encoder D - DDR Series 0 - No Comp G - GOLDLINE (B, M, EB) R - RBE (H) H - SILVERLINE L - Linear (Ironl
Danaher Motion Kollmorgen Mounting MOUNTING For proper ventilation, the SERVOSTAR S or the SERVOSTAR CD and BUS Module units should be mounted vertically. No horizontal distance between the drive and BUS Module is required. In systems using more than two SERVOSTAR units per BUS Module, divide the drives equally on either side of the BUS Module. These products are designed for mounting in an electrical enclosure to protect them from physical and environmental damage.
Danaher Motion Kollmorgen Mounting SERVOSTAR Sx Amplifier Model lbs / Kgs Unit Weight Mounting Hardware English (Metric) Applied Torque BUS Screw Connection Hardware Size/Torque Motor Screw Size/Torque Ground Screw Size/Torque Control Logic (AWG/ mm2) Motor Line (AWG/ mm2) Configurable I/O wire gauge Wire Size (AWG#) Spade Terminals Clearance Distance Side-to-Side Top/Bottom CK100 Kit C3 Mating Connector Hardware ® C5 Connector Screw Torque Sx03 Sx06 6.3 / 2.85 Sx10 Sx20 7.3 / 3.3 9.9 / 4.
Danaher Motion Kollmorgen Mounting Amplifier Model lbs / Kgs Unit Weight English (Metric) Mounting Hardware Applied Torque Connection Hardware Wire Size (AWG#) Clearance Distance Mating Connector Hardware Sx30 Sx55 Sx85 11.5 / 5.2 14.3 / 6.5 19.7 / 9.0 10-32 (M4) 20 lb-in (2.26 N-m.) 6-32 / 12lb-in (1.35 N-m.) BUS Screw Size/Torque Motor Screw Size/Torque Ground Screw Size/Torque Control Logic (AWG/ mm2) Motor Line (AWG/ mm2) Configurable I/O wire gauge 10-32 / 20 lb-in (2.
Danaher Motion Kollmorgen Mounting BUS Module BUS Module Model PA-LM PA08 PA14 PA28 PA50 PA75 PA85 Unit Weight Lb./Kg. 2.5/1.32 4.74/2.16 8.18/3.72 14.32/6.51 14.52/6.6 15/6.8 Mounting English (Metric) 10-32 (M4) Hardware Applied Torque 20 lb-in. (2.26 N-m) Line Screw Size/Torque 6-32/ 10-32/ M5/ Box Lug 12 lb-in 12 lb-in. 20 lb-in. (1.35 N-m) (1.35 N-m) 2.26 N-m) BUS Screw Size/Torque M5/ Connection 20 lb-in. Hardware (2.26 N-m) Ground Screw Size/Torque M4/12 lb-in. (1.35 N-m) Control Logic 18/0.75 14/2.
Danaher Motion Kollmorgen Mounting Product Family Control Specifications Product Model Current Loop Commutation Loop Velocity Loop Position Loop Analog Input (2, 3) Fault Output Relay (5, 6) Remote Enable (7, 8) Configurable Inputs(7, 9, 10, 11) Configurable Digital Output (7, 12) Control Specifications Update Rate 62.5 µs (16 kHz) Bandwidth <2000 Hz Update Rate 62.5 µs (16 kHz) Max. Commutation Freq.
Danaher Motion Kollmorgen Mounting Outline Dimensions Sx and PA Units E I J F C G A B H K Note: Fan (Sx85 Only) PHYSICAL DIMENSIONS Product Sx03/06 Sx10 Sx20 Sx30 Sx55 Sx85 PA08 PA14/28 PA50/75/85 A 10.39 10.39 10.39 10.39 11.89 11.87 10.39 10.39 11.89 Product Sx03/06 Sx10 Sx20 Sx30 Sx55 Sx85 PA08 PA14/28 PA50/75/85 A 264 264 264 264 302 301. 5 264 264 302 ® B 9.921 9.921 9.921 9.921 11.10 11.07 9.921 9.921 11.10 B 252.00 252.00 252.00 252.00 282.00 281.20 252.00 252.00 282.00 C 0.24 0.24 0.
Danaher Motion Kollmorgen Mounting Cx Units Cx10 99.1 [3.90] Cx 06 83.3 [3.28] Cx 03 67.3 [2.65] 36.6 [1.44] 163.0 [6.42] 6.7 [0.26] 2.0 [0.08] 3 ∅ 5.5 [0.22] 15.5 [0.61] 2 ∅ 10.0 [0.39] 244.0 [9.61] 256.0 [10.08] HEAT SINK 216.0 [8.50] 33.7 [1.33] PA-LM Units 56.9 [2.24] 52.1 [2.05] 185.4 [7.30] MAX. 26.2 [1.03] 3.1 [0.12] 175.5 [6.91] +15V -15V 1 LOGIC 158.8 [6.25] +8V 2 3 4 C5 147.3 [5.80] LOGIC POWER SUPPL Y LINE INPUT LA N/C LC EAR TH 2x 5.8 [0.
Danaher Motion Kollmorgen Wiring WIRING The environment that any electronic control system ‘lives’ in can effect its operation. Danaher Motion Kollmorgen 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. Please check with the factory for derating information.
Danaher Motion Kollmorgen Wiring Grounding System grounding is essential for proper performance of the drive system. A ground bus bar may be used as a single point ground for the system. Safety grounding should be provided to all pieces of the system from a “star point." In addition to the safety grounding, a high frequency ground must be provided that connects the back panel to the enclosure and, ultimately, to earth ground.
Danaher Motion Kollmorgen Wiring Non-insulated Cable Clamp The following figures shows how cable bonding is implemented using noninsulated metallic cable clamps. Sx Cx From the drive Terminal Strip Bonded to Back Plane To Motor Sx Drive Clamp Cx Drive Clamp Terminal Clamp Alternative Bonding Methods Another option is to use cable bonding clamps offered by Phoenix Contact (and others).
Danaher Motion Kollmorgen Wiring The next two figures 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 Wiring CE Filtering Techniques The SERVOSTAR drive system (BUS Module, drive, motor) meets the CE Mark standards stated in the front of this manual. It is imperative for you to apply proper bonding and grounding techniques, described earlier in this section, when incorporating EMC noise filtering components for the purpose of meeting this standard. Noise currents often occur in two types. The first is conducted emissions that are passed through ground loops.
Danaher Motion Kollmorgen • • • • • Wiring Filter should be mounted as close as possible to BUS Module. If separation exceeds 30cm. (1 ft.), flat cable (braid) is used for the high frequency connection between filter and BUS Module. When mounting the filter to the panel, remove any paint or material covering. Use an unpainted metallic back panel, if possible. Filters are provided with an earth connection. All ground connections are tied to ground. Filters can produce high leakage currents.
Danaher Motion Kollmorgen Wiring Motor Line Filtering Motor filtering may not be necessary for CE compliance of SERVOSTAR systems. However, this additional filtering increases the reliability of the system. Poor non-metallic enclosure surfaces and lengthy, unbonded (or unshielded) motor cables that couple noise line-to-line (differential) are just some of the factors that lead to the necessity of motor lead filtering. Motor lead noise may be either common-mode or differential.
Danaher Motion Kollmorgen 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.
Danaher Motion Kollmorgen Wiring I/O Filtering I/O filtering, while not a necessity for CE compliance, may be desirable (depending on system installation, application, and integration with other equipment). To avoid unwanted signals entering and disturbing the drive system or other associated equipment, place ferrite cores on I/O lines. The following chart lists some recommended ferrite parts used for I/O filtering and noise attenuation.
Danaher Motion Kollmorgen Wiring Cx Filter and Bonding Diagram Cabinet/Enclosure 1 Back Plane Contactor, Fuses, Xfmr, etc. 230 VAC XFMR EMI filter Controller I/O CNC / PLC / Controller 4 EMI filter 8 CD CD 6 7 5 2 3 9 Note 1 Routed to Motors Input power enters enclosure from metal conduit. This eliminates the need for shielded input power cable. Note 2 Single point ground. A bus bar (ground bus) is an excellent way to achieve this.
Danaher Motion Kollmorgen Wiring Sx Filter and Bonding Diagram 1 Cabinet/Enclosure Back Plane Contactor, Fuses, Xformer, etc. CNC / PLC / Controller Line Controller I/O EMI Filter 6 230 / 120 Xformer Sx Sx 7 EMI Filter 3 phase PA Load 9 5 4 2 3 8 Routed to motors Note 1 Input power enters enclosure from metal conduit. This eliminates the need for shielded input power cable. Note 2 Single point ground. A bus bar (ground bus) is an excellent way to achieve this.
Danaher Motion Kollmorgen Wiring System Interconnect The following sections provide connector information and the system connections up to the motor power and feedback connections. Cabling purchased from Danaher Motion Kollmorgen directly completes the system connections. Customers making their own cables can refer to Appendix A for drive/motor pinout connections.
Danaher Motion Kollmorgen Wiring Product Model Protective Functions Environment Cx03* UnderVoltage Trip (nominal) OverVoltage Trip OverTemperature Trip Internal heat dissipation (watts) Operation temperature Storage temperature Ambient humidity Atmosphere Altitude Vibration *NOTE: Model Numbers Cx0x200 are single phase only! Cx06* Cx10 90 VDC 430 VDC 80°C (176°F) 60 80 132 5°C (41°F)to 45°C (113°F) 0°C (32°F) to 70°C (158°F) 10% to 90% without corrosive gasses or dust Derate 5% per 1000 ft.
Danaher Motion Kollmorgen Main Input (BUS+ / BUS-) Rated Main Output (MA, MB, MC) Control Input (Sinking) Protective Functions Environment ® Wiring Product Model BUS (VDC) Rated Power at DC (kW) Continuous Power (KVA) at 165 VDC BUS Input (45°C (113°F) Ambient) Continuous Power (KVA) at 325 VDC BUS Input (45°C (113°F) Ambient) Continuous Current (Arms) Peak Current (Arms) for 500mSec Peak Current (Arms) for 2Sec PWM Frequency (kHz) PWM Motor Current Ripple (kHz) Form Factor (rms/avg) +8 VDC Supply V
Danaher Motion Kollmorgen Wiring BUS Module Electrical Specifications Product Model Voltage (VACL-L) Nominal ±10% 115VAC 1φ and 3φ 230VAC 1φ and 3φ Line Frequency KVA at 115 VAC PA-LM Main Output Power (Source) Logic Input Power Logic Output Power (Source) 115 VAC Continuous Current (amps) 230 VAC Continuous Current (amps) 115 VAC Peak Current (amps) for 2sec/50 ms 230 VAC Peak Current (amps) for 2sec/50msec during normal operation Line Fuses (FRN, LPN, or equivalent) DC BUS Voltage (Nominal) kW at 1
Danaher Motion Kollmorgen Wiring Product Model 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%) Protection Fault Contact Closing Period Functions (mSec) OverTemperature trip Internal heat dissipation Operating temp. (°C/°F) Storage temp.
Danaher Motion Kollmorgen Wiring Product Model Max. # of Drives Sourced Power (Source) PA50 PA75 PA85 Refer to the SERVOSTAR Bus Module Sizing Application Note. 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.
Danaher Motion Kollmorgen Wiring BUS Module Regen Information Internal Shunt Regulator External Shunt Regulator* Application Information Internal Regen External Regen Kits Product Model Peak current (amps) Resistance (ohms) Watts Fuse Rating (amps)(internal) Peak current (amps) Minimum resistance (ohms) Watts Capacitance (Farads) BUS Voltage (nominal) (VDC) VHYS (Regen turn-off) (VDC) VMAX (Regen turn-on) (VDC) Resistance (ohms) Power Rating (Watts) ER-30 ERH-40 PA-LM PA08 N/A N/A N/A N/A N/A N/A N/A 0
Danaher Motion Kollmorgen Wiring Kit Parts and Models Kit Parts / Kit Models 1000 ER-22 2.2 (two in parallel) 1000 ER-23 2.2 (two in parallel) 2000 A-79916-007 A-93317-027 A-79916-007 A-93317-027 10.5 15 21 30 A-93142-007 A-93142-008 A-93142-010 A-93142-010 Manual Manual Manual Manual Resistance (ohms) Resistor Overload Relay (Fast Trip) Hookup Power Rating (watts) Danaher Motion Kollmorgen Part No. Relay Trip Setting (amps) Danaher Motion Kollmorgen Part No.
3 INPUT POWER SoftStart Control SERVOSTAR® S and CD Series I2T Fault Regen Circuit OverCurrent Monitor OverVoltage Monitor UnderVolt Monitor YELLOW OPTICAL ISOLATION BUS- - + RED REGEN LED DCBUS POWER REGEN FAULT LED (NORMALLY CLOSED) FAULT: TO DRIVE (PA 14/28 ONLY) R JUMPER R-C FOR C INTERNAL REGEN EXTERNALLY OPTIONAL EXTERNAL REGEN RESISTOR BUS+ Danaher Motion Kollmorgen Wiring Wiring Diagrams Bus Module Simplified Schematic 31
SERVOSTAR® S and CD Series L2 L1 (SEE NOTE 10) (SEE NOTE 13) (SEE NOTE 13) L3 L2 L1 C B+ MC MB MA 6 9 1 2 3 4 5 6 7 8 9 10 11 12 13 25 24 23 22 21 20 19 18 17 16 15 14 C4 C3 C2 1 3 5 13 12 11 10 9 8 7 6 5 4 3 2 1 5 4 3 9 2 8 (SEE NOTE 10) (SEE NOTE 13) FEEDBACK (D25) RS-232 SERIAL LINK (IN1) (IN2) (IN3) (O1) ANOUT) C1 METER RX TX REPLACES C4 ON SERCOS MODELS DIAGRAM REPRESENTS TYPICAL CONNECTION TO MOTOR FEEDBACK DEVICE 5 4 3 2 1 (SEE NOTE 12) ANALOG INPUT ± 10
SERVOSTAR® S and CD Series L3 L2 NORMALLY OPEN AUXILLIAR Y POWER CONTACT FROM MAIN POWER CONTACTOR (SEE NOTE 4) (SEE NOTE 9) CUSTOMER SUPPLIED FUSING SHIELD TO STAR POINT (SEE NOTE 15 TO STAR POINT TO QUALIFIED PERSONNEL ONLY! ALWAYS REPLACE LC The fault contacts must be wired in series with the overload relay as shown in the drawing. This contact is normally open and closes after application of control and main power. This contact opens in fault conditions.
SERVOSTAR® S and CD Series L3 L2 CUSTOMER SUPPLIED FUSING Note 13 See the SERVO STAR Sx Hardware Specifications and the BUS Module Hardware Specifications for wire gauge and ferrule sizes. Note 12 Do not connect unused pins on C1 connector. Some manufacturers' cables connecting all the pins may produce unpredictable operation.
SERVOSTAR® S and CD Series Note: WHEN MATING MULTIPLE DRIVES TO ONE BUS MODULE, THE WIRE GAUGE MUST BE SIZED WITH RESPECT TO THE CURRENT RATING OF THE BUS MODULE. TERMINAL LUG SIZES BETWEEN THE BUS MODULE AND THE DRIVE MAY DIFFER. rEFER TO THE HARDWARE SPECIFICATIONS TABLE FOR TERMINAL SIZES. TO ADDITIONAL DRIVES Note: SOME PA LOGIC SUPPLIES CAN SOURCE UP TO FOUR DRIVES. CHECK THE BUS MODULE ELECTRICAL SPECIFICATIONS TABLE FOR THE MAXIMUM LOGIC SOURCE.
Danaher Motion Kollmorgen Wiring Pin-out Connections Front View C1: Communications Connector Pin Function 1 2 3 4 5 6 7 8 9 C1 1 2 3 4 5 6 7 8 9 C2 13 12 11 10 9 8 7 6 5 4 3 2 1 25 24 23 22 21 20 19 18 17 16 15 14 C3 1 2 3 4 5 6 7 8 9 10 11 12 13 C4 9 8 7 6 5 4 3 2 1 Pin Shield REC (RXD) (RS232) XMIT (TXD) (RS232) Reserved DO NOT CONNECT Common TxD+ (RS485) TxD- (RS485) RxD+ (RS485) RxD- (RS485) C3: User I/O Connector Function 1 2 3 4 5 6 7 Analog Signal Shield Analog Differential Input + (Hig
Danaher Motion Kollmorgen Wiring C7: MultiDrop Communications Type: 10 Pin (0.1”x 0.1”) Female Ribbon Cable. Connector and cable are included in the optional CK100 kit. This connector functions only when using the R-S232 interface. It will NOT function using RS-485. 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.
SERVOSTAR® S and CD Series 6 7 8 9 13 12 11 10 9 8 7 6 5 4 3 2 1 14 15 16 17 18 19 20 21 22 23 24 25 9 8 7 6 C4 C3 C2 C1 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 12 13 5 4 3 2 1 FEEDBACK (D25P) CABLE LENGTH. BE USED IN LOW CURRENTENCODERS USING SHORT MINIMIZE VOLTAGE DROP IN CABLE.
Danaher Motion Kollmorgen Wiring Feedback Devices The SERVOSTAR can receive resolver, encoder (with or without halls), or sine encoder feedback. Danaher Motion Kollmorgen offers a variety of motors with options for these various feedback devices. The device preference and the associated model number must be determined when the order is placed. Resolver The SERVOSTAR uses either single (two poles) or multi-speed (multiple poles) resolver feedback to monitor the motor shaft position.
Danaher Motion Kollmorgen Wiring RESOLUTION AND ACCURACY The SERVOSTAR calculates motor velocity as the derivative of position (change in position over time). With its patented technique, all readings are extended to a resolution of 16-bit. For velocity feedback calculations, the drive converts the resolver input to 18-bits of resolution, giving smooth motor velocity control.
Danaher Motion Kollmorgen 3. Wiring Hall signals provide information representing the approximate absolute location of the motor shaft. From this information, the motor can sinusoidally commutate forward until the index signal is detected - at which time, true position is known. These signals are isolated by an opto-coupler and can be differential or open-collector type signals.
Danaher Motion Kollmorgen Wiring Sine Encoder The SERVOSTAR can receive an analog (or sine) encoder feedback device to monitor the motor shaft position. As opposed to a digital encoder, which generates incremental square-wave signals, a sine encoder outputs analog differential sinusoidal signals. These sine signals are quadrature-decoded and passed to an interpolation circuit that breaks each 360° cycle into 256 parts before passing it to the drive’s control board.
Danaher Motion Kollmorgen • Wiring Sine encoders with Endat capability add another approach to communicating commutation position. Here, absolute position information is stored in the encoder and is serially communicated to the drive upon power up. The data is received synchronously by a clock signal provided by the drive. Absolute position is known immediately; therefore, an index signal is not needed.
Danaher Motion Kollmorgen Wiring RESOLUTION AND ACCURACY Internal resolution of the system can be derived through the following calculation: Encoder line resolution x 256 x 4 (quadrature). System accuracy is largely dependent upon the accuracy of the encoder itself. To get an approximate total value, the customer need only look to the specifications listed for the encoder being used.
Danaher Motion Kollmorgen Wiring 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). It is then encoded to a quadrature signal before being exported out of the drive. The maximum frequency limit is 1.2 MHz. A frequency limiter (MSINFRQ) is provided with burst frequency fault protection.
Danaher Motion Kollmorgen Wiring 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 East Coast Sales Office West Coast Sales Office 844 E. Rockland Road 17 Sarah’s Way 6700 Fallbrook Ave.
Danaher Motion Kollmorgen System Communication SYSTEM COMMUNICATION You communicate with the SERVOSTAR 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. The SERVOSTAR comes with its own software interface called MOTIONLINK.
Danaher Motion Kollmorgen System Communication 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. You can verify this 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 System Communication RS-485 Connection The drive can also be configured for RS-485 differential connection through the same C1 connector. You only need to wire the 9-pin mating connector for RS485. No software or hardware changes are necessary. Setting the drive’s DIP address is identical to that described for the RS-232. When addressing multiple units, the drives must be daisy-chained across C1. You cannot daisy chain across the C7 connector in RS-485 configuration.
Danaher Motion Kollmorgen System Communication Drive Address Switch 5 Switch 4 Switch3 Switch 2 Switch 1 L 1 0 1 0 1 M 1 0 1 1 0 N 1 0 1 1 1 O 1 1 0 0 0 P 1 1 0 0 1 Q 1 1 0 1 0 R 1 1 0 1 1 S 1 1 1 0 0 T 1 1 1 0 1 U 1 1 1 1 0 V 1 1 1 1 1 ** Note: When the switch setting is set for binary 0, the drive assumes a single-line serial configuration.
Danaher Motion Kollmorgen System Communication MOTIONLINK Installation Installing on PC • Insert the SERVOSTAR PSP CD-ROM to load MOTIONLINK for Windows • The CD-ROM should AUTORUN. If not, select Start | Run (or browse your CD-ROM drive) • Type “D:AUTORUN.EXE” and hit the Enter key (this assumes your CD player has a D: letter designation). • Select a product and follow the instructions on the screen.
Danaher Motion Kollmorgen System Communication Should you de-activate this screen, it can be reactivated by going to the Main MOTIONLINK screen, pulling down the Configuration menu, and selecting the New Drive (123) option. Startup Wizard • 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.
Danaher Motion Kollmorgen System Communication If the motor cannot be found in the database, click on the User Define tab. Contact Danaher Motion Customer Support for detailed instructions. • • Customizing to Application: Click the “Opmode” button in the Startup screen to select the mode of loop control desired; position, velocity, or torque. Click Exit to return to the MOTIONLINK Start-Up Wizard.
Danaher Motion Kollmorgen System Communication • Setting Drive Variable Parameters: From the Configure menu, click the Drive option. The same screen appears as described in the Startup screen section. Click Exit to return to Main MOTIONLINK Screen. • Setting Motor Variable Parameters: selecting the Motor option under the Configure menu, you can obtain the same parameter screen found in the Startup screen. Click Exit to return to Main MOTIONLINK Screen.
Danaher Motion Kollmorgen System Communication Terminal Mode Use the MOTIONLINK Terminal Mode (or any other “dumb” host) to directly monitor or modify the variable set and command the drive. This approach should only be taken when a PC with a Windows operating system is not available or you are well-versed with the SERVOSTAR variable and command set. The VarCom Reference Guide contains the complete variable and command set.
Danaher Motion Kollmorgen System Communication • Saving Variable Parameters to .SSV file: At the prompt, type DUMP. The DUMP command causes the drive to output variables and their contents to the serial port in the format of a variable file (this includes the trailing CONFIG command). This variable file format is an ASCII file consisting of a series of variable assignment statements. The resulting transmission of data from the drive can then be saved with a .SSV extension.
Danaher Motion Kollmorgen System Communication Power-Up Sequence Upon powering up, the SERVOSTAR performs a series of self-tests. If the Status Display illuminates a solid number, no errors were found and the EEPROM has loaded its variable parameters (or loaded with 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.
Danaher Motion Kollmorgen System Communication If the drive will not enable, you can check the state of the switches and flags by clicking the “Status” button in the upper right-hand corner of the Main MOTIONLINK screen. If using a terminal, you can query the drive for the value stored in the STATUS variable (refer to VarCom Reference Guide for an explanation on STATUS parameters). The Status Display indicates an enabled drive when the decimal point is illuminated solid.
Danaher Motion Kollmorgen SERCOS Interface Setup SERCOS INTERFACE SETUP The SERVOSTAR S- and SERVOSTAR C-Series drives comes 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).
Danaher Motion Kollmorgen SERCOS Interface Setup 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 Cable Length Specifications Low Power Maximum Minimum 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 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 Kollmorgen offers 30, 60, and 100cm plastic fiber optic cables with SERCOS interface compatible F-SMA connectors.
Danaher Motion Kollmorgen SERCOS Interface Setup 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 SERCOS Interface Setup 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.
Danaher Motion Kollmorgen SERCOS Interface Setup The following formulas may be used to convert to and from the SERCOS interface units and rpm. Vel {RPM} = Vel {cnts/CUCT * 256} * 1875 / (8 * Cnts * CUCT) Vel {cnts/CUCT * 256} = Vel {RPM} * 8 * Cnts * CUCT / 1875 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.
Danaher Motion Kollmorgen 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. Status Display DISPLAY APPEARANCE DRIVE STATE Power-up Momentarily illuminates all display segments (forming an 8) and the decimal point. Displays the operational mode (OPMODE) of the drive (0-8).
Danaher Motion Kollmorgen System Operation 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 reconfigurd. Not all commands and variables are active or meaningful in every OPMODE. 1.
Danaher Motion Kollmorgen 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.
Danaher Motion Kollmorgen System Operation 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 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: 1. If RELAYMODE = 0, the relay is closed when the drive is error free and ready to run. This is a ‘Drive Ready’ configuration. 2.
Danaher Motion Kollmorgen System Operation 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. The flash memory firmware controls the core processor and gives the SERVOSTAR its operating characteristics saved in EPROM. The version number of the firmware is read using the VER command.
Danaher Motion Kollmorgen System Operation The SERVOSTAR uses a fully digital, pole placement current loop with high bandwidth and a current loop sampling rate of 16 kHz (62.5 µS.). All coefficients of the current loop are digitally calculated inside the drive for a given set of motor and drive characteristics. The current loop also includes adaptive gain terms to compensate for some non-linear effects. The current loop incorporates electrical isolation for protection from the highvoltage BUS.
Danaher Motion Kollmorgen System Operation POSITION LOOP The final control configuration is the position loop. The purpose of this loop is to maintain motor shaft position. Like the previous loops, the position loop is fully digital and uses resolver, encoder, and sine encoder feedback signals to determine actual motor position. The drive can also accept a position signal from an external feedback device (e.g., load encoder).
Danaher Motion Kollmorgen System Operation Torque Loop Operation The design of the control loops was discussed in the previous section. Now, the operation as a system is presented. The SERVOSTAR has many internal variables that are used to examine and dictate system operation. Many of these variables and their locations in MOTIONLINK are presented graphically in the following discussions to help disclose meanings and relationships.
Danaher Motion Kollmorgen System Operation 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 which adjust the signal (ANOFF, ANDB, ANZERO), filters it (ANLPFHZ) and then scales it (ISCALE), before developing the current command (ICMD).
Danaher Motion Kollmorgen 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 16kHz rate.
Danaher Motion Kollmorgen System Operation Foldback The SERVOSTAR offers two types of FoldBack protection for both the motor and the drive. The drive’s microprocessor monitors the current feedback signal and develops a RMS value of this signal for the purpose of providing a value that represents the current in the motor. The system is similar to an “I-squared-T accumulator.
Danaher Motion Kollmorgen System Description SYSTEM DESCRIPTION The SERVOSTAR S or SERVOSTAR CD 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 Kollmorgen’s vast product basket of motors and their assorted feedback devices.
Danaher Motion Kollmorgen System Description Velocity Control • Digital velocity loop control (Velocity Mode - OPMODE 0 or 1) receiving serial (J), analog (ANIN), or I/O triggered commands (MISPEED1, MISPEED2, MISPEED3, IN1, IN2, IN3, IN1MODE, IN2MODE, IN3MODE). • Velocity stepping and jogging capability (STEP, J). • Serial control through stored commands triggered through the Configurable I/O (IN1, IN2, IN3, IN1MODE, IN2MODE, IN3MODE).
Danaher Motion Kollmorgen System Description • Simple absolute and incremental indexing with I/O triggering capability (MAPOS, MASPEED, MIDIST0, MIDIST1, MIDIST2, MIDIST3, MISPEED0, MISPEED1, MISPEED2, and MISPEED3) through either the serial port or the hardware configurable inputs (IN1, IN2, IN3, IN1MODE, IN2MODE, IN3MODE).
Danaher Motion Kollmorgen System Description Motor Controllability • Provides linear and rotary motor control (MOTORTYPE, MPITCH, MENCRES) with automatic unit conversion. • Configurable back EMF characteristics for effective current loop controller design and command (MBEMF, MBEMFCOMP). • Danaher Motion Kollmorgen’s patented Torque Angle control to maximize motor output power (MTANGLC, MTANGLP, MVANGLF, MVANGLH). • Motor speed and current limits (MSPEED, MICONT, MIPEAK).
Danaher Motion Kollmorgen System Description ENCODERS • Maximum frequencies to 3 MHz before quad. • Up to 10 million counts per motor electrical cycle (MENCRES). • Configures automatically (ENCINIT, ENCINITST, ENCSTART, IENCSTART). • Index pulse offsetting capability (MENCOFF). • Variety of encoder types (MENCTYPE): 1. Encoder with or without index. 2. Encoder-hall effects with or without index (MHINVA, MHINVB, MHINVC, HALLS). SINE ENCODERS • 256x internal interpolation.
Danaher Motion Kollmorgen System Description • SERCOS interface communications port (SERCOS interface versions only). 1. 2-msec update rate. 2. Complete set of manufacturer’s IDNs. 3. MOTIONLINK communication through the serial port. • Encoder Equivalent Output signal (C4 connector) eliminates the need for an additional position feedback device. The maximum frequency of this output is 3 MHz for standard encoders and 1.2 MHz for sine encoders. 1.
Danaher Motion Kollmorgen System Description • A feedback device screen that provides realtime pictorial positioning information. It also includes a resolver zeroing routine and an encoder initialization folder. • A tuning screen designed to allow you to adjust control loop gains quickly while visibly watching the affects on performance. • A control loops screen that provides direct manipulation of velocity and position loop gain parameters.
Danaher Motion Kollmorgen System Description • 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. • Configurable motor thermal protection that accepts various thermostat types (THERM, THERMODE, THERMTYPE, THERMTIME). Configurable drive thermal protection through the fold-back feature (FOLD, FOLDMODE).
Danaher Motion Kollmorgen System Description 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. 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 • System Description The PA-LM unit is a logic supply only and should be used in multi-axis applications where the number of drives exceed the logic capabilities of the BUS Module. This unit comes with three green LED’s that verify the presence of the +15 V, -15 V, and 8 V sources. See the Bus Module Electrical Specifications for details on these features.
Danaher Motion Kollmorgen Troubleshooting TROUBLESHOOTING Technical papers and publications about the SERVOSTAR and its associated applications complete the information package necessary for you to become well versed with the product. Danaher Motion Kollmorgen’s engineering and technical resource staffs have prepared these notes. The PSP CD-ROM contains technical content stored in an electronic .PDF format.
Danaher Motion Kollmorgen Troubleshooting 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 Troubleshooting FATAL FAULT ERROR CODES Status Display Fault Message o P r0 Power stage OverTemp OverVoltage OverCurrent External feedback fault r1 r2 Resolver line break RDC error r3 Sine Encoder init fail r4 r5 r6 r7 r8 r9 r10 A/B line break Index line break Illegal halls C/D line break A/B out of range Burst pulse overflow Endat Communication Fault Under voltage Motor over temperature Positive analog supply fail Negative analog supply fail OverSpeed OverSpeed EEPROM f
Danaher Motion Kollmorgen Troubleshooting NON-FATAL ERROR CODES Error Message No Error Unknown Command Unknown Variable Checksum error Drive Active Drive Inactive Value out of range Negative Number Not in proper Opmode Syntax Error Tune Failed Bad Bandwidth Bad Stability Not programmable Current loop design failed MENCRES out of range MENCOFF out of range MSPEED out of range MBEMF out of range MJ out of range ACC out of range DEC out of range DECSTOP out of range VLIM out of range VOSPD out of range VSCAL
Danaher Motion Kollmorgen Troubleshooting Error Message 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 Initialization Process Active Tune failed-no rotation Tune failed-current sat Tune failed-no vel design Disable During Tune Hold During Tune Low Velocity Limits Use Lower Bandwidth Drive in Dual Feedback mode Drive is in Gear
Danaher Motion Kollmorgen Troubleshooting Error Message Possible Cause 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 Err # The command or variable requested is password protected and intended for factory use only A position capture occurred during homing A homing request was made during position capture The requested command can’t be processed due to pos
Danaher Motion Kollmorgen Troubleshooting 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. When a fault is detected, it is logged in the internal error log, indicated in the Status Display, enunciated over the serial port, and in most conditions causes a drive disable.
Danaher Motion Kollmorgen 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 an ‘u’ in the status display.
Danaher Motion Kollmorgen Troubleshooting • Memory reliability: During the initialization process upon power up, the run time, variables memory (RAM - Random Access Memory), and the program memory (EPROM - Electrically Programmable Read Only Memory) are tested. If a RAM fault is detected, an ‘I’ is displayed and the drive is halted. If an EPROM fault is detected, a ‘c’ is displayed and the drive is halted. The non-volatile memory (EEPROM) is also checked for integrity upon power-up.
Danaher Motion Kollmorgen Troubleshooting Firmware Upgrades From time to time, Danaher Motion Kollmorgen adds features to its products that expand their overall capabilities. Features added to the SERVOSTAR can be easily implemented at the customer’s site. This is accomplished by downloading new firmware via the drive’s serial port directly from a host computer. The customer ordering a firmware upgrade receives a file labeled “UPGRADE.EXE”.
Danaher Motion Kollmorgen Appendix A APPENDIX A Motor Pinouts The SERVOSTAR S and SERVOSTAR CD product families can be mated with a variety of motors. Cable sets (motor and feedback) can be purchased directly from Danaher Motion Kollmorgen; which gives you a complete plug-nplay system. However, you may find it necessary to manufacture your own cable sets.
Danaher Motion Kollmorgen Appendix A SR/CR RESOLVER Connection SERVOSTAR GOLDLINE B, M, EB, XT C2 B/M/EB XT 50X & 70X XT 30X 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 ) Pin A Pin B Pin A Pin B Pin 3 Pin 7 Wire Color (from resolver to motor receptacle) Black Red Pin D Pin C Pin D Pin C Pin 8 Pin 4 Yellow Blue Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin Pin F E T U SERVOSTAR 5 9 2 6 DDR C2 Resolver Connector Pin
Danaher Motion Kollmorgen Appendix A SE/CE Encoder Connection SERVOSTAR GOLDLINE B, M, EB & XT C2 Encoder Receptacle Pin 1 Pin 2 Pin 3 (shield) Pin 4 Pin 5 Pin 6 (Shield ) Pin 7 & 8 Pin 9 Pin 10 Pin 11 Pin 12 (Shield ) Pin 13 Pin 14 (Shield ) Pin 15 Pin 16 Pin 18,19 & 20 Pin 22 Pin 23 Pin 24 Pin 25 B, M, EB Series XT Series MS threaded MS Threaded Pin A Pin A Pin M Pin M Wire Color (at Motor Receptacle) XT Series Euro Style Pin 1 Pin 2 Blue Blue / Black Pin B Pin C Pin B Pin C Pin 3 Pin 4 Green
Danaher Motion Kollmorgen SERVOSTAR C2 Pin 1 Pin 2 Pin 3 (shield) Pin 4 Pin 5 Pin 6 (Shield ) Pin 7 & 8 Pin 9 Pin 10 Pin 11 Pin 12 (Shield ) Pin 13 Pin 14 (Shield ) Pin 15 Pin 16 Pin 18,19 & 20 Pin 22 Pin 23 Pin 24 Pin 25 Appendix A RBE(H) SILVERLINE 0802 Encoder Receptacle Pin 3 Pin 6 0802 Wire Color Blue Blue / Black Encoder Receptacle Pin 6 Pin 5 Pin 4 Pin 7 Green Green / Black Pin 8 pin 7 Pin 10 Pin 12 Pin 13 Pin 14 Red Brown Gray White Pin 2 Pin 1 Yellow Pin 5 Pin 8 Pin 9 ( see note 1 )
Danaher Motion Kollmorgen Appendix A PLATINUM XT Motor Connection When running the SERVOSTAR amplifier with a PLATINUM XT brushless motor, additional inductance is required between the amplifier and motor. Danaher Motion Kollmorgen offers the IP-10/30 inductor module rated at 900 µH.
Danaher Motion Kollmorgen Appendix A System Connection Diagram ® ® SERVOSTAR S and SERVOSTAR CD Series 102
Danaher Motion Kollmorgen Appendix B APPENDIX B Programmable Positioning Configurable Inputs trigger a higher level of programming capability than the SERVOSTAR S and SERVOSTAR CD-Series can offer through its buffer memory. Designed to be a compact and low cost solution, the BJP and SERVOSTAR system provides full programmable servo performance for many single and multi-axis applications. This Appendix provides system wiring diagrams to specifically interface with the SERVOSTAR system.
Danaher Motion Kollmorgen Appendix B Verify that the SERVOSTAR motor direction variable (DIR) is set to zero. Otherwise, the motor runs away when controlled by the BJP.
Danaher Motion Kollmorgen Appendix B The BJP uses a slightly different interface called "MOTIONLINK Plus." Install this package from the PSP CD-ROM. Once proper connection is completed and communication is established through the BJP, refer to the User’s Manual for programming instructions. The figure below shows the external interface to the BJP. Reference the User's Manual for detail explanations.
Danaher Motion Kollmorgen ® Appendix B ® SERVOSTAR S and SERVOSTAR CD Series 106
Danaher Motion Kollmorgen Appendix C APPENDIX C 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.
Danaher Motion Kollmorgen Appendix C 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 Appendix C 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 Cphase 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.
Danaher Motion Kollmorgen Appendix C Since encoders are incremental devices, a loss or gain of a pulse creates system errors. Electrical noise is the single biggest factor in miss-counts. Transmitting the signals differentially provides the largest margin of noise rejection and the best signal fidelity. The SERVOSTAR is designed to receive only differential signals. Some "less expensive" encoders provide TTL or "Open Collector" signals. These are not compatible with the SERVOSTAR.
Danaher Motion Kollmorgen Appendix C MENCTYPE 0 Read Hall Codes Establish Commutation Angle as though in the middle No Yes Marker Channel Occur? Hall Code Change? Adjust Commutation Angle No Marker Channel Occur? Yes Establish new Commutation using MENCOFF End ® ® SERVOSTAR S and SERVOSTAR CD Series 111
Danaher Motion Kollmorgen Appendix C 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.
Danaher Motion Kollmorgen Appendix C MENCTYPE 0 Incremental with A/B/I and Hall Channels MENCTYPE 0 is the most robust encoder system. The drive expects the signals as feedback from the motor. The hall channels is synthesized either in the encoder or discrete devices (Hall sensors) integrated in the motor windings. On power-up, the hall effect channels are read and a code is sent to the microprocessor to give it a coarse position for the motor.
Danaher Motion Kollmorgen Appendix C MENCTYPE 2 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 MENCTYPE 3 and 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 Appendix C MENCTYPE 4 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 Appendix C 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.
Danaher Motion Kollmorgen Appendix C MENCTYPE 1 and MENCTYPE 2 (A/B/I without Halls) require the marker to be aligned to the motor's BEMF waveform. Danaher Motion Kollmorgen has not defined any particular alignment standard. Defining your own alignment standard could be beneficial. MENCTYPE 3 and MENCTYPE 4 (A/B only) require no alignment or adjustments. MENCTYPE 6 (A/B/I with Halls) requires the same alignment as MENCTYPE 0 but does not require that MENCOFF be set.
Danaher Motion Kollmorgen Appendix C 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. This diagram 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. Linear motors, with armature moving away from leads.
Danaher Motion Kollmorgen Appendix C Troubleshooting Several problems can occur with encoder-based systems. The most common problem is miswiring. The section on system phasing (above), 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 Appendix C Design Considerations The SERVOSTAR has a maximum frequency input for incremental encoders of 2.5 MHz. This cannot be exceeded under any circumstance. Encoders consume 5 V. The 5 V is typically regulated inside the drive through a cable to the encoder. Tolerances on the 5 V must be considered for IR loss within the cable.
Danaher Motion Kollmorgen Appendix C MHINVB - Invert the active level of Hall channel B. MHINVC - Invert the active level of Hall channel C. MPHASE – Allows commutation offset. Example This procedure is for commutation only and assumes analog (OPMODE 3)operation. 1) Define a Positive Motor Direction This is somewhat arbitrary, but must be consistent. To keep confusion to a minimum, try to match the motor's definition of A+/A- and B+/Bto the CD definitions for purposes of hardware connections.
Danaher Motion Kollmorgen Appendix C 4) Determine the Correct Hall Phase Sequence Connect the Halls to the CD, leaving other inputs/outputs disconnected or disabled. Push the motor by hand in the positive motor direction. Use the HALLS command to verify that the sequence is 001, 011, 010, 110, 100, 101. Re-arrange the Hall sensor leads until you find the combination that yields the proper binary counting sequence while moving the motor in the positive motor direction.
Danaher Motion Kollmorgen Appendix D APPENDIX D Resistive Regeneration Sizing 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.
Danaher Motion Kollmorgen Appendix D Energy Calculations To determine if a system needs a regeneration resistor, use the following procedure: EQUATION 1 Define the term EM which is the kinetic energy of the motor/load minus the system losses. EM = (1.356/2)(JM + JL) ω M2 – 3I2M (RM/2)td – (1.356/2)TF ω Mtd Joules Where: JM = rotor inertia (lb – ft – sec2) JL = load inertia (lb – ft – sec2) RPM ωM = motor speed before decel (rad/sec) = 9.
Danaher Motion Kollmorgen Appendix D DETERMINING RESISTANCE VALUE The maximum allowable resistance of the regen resistor is that value which will hold the BUS under its maximum value when the regen circuit is initially switched on.
Danaher Motion Kollmorgen Appendix D When the time between decelerations becomes very large, Equation 5 become very small. In cases such as these, the average wattage is not a meaningful number. Peak wattage and the time which the resistor will see peak wattage become the main concerns.
Danaher Motion Kollmorgen Appendix E APPENDIX E Series 5 UCB2 Digital Control Board The SERVOSTAR® servo amplifiers incorporate a number of additional features in the Series 5 model. The addition of these features is possible due to an upgrade to the UCB2 digital control board. Part Number CD Series 5 Part Number Guide Cx zz 5yw Feedback E: Encoder B: Sine Encoder R: Resolver Cont. Current 03: 3Amp 06: 6Amp 10: 10Amp Logic Power 5: 300V 6: Ext.
Danaher Motion Kollmorgen Appendix E Summary of New Features Feature Sine encoder Sine encoder calibration Stegmann Hiperface SERCOS Support for CD600 Encoder simulation Encoder initialization Software Resolver Extended I/O Description Sine encoder feedback is supported on the main control board. Interpolation level is set up to 4096 (MSININT). Sine encoder signals are calibrated in order to increase the accuracy of the interpolation (SININIT). Support Hiperface (Stegmann) interface. MENCTYPE=10.
Danaher Motion Kollmorgen Appendix E On power up, since the absolute motor position is unknown, two methods may be implemented: • Applying a forced commutation to move the motor to a predetermined position where the torque generated is zero and updating controller variables accordingly. • Using a motion control algorithm that brings the commutation angle of the motor from the initial, unknown position to the current motor position (instead of moving the motor).
Danaher Motion Kollmorgen Appendix E Sine/Cosine Calibration The software Sine Encoder and software resolver algorithms are based on sampling the incoming sine and cosine signals. The accuracy of the process depends on the sampling accuracy of the sine and cosine values. In order to prevent accuracy degradation due to electronic component tolerances, the sine and cosine values must be gain- and offset-compensated. The process of finding the gain and offset compensation parameters is called “Sine Zero”.
SERVOSTAR® S and CD Series L3 (SEE NOTE 2) L2 L1 (SEE NOTE 1) FUSE 3 FUSE 2 FUSE 1 SHIELD TO STAR POINT THE SERVOSTAR CD OPERA TES WITH VOL TAGES AS HIGH AS 230 VAC AND 400 VDC. USE CAUTION. REFER INSTALLATION AND TROUBLESHOOTING TO QUALIFIED PERSONNEL ONLY. + Front of Drive STAR POINT MOTOR POWER HEAT SINK 1 10 HIGH VOLTAGE MAY EXIST UP TO 5 MINUTES AFTER INPUT VOLTAGE IS REMOVED.
Danaher Motion Kollmorgen Appendix E Top View C7 C8 C9 1 10 24 VDC Input Connector Pin-Out Pin No.
Danaher Motion Kollmorgen Appendix E Sine Encoder Feedback C2 Feedback connector Calibration SININIT SININITST SINPARAM Application: MENCRES = ECR, # of sin per one rev MSININT (interpolation level ) 1, 2, 4, 8, 16, 32, 64,128,256 ,512,1024,2048,4096 SIN- C2 pin 2 SIN+ C2 pin 1 Drive 1Vpp@2.
Danaher Motion Kollmorgen Appendix E Resolver Feedback Resolver Requirment and specification Can use single(two poles) or multi-speed(multiple poles) resolver feedback to monitor the motor shaft Type: Control transmitter Transformation Ratio: approx.0.5±0.1 Modulation Frequency: approx. 8 kHz Input voltage (from drive): 6.
Danaher Motion Kollmorgen Appendix E Software Resolver Interface The resolver-to-digital (RDC) conversion is accomplished in the Series 5 products using software techniques, as opposed to using a dedicated integrated circuit. The benefits of this mechanism include: § Enhanced system performance because the resolution is not a function of the velocity. § Increased accuracy due to the ability to calibrate and match the Sine and Cosine signals. § Increased reliability due to the use of fewer components.
Danaher Motion Kollmorgen Appendix E For information on the new commands, refer to the SERVOSTAR® S and SERVOSTAR® CD VarCom Reference Manual.
