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S200 - MEI`s Technical Support

1. Danaher Motion Kollmorgen 03 2006 Mounting the Drive 5 2 3 SynqNet AC Drive a i Co aa CD gt D ce co CD e CD p 13157 457 RECOMMENDED MOUNTING Qj 018 HARDWARE 8 or M4 457 EIS JEMEN e e 101 25 56 2146 Gag 5475 432 i 1 n Li B P t T E 6 89 H dm 17501 6 55 166 37 m UUUUUUUUUSGOQGQUUUNU F pc Oc 3 FEU 4 q 1 XH IS RIGHT SDEVIEW REARVIEW oly 432 DIMENSIONS ARE IN INCHES MM 5200 Reference Manual M SM 200 01 27 Mounting the Drive 03 2006 Danaher Motion Kollmorgen 5 2 4 SynqNet DC Drive Hi
2. Unless otherwise specified the specifications worse case limits and apply over the specified operating ambient temperature and NOTE over the specified operating line voltage 3 1 DRIVE FAMILY POWER AC Input DC Input 520260 520360 520660 520330 520630 Peak Output Current RMS 0 to 40 C Amb 4 5 9 0 18 0 9 0 18 0 ARMS Minimum Peak Current Time Starting from 0 amps sec 3 0 3 0 3 0 i 3 0 3 0 Continuous Output Current Convection 0 to 30 C amb ARMS 2 3 4 5 9 0 4 5 7 5 40 C amb ARMS 1 5 3 0 6 0 3 0 6 0 50 C amb ARMS 1 0 2 0 4 0 2 0 4 0 Peak Output Power 240 VAC VA 3 Phase 1500 3000 6000 120 VAC VA 1 750 1500 2400 Phase 75 VDC VA 750 1500 Drive Continuous Output Power 600 1100 2000 watts 240 1 Phase 500 900 1500 _ _ watts 120 1 Phase 250 450 _ i _ _ watts 75 VDC watts 250 500 Continuous Motor Shaft Power 323000 RPM Nominal Bus 10 0 to 30 C amb watts 300 750 1500 180 315 40 C amb watts 200 500 1000 125 250 RMS Line Current at Continuous Output Power 240 VAC 3 Phase ARMS 2 7 5 0 9 0 240 VAC 1 Phase 4 3 ARMS 3 4 6 5 12 0 120 VAC 1 Phase a ARMS 3 4 6 5 12 0 BUS Current 75 VDC at Continuous Output Power Average 3 0 6 7 Instantaneous Peak _ _ 127 255 Power Diss 4
3. 1 01 25 56 _ 0 18 4 45 H in d VS i MOOAR AAR 6 90 55 UUU U 175 28 166 37 UUUUUUUUUOGQGUUUSU T zB 4 69 Em FRONT VIEW RIGHT SIDE VIEW REAR VIEW DIMENSIONS ARE IN INCHES MM 5200 Reference Manual M SM 200 01 25 Mounting the Drive 03 2006 Danaher Motion Kollmorgen 5 2 2 Base DC Drive TE 018 4 57 RECOMMENDED MOUNTING HARDWARE 48 OR M4 00 18 64 57 A 0 97 24 64 _ 016 28 70 4 06 i S e F a 500 5 68 152 40 144 27 LH 0 16 4 06 e Er DE FRONT V RIGHT SIDE VIEW REAR VIEW DIMENSIONS IN INCHES MM 26 M SM 200 01 5200 Reference Manual
4. dnjes AN gq MER jueun2 Oe qeljBA xxxx JON 3 oes pey peunseeJN yoeqpee J Y y PIOH 95 4 EM NEL IAM snui JoyeJ6eju doo Y aiso pi PWD a Qa ssed n 310d TE enbJo A A A JON JON snigiurii apowdo 04 gt GUISH oJgpulo f f LL vr du open eyes 4 pui euy Sc vf TENEO Md 810d Z plug euy MO 7 uogsog PUOISA A BOIEUY Vc vr 2 5 71 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Advanced Configuration POSITION CONTROL DIAGRAM 8 2 dmes AN e qeueA XXXX yoeqpeeJ peunsee N yoeqpes uonisog uonisod lt MO Bea QF Ayooja Y 78699 JON 19N
5. Recommended Fusing Line S20260 20360 S20660 Inputs Type 250 VAC Time Delay Fuse 240 VAC 3 Phase ARMS Bussmann Bussmann Bussmann MDA 5 MDA 8 MDA 15 240 VAC 1 Phase ARMS Bussmann Bussmann Bussmann MDA 5 MDA 10 MDA 20 120 VAC 1 Phase ARMS Bussmann Bussmann Bussmann MDA 5 MDA 10 MDA 20 32 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen Wiring the Drive 03 2006 DC INPUT DRIVE WIRING Danaher Motion Kollmorgen 6 3 9 8 m gt eu 1947260 2 amon QNO THLO SN NLY P zou Sf tw BuuiM jddng 9 FNINO zg e SC aio lt pode snar 5 ve ano mesure AE JaMOd 01 U0J TaLO val e NI 8 H LNO 8 gt lt gt 5 lZ NISH2 1n0 E 06 02 __ 5 02 Niv H3 100 UIEN rri 6l ur vRo7IROvHo gt lt 2 8 Ino zuo gt THIO Wr V 1n0ZH5 gt Ee eI St ranra gt YOLOW A v ZNOW 2va _ gt ____ 5 NINO EE i a 9 ck a lt M3SVHd E s PU ranis lt er Musso E 6 INMd d3 LS LdNISH Ted z1nod D pS dL dL IMAA 77
6. Parameter Value CommMode SetupS2 2 Default value with switch S2 2 set to the up position labeled 6 on the drive or 6 Step CommOff 0 Degrees Default value OpMode SetupS2 1 Default value with switch S2 1 set to the down position labeled I on the drive or Torque Current KIP Set directly with the serial port when S1 is set to position 0 or Set S1 to the appropriate position for the inductance of the motor be used refer to Configuring Current Mode with 6 Step Hall Feedback I2TFO Set to the motor s thermal time constant 2 Set the motor s continuous current rating ILmtPlus Set to the lower of 100 or the percent of the motor s peak ILmtMinus current rating divided by the drives peak current 5 Sets the source of the command analog or command variable CmdGain Sets the command gain for the command input CmdOffset Sets the command offset for the command input CmdF0 Sets the filtering on analog input commands Sa aC CUE Enables the hardware over travel limits 64 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Basic Configuration 7 4 1 4 1 A CAUTION CONFIGURING WITH SFD FEEDBACK Motor Parameters When the drive is powered up and connected to a motor with SFD feedback the drive will automatically configure itself for the attached motor by loading the default motor parameters The default motor p
7. ca CTD X gt gt CJ cy aq ca 3 97 100 84 0418 457 qeu pm FECOMMENDED MOUNTING 0 18 HARDWARE 8 or M4 o TOPVIEW I 0 97 _ 190 _ 2464 4826 ode 4 06 i VIE Tr L HO Q olo H E 600 568 2 E 15240 14427 d N E Nu M 1 ode FRONT VIEW RIGHT SDE VIEW REARVIEW 406 DIMENSIONS ARE IN INCHES MM 28 M SM 200 01 5200 Reference Manual Wiring the Drive lt 03 2006 DANGEROUS voltages are present on power input and motor output terminals AC INPUT DRIVE WIRING READ these instructions before connecting power Damage can result from MISWIRING at the power terminals WIRING THE DRIVE WARNING Danaher Motion Kollmorgen 6 6 1 ejqeo pue peulquuoo e sJejjo os e sejqeo 10 S 9 x Buipjeius 2 pue z S ejep eoepiejui 2e 104 xipueddy u huson ees 1e qnop JeBejo QSXxzS 104 gt e S JON riz J fon 6 ZH 9 p TWULNAN OVA 0210 V1 t OVA 021 0 E OVA 021709 Z1 92 r1 ovz 61 sz it Qo VNY IVANU vaman c ova marozo
8. Capacitance Requirements 3 9 ARMS DC S200 6 18 ARMS DC S200 2 000 uf drive at 75 V bus 4 000 uf drive at 75 V bus 4 000 uf drive at 48 V bus 8 000 yf drive at 48 V bus 16 000 pf drive at 24 V bus 32 000 uf drive at 24 V bus This can be the output capacitor of an unregulated power supply or a capacitor in parallel with the output of a regulated supply In most cases this capacitor does not need to be close to the drive so a single capacitor can be shared by multiple drives This capacitor does several jobs 1 Bus capacitance absorbs net regenerated mechanical energy from the inertia when the motor decelerates If the bus capacitance is sufficient regeneration causes a controlled limited rise in bus voltage and the over voltage fault is not tripped If the regenerated mechanical energy is high additional bus capacitors can be added in parallel The bus capacitance can be increased almost without limit The over voltage fault is a non latching fault that turns off the inverter transistors when the bus voltage is above the over voltage threshold An over voltage fault trip interrupts the regeneration of mechanical energy back to the bus This limits the bus voltage rise and protects the drive However it interrupts motor torque so the machine cycle is affected In most cases it is undesirable to allow the bus voltage to pump up to the over voltage fault threshold In many applications much or all of
9. tege eue ep EAE 118 E 2 3 Declaration of Conformity sse eene 119 E 3 Installation and 5 121 4 Safety 5 121 5 European Compliance resinte rt aut e p Hd e gt peer vane ced 121 E 6 Low Voltage Directive and EN50178 seen nnns 122 E 7 UL sand cUL Conformance 2 ui ee E rer tee rie 123 E 8 Additional Safety Precautions essent 124 E 9 EMC Compliance with EN61 800 3 125 10 AC Mains Conducted 5 5 125 E11 Regen ResistOr iiiter rit e iere e done o o pt thee ee o aee 126 E 12 Additional EMC Information eene nnne nnns 126 E13 Customer Support ie eoe tede e oe dere ee obe e edere aeu 126 iv M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 S200 Series Drives 1 5200 SERIES DRIVES Industry Leading Performance In A Small Package Danaher Motion s Kollmorgen 5200 brushless servo drives puts high performance servo technology into lower power applications than was previously possible without having to compromise on reliability or package size Coupling an S200 drive with Danaher Motion s AKM servomotor provides a complete servo control solution designed to excel in applicatio
10. 29 6 2 JT AG Input Drive POWER sssr ertoe rte e RR Ege E ge AD RE ee 30 6 3 DC Input Drive Wiring irr eer e eki EEU E 33 6 4 J1T DC Input Drive Power ete ran epo e re Ape FER deed 34 6 4 1 DC Power Supply Requirements esee nee 35 6 4 2 Bus Voltage ee Hio itte igit repete ip e e 36 6 4 8 Control Voltage siii oneri nee eed eerte dre eee 36 6 4 4 Grounding is eee ein Rte iene eee 37 6 4 5 Bus Capacitance ced ge coe ei dee s 37 6 4 6 Bus Switching and FUSING seeeeee emm een 37 6 5 2 Motor Power Connector sese eene nnne nnn enne 38 6 6 J3 Feedback Connector oie PUE Red 39 6 7 J4 Command l O Connector 4 desee dne eade ndun 40 6 7 1 General Purpose Inputs ere n i 40 6 7 2 General Purpose Outputs Prid nee 44 6 7 3 Speed irent pr terere peine aote 46 6224 SED S 47 6 55 DAG Monllors eruere reet mtt dre trn erbe Re dnas 48 6 7 6 Encoder Outputs Inputs sssssseeeeeene enm enne 48 6 7 7 Analog Command Input sssseseeeeeeeene enne enne 50 6 8 J5 Port Conneclor todo e a ee t e ruis 51 6 8 2 Serial Interface 52 6 8 3 5 232
11. Pin Meaning Description ON Repeater on network cyclic Repeater BLINK Repeater on network not cyclic OFF Repeater off power off or reset _ Link Active LNK Link Activity OFF Link Inactive 5200 Reference Manual M SM 200 01 55 Wiring the Drive 03 2006 Danaher Motion Kollmorgen 6 12 J13 DISCRETE l O CONNECTOR J13 is a Standard D Sub 15 pin Male 10 woe 11 connector 10 e eo6 5 ee 1 J13 Connector view from front of drive Pin Description J13 1 OINP COM J13 2 OINP1 HOME IN J13 3 OINP2 POSLIMIT IN J13 4 OINP3 NEGLIMIT IN J13 5 OINP4 NODE DISABLE J13 6 GP RS422 IN3 J13 7 GP RS422 IN3 J13 8 OOUT1 J13 9 OOUT1 J13 10 VO J13 11 VO J13 12 GP RS422 INO J13 13 GP RS422 INO J13 14 GP RS422 IN1 J13 15 GP RS422 IN1 Mating Connector Information 15 Pin Female High Density D Sub NorComp 180 015 202 001 Female D Sub connector solder NorComp 978 009 020 121 Metalized plastic back shell kit Refer to www norcomp net 56 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Wiring the Drive 6 13 J14 AUX FB CONNECTOR J14 is a Standard D Sub 15 pin Female 100000 connector 600000 10 100000 5J J14 Connector view from front of drive Pin Description J14 1 AUX CU J14 2 AUX CV CLOCK J14 3 AUX CV CL
12. 5200 Reference Manual M SM 200 01 45 Wiring the Drive 03 2006 Danaher Motion Kollmorgen 6 7 3 bib NOTE The voltage of the external power source needs to be 30 VDC or less and can be the same source used to provide power to the inputs A clamp diode must be added across the coil to clamp the voltage during turn off High Speed Input High Speed The S200 has one high speed input for use with PWM Input input commands or with Step Input in Position Mode J4 10 11 Step or PWM J4 11 HSINP1 9 The high speed input works directly with 5 V input 3 0 to 6 0 V range without the use of a current limiting resistor To operate the input with voltages higher than 5 V an external current limiting resistor is required in series with the input The input current should be in the range of 9 to 24 mA for proper operation The following table lists the recommended current limiting resistors for supply voltages greater than 5 V In Step Dir Position Mode the transition edge from LED current to no LED current yields a step count The transition edge from no LED current to LED current yields no action Maximum step frequency is 1 5 MHz Minimum pulse width is 250 ns For single ended operation it is recommended that both wires J4 10 and J4 11 run in the cable be terminated at the control source differential noise High Speed A differential drive is recommended for the Step Input To Input provide maximum noise immuni
13. 102 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Appendix A Power Supply Design APPENDIX A POWER SUPPLY DESIGN A 1 A 1 1 DESIGN This section has additional considerations for DC power supplies Single Power Supply Operation A single power supply can be used to provide main or motor power and control power for the DC power input The voltage range of a single supply is 20 V to 90 V The drive can be damaged if the supply voltage exceeds 90 V even briefly The DC level plus transients plus regenerative pump up MUST NEVER exceed 90 V Wire the single supply terminal to J1 3 Bus and to J1 1 CTRL and the power supply terminal to J1 2 Bus Ctrl Gnd This power supply is typically unregulated but a regulated supply can also be used The power supply outputs must be isolated from the power line See Regulatory Information for more details on isolation requirements Wire both the power supply negative terminal and the drive chassis to earth for safety The maximum continuous and peak 3 sec main power and current at 75 V bus for the 5200 DC drives is shown in the table below 3 9 ARMS S200 DC 6 18 ARMS S200 DC Main continuous 250 watts 500 watts 3 33 ADC at 75 V 6 67 ADC at 75 V Main Peak 3 sec 750 watt 1 500 watt 10 ADC at 75 V 20 ADC at 75 V The next figures provide representative connection diagrams and some detai
14. HEB m m L1noa ais EE B NI gt lt gt LdNISW WO9 835 9 a LIGIHNI lt lt NIN St ads LISIHNI 2 S TIVH leg er or ASE UIS k 435 33 M SM 200 01 5200 Reference Manual Wiring the Drive 03 2006 Danaher Motion Kollmorgen 6 4 A CAUTION J1 DC INPUT DRIVE POWER The S200 DC input drives should be powered from power supplies with reinforced isolation On DC input drives J1 is a 3 pin pluggable connector Pin Description O J1 1 CTRL J1 2 BUS CTRL GND J1 Connector view 0133 BUS from front of drive To avoid damage to the connector and drive NEVER plug or unplug J1 with power applied Mating Connector Information Screw Terminal Connector 12 24 AWG Wire Range Phoenix MSTB2 5 3 STF 5 08 BK OR Spring Cage Clamp Connector 12 24 AWG Wire Range Phoenix FKC 2 5 3 SFT 5 08 BK OR Crimp Connector Crimp Shell 14 20 AWG Wire Range Phoenix MSTBC 2 5 3 STZF 5 08 BK Crimp Contact 14 16 AWG Wire Range Phoenix MSTBC MT 1 5 2 5 Crimp Contact 18 20 AWG Wire Range Phoenix MSTBC MT 0 5 1 0 Refer to www phoenixcon com J1 1 Control power input The DC drive accepts 10 to 90 VDC CTRL on this input referenced to J1 2 An isolated regulated or isolated unregulated power supply can
15. 14 5200 Reference Manual M SM 200 01 Table of Contents 03 2006 Danaher Motion Kollmorgen 4 1 3 5200 Tools Communications Wizard seeee e 15 4 1 4 Motor Feedback Configuration seem 17 4 1 5 SAVE Option veri oie veta epit eta Eee aep eed 17 4 2 5200 SynqNet Drive teer teret ee 17 4 2 1 and SynqNet Controller Installation 17 4 2 2 5200 Tools Software Installation ne 18 4 2 3 Hardware Setup i iro rte OR secte c etit Sete re einn 18 4 2 4 5200 Tools Communication Wizard 19 4 2 5 SynqNet Configuration ier 21 4 2 6 Motor Feedback Configuration 21 4 2 Save e UR nin 22 5 Mounting the Drive i ttum cede aaah heen 23 5 1 Mounting Dimensions o tappa 23 5 2 Mechanical Outline Drawings nnns 25 5 2 1 AG Drive 25 522 Base DG Drive eene ERR Reip 26 5 2 3 trt terrm DIE ep t ete Re 27 5 2 4 SynqNet DG Drive ehh HERE IR RE 28 6 Wiring the Drive iiie iie reme io 29 6 1 AC Input Drive Wiring pi Re
16. CAUTION 12 13 REGEN RESISTOR Regen Wiring AC drives For complete instructions pertaining to an external regen resistor with an AC input drive refer to Base AC Drive Wiring In addition to the information in that section users installing drives for use in a CE installation should use an appropriately grounded shielded regen cable to reduce overall system emissions Accessible Regen Cables When using an external regen resistor if regen cabling is accessible during normal machine operation the cable should be a shielded cable rated at 450 VDC with the shield connected to PE High Frequency Grounding of Regen Cable Shield When using a regen resistor in a CE installation the cable should be appropriately rated and have a braided shield connected to PE for safety and clamped to the ground plane with a 360 clamp for EMC purposes ADDITIONAL EMC INFORMATION SOURCES Additional information on EMC performance and noise reduction techniques can be found on the Danaher Motion website www DanaherMotion com Kollmorgen Application Note EMI Noise Checklist Pacific Scientific Application Note 106 Reducing Motor Drive Line Noise Pacific Scientific Application Note 107 Reducing Motor Drive Radiated Emissions CUSTOMER SUPPORT Danaher Motion products are available world wide through an extensive authorized distributor network These distributors offer literature technical assistance and a wide rang
17. factory factory factory factory factory default default default default default 96 932 48 416 24 208 12 104 6 052 0 6 17 9 03 3 09 4 50 1 55 2 25 0 52 0 75 0 27 0 38 1 9 04 13 39 4 51 6 69 2 26 3 34 0 76 1 11 0 39 0 56 2 13 40 19 56 6 70 9 78 3 35 4 89 1 12 1 63 0 57 0 81 3 19 57 9 79 28 89 14 44 4 90 7 22 1 64 2 41 0 82 1 20 4 28 90 14 45 7 23 43 34 21 67 10 83 2 42 3 61 1 21 1 80 5 43 35 21 68 10 84 63 80 31 90 15 95 3 62 5 32 1 81 2 65 6 63 81 31 91 15 96 95 11 47 55 23 76 5 33 7 92 2 66 3 96 7 95 12 47 56 23 77 7 93 144 49 72 24 36 12 12 04 3 97 6 02 8 144 50 72 25 36 13 12 05 216 74 108 4 54 20 18 06 6 03 9 03 9 151 position 0 allows setting the non volatile KIP via the serial port to any valid value in 6 Step mode The value written will replace the default value listed in position 0 of the table 511 512 Rotary SynqNet ID Switches SYNQNET ID M e A 2 gt S12MSB S11LSB The SynqNet ID switches can be used to help distinguish and differentiate a drive on the network by assigning a unique ID to the drive To set a SynqNet ID to an S200 drive turn the 511 LSB Least Significant Bit and 512 MSB Most Significant Bit switches to a desired letter number combination The SynqNet ID can then be read using the following utilities Motion Console and Version exe Utility
18. 20630 CNS 200 90 VDC 6 18 ARMS Base Unit CAN Indexer option card 20330 SRS 200 90 VDC 3 9 ARMS Base Unit SynqNet option card with RJ 45 connectors 20630 SRS 200 90 VDC 6 18 ARMS Base Unit SynqNet option card with RJ 45 connectors 20330 SDS 200 90 VDC 3 9 ARMS SynqNet with Micro D connectors 20630 SDS S200 90 VDC 6 18 ARMS SynqNet with Micro D connectors 5200 Reference Manual M SM 200 01 3 Before You Begin 03 2006 Danaher Motion Kollmorgen 2 BEFORE YOU BEGIN 2 1 SAFETY READ these instructions before connecting power Damage can result from MISWIRING at the power terminals WARNING DANGEROUS voltages are present on power input and motor output terminals Only qualified personnel are permitted to transport assemble commission and maintain 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 Read all available documentation before assembling and using Incorrect handling of products described in this manual can result in injury and damage to people and or machinery Strictly adhere to the technical information regarding installation requirements e Keep all covers and cabinet doors shut during operation Be aware that during operation the product has electrically charged components and hot surfaces Control and power cables can carry a
19. It also lowers the cost of the supply by reducing its silicon current In addition it also absorbs regenerated energy with a limited pump up of voltage and stabilizes the bus voltage for better dynamics While the maximum peak to continuous power capability is 3 1 most applications have much higher ratios The requirement that the main supply have a high peak to continuous power ratio is very important in selecting or designing the power supply 104 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Appendix A Power Supply Design A 1 2 gt gt Main Supply Output Capacitance J1 3 to J1 2 The location of the main output capacitor is not critical Up to 10 ft from the drive is an acceptable length as long as the wire is sized so resistive drops at peak current are low Voltage clipping of the inverter can cause the peak bus current to equal the motor current A good rule is to size the bus wiring for 18 ARMS x rt 2 25 4 ARMS peak per drive Use at least 16 AWG The inductance of the bus and ground wiring is not critical because the internal drive bus capacitance can handle all the PWM current in most cases Servos put high peak power demands on the power supply The easiest and best way to build a power supply to deliver and absorb pulses of peak power is for the supply to have an appropriately sized output capacitor
20. gt 5 e uz E 11008 HO Bey 2 2 1 pp es j SNe gt V jeuondo tly 02 NI Y HO 100 WHO SEE NE z 6l 8L NT Ind ZHO ad 4 Ino ZHO gt 4 9 0 S l zNowova 7 AVE Ll NOW ova gt M3svua lt lt dr 1v8dis HdNISH er 0L INMd d3 S LdNISH 1 JA a 21 gt K lt 9 zinoa gt lt lt S m L S unva noa gt M gt 9 Minoa gt gt OV S NO9 35 Q CugiHND na Gt Gas z 0 0 cS 318VN3 LdNIG STIVH uda y vf NGS amd 035 ma 29 M SM 200 01 S200 Reference Manual Wiring the Drive 03 2006 Danaher Motion Kollmorgen 6 2 NOTE CAUTION J1 AC INPUT DRIVE POWER The S200 AC input drives are capable of direct line operation All units are fully isolated and do not require external isolation transformers The inrush current on the connection to the line is internally limited to a safe level for the drive There are no voltage selection or ranging switches required to operate within the specified voltage input ranges The S200 series drives are functionally compatible with all standard forms of three phase AC lines e Grounded neutral WYE Open Delta Grounded Leg e TEE The customer is responsible for supplying the appropriate fuses or circu
21. 1 5 ms 2 0 ms Recommended Fusing Line S20260 S20360 S20660 Inputs Type 250 VAC Time Delay Fuse 240 VAC 3 Phase ARMS Bussmann Bussmann Bussmann MDA 5 MDA 8 MDA 15 240 VAC 1 Phase ARMS Bussmann Bussmann Bussmann MDA 5 MDA 10 MDA 20 120 VAC 1 Phase ARMS Bussmann Bussmann Bussmann MDA 5 MDA 10 MDA 20 AC Control Inrush Current amp Fusing Worse Case Inrush Peak Current at 240 10 A 0 VAC Inrush Pulse Width 1 60 ms Fusing Control Inputs Bussmann MDA 1 2 AC Power On Delay Control Power Applied to Drive Operational 1 25 seconds 5200 Reference Manual M SM 200 01 Specifications 03 2006 Danaher Motion Kollmorgen 3 3 DC INPUT DRIVES CONTROL AND POWER 3 31 DC Control Power Supply Control Voltage Range VDC 10 to 90 J1 1 to J1 2 Control Input Power watts 2108 20 watt min supply recommended Refer to the DC Power Supply Section for detailed application information and requirements 3 39 2 DC Bus Voltage and Faults BUS Voltage Range VDC J1 3 to J1 2 20 to 90 BUS Undervoltage Fault 17 VDC nominal BUS Overvoltage Fault 91 VDC nominal 3 9 3 DC Power On Delay Control Power Applied to Drive Operational 1 5 seconds 3 4 MOTOR CURRENT CONTROL Motor Phase Current Waveform
22. 60 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Basic Configuration 7 1 3 1 MOTION CONSOLE In the SqNode Summary window under the Info tab the SynqNet ID is displayed in the Switch ID field See screenshot below SYNQNET ID 11 5 S12 A NEL oxi A Exact Match Drive coue h Mator h Type option FPGA Type JA FPGA VendorDevice FPGA Version o FPGA Defaut Version Mode Number 7 1 3 2 VERSION EXE UTILITY The version exe utility also displays the Switch ID field See screenshot below SYNQNET ID 11 5 S12 A c Command Prompt E MEING3 03 G RMP bin WinNT Svers ion PI version 63 63 66 PI firmware version 575 option MP firmware version 575 revision sub revision 2 option 8 branchld 8 river version 3 00 LD version BxBBi11 option 8x2892 incon version x 233 package 8x9281 T814 880802 Serial Number 448743 1 Nodes String 1 nodes In port nodes 8 Kollmorgen 208 Node Type 8x8883808038 ID UxCHFEBB836 Option it 6x66660008 Ver 0 02500346 Serial 456132 Branch 4 Model Type RUNTIME Unique it 6x66866026 Default YES Switch 6x666608A5 ID Match YES Drive Firmware version perating system Windows XP build 2688 Service Pack 1 PU x86 Family 15 Model 2 Stepping Intel lt R gt PentiumCR 4 CPU 2 88GHz Clock 2793 MHz MEING3 3 8
23. Bus Under Voltage 9 Motor or Short 10 Output Over Current 11 Hall Fault 12 SFD Configuration Error 13 SFD Short 14 SFD Motor Data Error 15 SFD Sensor Failure 16 SFD UART Error 17 SFD Communication Error 18 Option Card Watch Dog Timeout 19 Position Error Too Large 20 OC Fault 5200 Reference Manual M SM 200 01 97 Diagnostics and Troubleshooting 03 2006 Danaher Motion Kollmorgen Fault Generation The following sequence occurs when the protection circuits generate a fault e or more faults are detected by the control logic The fault source is latched only for latched faults The output stage is disabled The LED indicates the appropriate fault code For non latched faults when the fault condition is cleared the drive re enables automatically Latched faults are cleared by setting the Enable input to the disable state or by cycling off on the Control Power NOTE The large bus capacitors store substantial energy To use the control power to reset a fault the power should be removed for at least 30 seconds to ensure that the fault resets Self resetting faults disable the drive and do not return it to normal operation until 50 100 ms after the fault condition clears When multiple faults occur the highest priority fault is reported After that fault is cleared and the drive is reset by cycling the enable
24. Dipeak or 18 310 to 18 310 rpm is the value of the output of the command processing block This variable s units depend on whether the drive is in current or velocity control mode See OpMode for control mode information DInp1 Inactive Active Indicates the state of the drive s enable input on the Command I O connector J4 0 Active state current flows in opto isolator input diode 1 Inactive state no current flow DInp2 Inactive Active For SynqNet see mpiMotorGeneralln Indicates the state of the hardware input DINP2 on the Command I O connector 0 Active state current flows in opto isolator input diode 1 Inactive state no current flow DInp3 Inactive Active Indicates the state of the hardware input DINP3 on the Command I O connector 0 Active state current flows in opto isolator input diode 1 Inactive state no current flow 5200 Reference Manual M SM 200 01 83 Advanced Configuration 03 2006 Danaher Motion Kollmorgen DInp4 Inactive Active Indicates the state of the hardware input DInP4 on the Command I O connector J4 For OpMode Position PosCmdSrc Step Dir this input is the Direction input In the inactive state no LED current with positive GearOut PosCmd increments with each Step input edge i e the motor moves clockwise 0 Active state current flows in opto isolator input diode 1 Inactive state no current flow DriveOK Fault No Fault Drive fault st
25. In Sine or six step mode output torque Motor Pure sinusoidal or six step Kr Drive depending on feedback device Motor Shaft Torque Ignoring motor magnetic saturation Peak hot motor winding Kr N m ARMS Drive Ipeak Multiply Kr by 1 06 for cold motor winding ARMS AKM or PMA motors Instantaneous Kr N m ARMS IFB ARMS 3 4 1 Current Loop Bandwidth Maximum Bandwidth AC Input Drive KHz DC Input Drive kHz 5 Recommended Bandwidth AC Input Drive KHz 2 DC Input Drive kHz 3 SFD Auto Set kHz AC amp DC 2 Bandwidth Variation For Fixed Motor L 2 5 regulated independent of bus voltage Update Period us 0 8 Recommended Max Motor Electrical Frequency Hz AC Input Drive Hz 600 DC Input Drive Hz 900 8 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Specifications 3 4 2 Offset Current Drive Typical Worst Case Over Temp 520250 0 2 12 0 5 32 mA 520260 0 2 12 mA 0 5 32 520330 0 2 25 mA 0 5 64 mA 520350 0 2 25 0 5 64 mA 520360 0 2 25 0 5 64 mA 520660 0 2 50 mA 0 5 128 mA 520630 0 2 50 0 5 128 3 5 VELOcITY LOOP Maximum Stable Bandwidth Hz with SFD 800 Update Period ys 0 8 Range rpm 0 to 18 300 Command Resolution lt 0 001 rpm analog 0 558 rpm serial 3 5 1 Velocity
26. NOTE 6 An adequately sized bus capacitor helps provide the high peak bus current needed for rapid motor acceleration with minimum bus voltage sag If the bus voltage sags excessively during acceleration inverter voltage saturation occurs with loss of motor torque Bus capacitance lowers peak current requirements in the silicon of the power supply Sizing the power supply for average power rather than peak power lowers power supply cost and size In most cases a bus capacitor does not need to be mounted close to the drive The inductance of the bus and ground wiring is not critical because the internal drive bus capacitance generally handles all the PWM current of the drive A local capacitor is not needed in the following cases e 3 9 ARMS DC 5200 e 6 18 ARMS DC S200 with HSTemp less than 65 C e 6 18 ARMS DC 5200 mounted adjacent to other S200 drives with main bus supplies tied locally together The internal bus capacitors of the adjacent drives should provide the needed capacitance The exception is a single isolated 6 18 ARMS DC 5200 drive running hot HSTemp 65 C In this case connect across the bus within 1 ft of the drive using twisted wire 470 pf min 100 V low ESR and an aluminum bus capacitor Bus capacitor for multiple drives A conservative rule is to scale up the recommended output capacitance for one drive by the number of drives If this value is too large the capacitor can be calculated from en
27. Offline Communications Mode 5200 Reference Manual M SM 200 01 19 Quick Start Guides 03 2006 Danaher Motion Kollmorgen 4 2 4 2 START COMMUNICATION WIZARD Open the Communication Wizard by selecting it from the toolbar Utilities gt Communication Wizard or clicking the shortcut icon 175200 Tools Base SynqNet Units D 5200 Tools Base SynqNet Files View Utilities Help Files View Utilities Help Communication Wizard cem a EX 2 Tuning Wizard Offline Restore Factory Defaults Variable Statistics Select SynqNet as the Communications Mode Communications Mode C Serial SynqNet M SynqNet Settings Select Controller Controller 0 Select Node SynaNet Node 0 m Serial Port Settings Select Port COM1 y Select Baud Rate 19200 If you do not know which type of drive is connected click the Test button The returned message will either say that there is no connection confirm that you have an S200 connected or tell you that the connected node is NOT an S200 drive After you have confirmed your setup click the OK button i Files View Utilities Help g 2 E NODE 0 52036 240 3 94rms Status Drive Setup Motor Summary Offline The installed S200 drive s will now be listed as Online and will list its configuration and status option
28. RTN VO RTN o 100 ON DISCRETE IO i GP RS422 INO 1 GP RS422 INO GP RS422 IN1 GP RS422 IN1 J14 J13 200 SYNQNET y Sa 2299 5 15 s dU e e e e e e e e e e e e go 12 5 c gt o J1 SynQNet In OPTION CARD 1 2 3 4 5 6 7 8 ON OAR CONN_RD1 CONN_RD1 CONN_TD1 CONN RTERM1 CONN RTERM1 CONN TD1 CONN TTERM1 CONN TTERM1 CONN_TDO CONN TDO CONN_RDO JIN IN IN IN AN CONN_TTERMO CONN_TTERMO CONN RDO0 CONN RTERMO INN CONN RTERMO 5200 Reference Manual M SM 200 01 53 Wiring the Drive 03 2006 Danaher Motion Kollmorgen 6 10 J11 SYNQNET IN PoRT CONNECTOR J11 is a Standard 5 connector e J11 Connector view from front of drive Pin Description J11 1 CONN_TDO J11 2 CONN_TDO J11 3 CONN_RDO J11 4 CONN_TTERMO J11 5 CONN_TTERMO J11 6 CONN_RDO J11 7 CONN_RTERMO J11 8 CONN_RTERMO SHLD UUP1 and UUP2 are unused pair 1 and 2 When using a standard CAT5 cable these pairs are connected to the two unused pairs in the 4 pair 8 wire cable NOTE Standard 5 design practice is to terminate these pairs on the PCB to reduce noi
29. Step 63 7 4 Configuring with SFD Feedback essen nnne 65 TAT Motor Paramieters ire iere tpe 65 LAZ Torque Current Mode erre ra a s a aenn ran apan siie der Po aSa ireen iE 66 GAS Velocity Mode ii ete EE REPE ERR 67 CEA POSITION rene eese dne 68 7 5 Reversing Motion Direction esee nnne nnns nnne 69 Advanced Configuration ccccccceceseeececeeeeeeeeeeeeeceeeeeeeeeasnaneeseseseesseaeeesesesesesaneeeeeeseeeeeaes 70 8 1 Control Block Diagram sss enne 71 8 2 Position Control Diagram sisse ener nnne nennen 72 8 3 Parameters and Variables enne nnns nnns enne 73 8 3 1 Parameter and Variable Storage sse 73 8 3 2 Model Dependent Scale Factors sse 74 8 3 3 Read Write NV 75 8 3 4 Status And Control Variables 83 SynqNet Configuration nennen nennen nennen nenas innen inne nnne inner nnne nn 88 9 1 Drive FPGA Table ebbe baie vens 88 9 2 Drive Monitor te EE o RE ER e 89 9 2 1 Drive Monitor Table c i tte cree etc ete 89 9 2 2 Monitoring Real time Data from Drive 89 9 3 A
30. Supply Current 48 VDC BUS 75 VDC BUS 3 3 ADC at 520330 Continuous Peak 160W 3 3 ADC at 250W 3 sec 10 ADC at 10 ADC at 750 W 480 W 6 7 ADC at 520630 Continuous Peak 320W 6 7 ADC at 500W 8 sec 20 ADC at 20 ADC at 3 000 W 960 W BUS Supply Current 48 VDC BUS 75 VDC BUS 3 3 ADC at 520330 Continuous Peak 160 W 3 3 ADC at 250 W 3 sec 10 ADC at 10 ADC at 750 W 480 W 6 7 ADC at 520630 Continuous Peak 320 W 6 7 ADC at 500 W 3 sec 20 ADC at 20 ADC at 3 000 W 960 W 5200 Reference Manual M SM 200 01 35 Wiring the Drive 03 2006 Danaher Motion Kollmorgen Bus Supply The BUS Supply should have the following characteristics Characteristics e Must provide safety isolation from the power line 6 6 4 2 NOTE 4 3 e be regulated or unregulated e Bus Supply Return is connected to the Control Supply Return and I O RTN in the drive Typical BUS Supply e Unregulated Isolating step down transformer with secondary rectified into capacitive filter e BUS Supply Return is connected to earth ground Wiring from BUS 10 ft maximum Supply to Drive 16 AWG minimum Twisted pair Daisy chaining of multiple drive OK No contactor or switching in the BUS wiring Control Voltage J1 1 to J1 2 Control Supply Type Isolating Unregulated or Regulated Common GND with bus supply and I O RTN 20 watt supply or 1 amp short circuit Control Supply Wiring Wire control J1 1 to bus J1 3 or
31. Wire control J1 1 to separate supply to preserve status and fault information 10 VDC to 30 VDC supply can be shared by Control and 1 0 Control Supply 20 to 110 mA at 75 VDC Current 60 to 330 mA at 24 VDC 125 to 660 mA at 12 VDC 10 VDC to 90 VDC Bus Voltage Bus voltage outside the operating range 20 to 90 V causes an undervoltage or overvoltage fault Undervoltage and overvoltage faults are self cleared when the fault conditions are cleared Do Not allow the Bus Voltage to exceed 90 VDC as it can damage the drive Target design center voltage for unregulated supply is 70 to 75 VDC This provides 15 to 20 VDC margin for line tolerance transformer regulation and regen pump up Design center voltage for a regulated supply can be up to 80 VDC Control Voltage The control voltage range for normal operation is 10 VDC to 90 VDC The control voltage can either be wired to the bus voltage so one supply can power the drive or from a separate supply Separately powering the control from the bus allows the bus to be powered down for safety while drive status and fault information remain available NOTE Control and I O can share a single 10 VDC to 30 VDC power supply Do NOT allow the Control Voltage to exceed 90 VDC as it can damage the drive 36 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Wiring the Drive 6 4 4 6 4 5 6 4 6 Grounding
32. Wiring Eee Ee eee HELPER 52 6 9 SynqNet Option Card Wiring sessi eene nnne nnns enne 53 6 10 J11 SynqNet IN Port Connector nnne nennen entren 54 6 10 1 SynqNet LEDs iecore rre Irene Innere diee eode rete Reden 54 6 11 J12 SynqNet OUT Port Connector eee 55 6 11 1 SynqNet LEDs inte thee ti eerie exei vete dene 55 ii M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Table of Contents 10 11 6 12 13 Discrete VO Connector iieaeoe essent enn nennen nennen nennen nnn 56 6 13 J14 AUX FB Connector 57 6 13 1 Auxiliary Feedback Device enne 57 Basic Configuration in nnne inia niin 58 7 1 S5witch Seltings iiem tage ete dee e Yee eee eee epe ea ene ea eee uon 58 7 14 S2 DIP Setup i 58 7 1 2 S1 Rotary Setup Switch arerin neiaa eene 59 7 1 3 11 512 Rotary SynqNet ID Switches 60 7 2 Configuring for Brush 62 7 3 Configuring Current Mode with 6 Step Hall 63 7 3 1 Torque Block with 6 Step Feedback 63 7 3 2 Setting Drive Parameters for 6
33. an equation Cmdlin User Input CmdOffset CmdGain NOTE The range and resolution of CmdOffset is affected by the value of CmdGain Its range covers the entire range of Cmdin CmdSrc Analog PWM CMD or Command Variable CmdSrc selects the source of the command It selects between using the command I O connector analog input or PWM CMD digital input or the serial command parameter 00 Analog input sets command default 01 PWM input sets command 76 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Advanced Configuration 10 Software Command Variable sets command analog input Cmd proc 11 Software Command Variable sets command PWMCMD input proc Command DIpeak or 18 310 rpm Not supported over SynqNet Sets the value of the command when CmdSrc is set to Command variable as opposed to the standard Analog or PWM CMD digital hardware inputs The parameter units depend on whether the drive is in current or velocity control mode When OpMode is set to Position this variable is not used CommMode SetupS2 2 SFD 6 Step Brush Selects the commutation mode of the drive The following table describes the different values for this parameter Mode Description SetupS2 2 DIP switch S2 position 2 selects between 6 step and SFD commutation feedback SFD Forces the drive to use SFD for feedback 6 Step Forces the drive to use 6 step Brush Forc
34. be used This input can be connected to input J1 3 and powered by the same supply as Bus The control power supply should be rated for 20 watts While the power drain typically is 2 W to 8 W a 20W supply ensures reliable starting of the drive J1 2 Power return for the control and BUS power supplies The BUS CTRL BUS CTRL GND is connected to I O RTN internally in the drive GND J1 3 Main power input to the drive The DC drive accepts 20 to BUS 90 VDC on this input referenced to J1 2 An isolated regulated or isolated unregulated power supply can be used The 5 power drain with Bus voltage at 75 VDC is in the range shown below It varies according to the application and motor 520330 3 Amp 520630 6 AMP 250 watt 500 watt Continuous Power 5 750 1 500 watt 34 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Wiring the Drive Refer to the DC Power Supply Requirements section for detailed requirements selecting a compatible power supply NOTE g p p ppiy PE Protective Earth connection point This chassis ground point Screw must be connected to Protective Earth ground The Connection connection at the Protective Earth ground end must be hard wired do not use a pluggable connection 6 4 1 DC Power Supply Requirements Bus Voltage J1 3 to J1 2 20 VDC to 90 VDC BUS
35. detector RCD cannot be depended on for safety Connection for an optional regeneration power resistor to absorb regenerated energy from the motor Models 520260 520360 typically use 36 520660 typically uses 12 5 although other values within the minimum resistance specification can be used Use a Wire wound resistor with 1500 5 isolation between terminals and case Many applications do not require a regen resistor If over voltage faults occur during motor deceleration then the more kinetic energy is being returned to the bus capacitors than they can handle Connect the proper ohmage 50 to 300 watt power resistor from this terminal to terminal J1 4 BUS in order to eliminate the over voltage faults The power rating of the regen resistor depends on the amount of regenerated energy that needs to be dissipated The regen input is not short circuit protected The regen resistance MUST be within specified ranges to prevent damage to the drive For example WARNING between 25 to 50 for the S20260 S20360 drives For safety either mount the external resistor on a grounded panel or wire it to a grounded connection The terminals of the resistor MUST NOT be NOTE grounded ha Wait 5 minutes after power is removed for the bus cap voltage to decay to a safe level before touching the regen resistor or wiring Monitor the voltage WARNING on the bus caps with a voltmeter from BUS J1 4 to BUS J1 3 J1 3 BUS J1
36. energy absorbed or delivered for a 5 V change from a 75 bias is 3 joules for 8 000 uf 7 joules for 20 000 uf 16 joules for 45 000 uf Bus DC Input Power Bus input power can be estimated by adding motor shaft power and motor resistive winding loss The shaft power equation is Shaft power watt Torque N m x Speed rad sec 5200 Reference Manual M SM 200 01 109 Appendix A Power Supply Design 03 2006 Danaher Motion Kollmorgen where rad sec rpm 60 x 2 The equation for motor resistive heat loss is Winding loss watt 1 5 x Riine to ine X IRms X 5 110 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Appendix B Cables APPENDIX B CABLES B 1 B 2 LONG CABLES The DC resistance of long motor power cables steals some of the available voltage when motor current is high The principal effect of this is some reduction in peak motor power so acceleration and deceleration times can be longer The cable resistance has no significant effect on lower speed torque or top speed For most applications the loss of performance is small with cables up to the maximum cable length specification Do not operate an S200 DC Input Drive with long cables at the lower end of the bus voltage range because too much of the available voltage is stolen by the cable resistance For 5200 AC Input Drives the DC resistance of the motor power cable is rarely an issue because the voltage drop across the res
37. input the next highest priority fault that still exists will be displayed 98 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Diagnostics and Troubleshooting 11 2 DIAGNOSTICS The following table lists the 5200 fault codes and possible causes of the fault condition Status LED Blink Code Fault Description Possible Cause ON No faults power stage Enabled Normal Operation OFF Control power not applied or insufficient control power applied Loose or open circuit wiring of control power input Low input voltage to control power supply Fast Blink No faults power stage Disabled Hardware or Software Enable inactive to enable drive apply hardware enable and set software enable Not Assigned Motor Over Temp Motor temperature exceeds allowed limit High ambient temperature at motor Insufficient motor heat sinking from motor mounting Operating above the motor s continuous current rating Motor temperature sensor failure or not connected Drive Over Under Temp Temperature of drive heatsink chassis is outside of allowed limits High or low drive ambient temperature Restriction of cooling air due to insufficient space around unit Operating above the drive s continuous current rating Drive I t Too High The product of the drives output current multiplied by time has exceeded allowed limits If current foldbac
38. leveling and regeneration absorption capability 106 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Appendix A Power Supply Design 9 Regulated power supply Some regulated supplies do not tolerate an increase in voltage above the supply voltage set point In this case insert a diode between the positive supply terminal and the positive capacitor terminal to prevent reverse current flow into the supply The diode should be a rectifier diode with a voltage and current rating equal to or greater than the supply A low ohm 1 0 power resistor between the power supply and the capacitor may be desirable By reducing the stiffness of the voltage across the capacitor it enhances the ability of the capacitor to supply current to the drive during motor acceleration and prevents the current limit of the regulated supply from cutting in 10 Bus wire resistance 11 Bus wire current is the sum of DC current providing power to the drive and AC current between the drive and external capacitor The wire between the drive and external bus capacitance should be a low enough resistance so peak currents do not cause excessive voltage drop in the wire Peak instantaneous bus current can be up to 25 A per drive Size the positive Bus wiring to minimize the peak voltage drop As a general guide use no smaller than 16 AWG wire to span 10 feet from the drive to the shared energy leveling capacitor The AC and DC bus cu
39. or from the Windows Start button Programs gt Danaher Motion gt S200Tools The default location for S200Tools exe is C Program Files Danaher Motion S200Tools Dee 1205 Ate Costes Made Tor Canet When the S200 Tools program is launched for the first time no drives should be listed under the Online or Offline Communications Mode START COMMUNICATION WIZARD Open the Communication Wizard by selecting it from the toolbar Utilities gt Communication Wizard or clicking the shortcut icon 5200 Reference Manual M SM 200 01 15 Quick Start Guides 03 2006 Danaher Motion Kollmorgen D 5200 Tools Base Unit 225200 Tools Base Unit Files View Utilities Help Files View Utilities Help c E 4 Communication k E 4j 2 Tuning Wizard Offline Restore Factory Defaults Variable Statistics Select Serial as the Communications Mode and select the appropriate COM port Communication Wizard Communications Mode Serial SynqNet SynglNet Settings Select Controller Controller Select Node SynaNet Node 0 zl M Serial Port Settings Select Port coe Select Baud Rate fi 9200 cot If you do not know which type of drive is connected click the Test button The returned message will either say that there is no connection confirm that you have an S200 connected or tell you that the connected node i
40. previous sections E 4 SAFETY REQUIREMENTS As the user or person applying this unit you are responsible for determining the suitability of this product for the application In no event will Danaher Motion be responsible or liable for indirect or consequential damage resulting from the misuse of this product Read this manual completely to effectively and safely operate the S200 E 5 EUROPEAN COMPLIANCE In Germany these include e DIN VDE 0100 instructions for setting up power installations with rated voltages below 1000 V e DIN EN 60204 Part 1 VDE 0113 part 1 instructions relative to electric equipment in machines for industrial use e DIN EN 50178 VDE 0160 instructions relative to electronic equipment for use in power installations 5200 Reference Manual M SM 200 01 121 Appendix E Regulatory Information 03 2006 Danaher Motion Kollmorgen E 6 Low VOLTAGE DIRECTIVE AND EN50178 To ensure compliance with the Low Voltage Directive and EN50178 following these requirements Electronic drives contain electrostatic sensitive devices that can be damaged when handled improperly Qualified personnel must follow ESD protection measures For example wear grounded heel and wrist straps when contacting drive The climatic conditions shall be in accordance with EN 50178 climatic class Type B temperature and relative humidity Class 3K3 The drives shall be installed in an environment of Pollution Degree 2 or
41. rev Feedback Source Base Unit Feedback X Motor Feedback Configuration The next step is to set the proper motor feedback configurations SFD If you are using SFD motor feedback no further configuration is needed SiNCOS OR COMCODER If you are using SinCos or ComCoder as motor feedback use the equations below to determine the appropriate parameters for setup Kip Kip 2 PI 2000 motor line to line inductance Ex IH inductance 0 018 Kip 2 PI 2000 0 018 Kip 226 V A 5200 Reference Manual M SM 200 01 21 Quick Start Guides 03 2006 Danaher Motion Kollmorgen 4 2 7 I2TFO I2TFO 5 2 PI motor time constant in minutes 60 Ex Mtc 20 minutes I2TFO 5 2 PI 20 60 I2TFO 0 000663 Hz I2TTrip I2TTrip motor continuious current 1 25 Ex Ics 4 Arms I2TTrip 4 1 25 I2TTrip 5 Arms ILmtPlus ILmtPlus motor peak current drive peak current 100 Ex Motor 1 4 5 Arms Drive Ip 9 Arms Motor Ip 4 5 9 100 Motor Ip 5096 ILmtMinus Typically ILmtMinus is set to the same value as ILmtMPlus Although there can be asymetrical current limits in the drive Dpoles Dpoles motor poles Save Options There are three types of Save options It is important to know how to use each type to ensure that configurations are not lost e Download NV This button will save the parameter settings displayed in S200 Tools to the selected drive These parameters are saved t
42. rotary motor commutation this scaling converts the Aux Feedback position word to a word with 24 bits per revolution For linear motor commutation it converts to 24 bits per motor magnetic pole pitch distance The table below lists a number of commonly desired settings for AuxFBDivisor Incremental A quad B encoder No motor commutation 1 encoder AuxFBDivisor 2 16 777 216 quadrature count 1 Aux Feedback count Commutating a rotary motor or 24 bits per AuxFBDivisor number of quadrature revolution counts per mechanical revolution Commutating a linear motor or 24 bits per AuxFBDivisor number of quadrature magnetic pole pitch counts per magnetic pole pitch 1 Vp p Sin Cos No motor commutation 1 16 bit interpolated AuxFBDivisor 2 256 Isb 1 Aux Feedback count Commutating a rotary motor or 24 bits per revolution AuxFBDivisor number of Sin Cos cycles per mechanical revolution Commutating a linear motor or 24 bits per AuxFBDivisor number of Sin Cos cycles magnetic pole pitch per magnetic pole pitch AuxFBType Type Supported over SynqNet This parameter selects the type of feedback wired to the AuxFB connector It is a combination of the following single bit parameters AFBHallDis AFBDivisorSrc AFBEnDatEnb and AFBFBSrc The following table defines the state of these parameters for each supported feedback device Type AFBHallDis AFBEnDat
43. the rotational mechanical energy is dissipated as heat in the motor windings when the motor decelerates The maximum regenerated rotation energy back to the bus occurs counter intuitively during a low torque deceleration from high speed In this case the resistive losses in the motor are low If mechanical drag is low much of the stored rotational energy is regenerated to the bus 2 Bus capacitance absorbs net regenerated inductive energy from the motor winding when the drive is disabled or faulted The worse case regenerated inductive bus voltage rise is a trip of the bus over voltage fault when decelerating the motor at full torque Tripping the bus over voltage fault while stopping the flow of regenerative mechanical energy back to the bus causes a fraction of the inductive energy stored in the windings to regenerate to the bus causing the bus voltage to go higher than the over voltage threshold If there is insufficient bus capacitance to absorb this energy the bus voltage rise is excessive and can damage the drive Failure to provide adequate external capacitance on the main bus can damage the drive The regeneration of motor inductive energy allows some pump up of the bus voltage above the bus over voltage threshold 3 Bus capacitance improves motor dynamics by holding the bus voltage stable during acceleration 5200 Reference Manual M SM 200 01 105 Appendix A Power Supply Design 03 2006 Danaher Motion Kollmorgen NOTE
44. to load the values into active use When downloading or uploading to the S200 from S200Tools software all drive settings are copied It is not possible to upload or download only one parameter or variable In the online branch of S200Tools the Drive Setup screen of S200Tools operates differently than in offline Under the Drive Setup screen any change to a parameter is automatically communicated to the drive s temporary memory Once all the parameters are Set you should use the File menu to do a file save on the PC to save the drive configuration S2C If a drive is connected you can click the Download Drive or the Download NV buttons to send the parameter set into the drive In the online section of S200Tools the Status screen allows a custom selection of NV Parameters and variables to be selected This screen is useful for interactively making setup changes and to view drive status When changes are made to an NV Parameter or a Variable in this screen the value in the 5200 Tools PC memory is automatically copied to the 5200 RAM memory for that particular parameter Clicking NV Save on the Status screen uploads the current state of the drive temporary RAM and downloads all these settings to the 5200 non volatile memory This step should be done before power cycling the drive control power and losing the drive setup changes 5200 Reference Manual M SM 200 01 73 Advanced Configuration 03 2006 Danaher Motion Kollmorgen 8 3 2 Model D
45. 0 17 29 60 8 12 5200 Reference Manual M SM 200 01 5 Specifications 03 2006 Danaher Motion Kollmorgen AC Input DC Input 520260 520360 520660 520330 520630 Pconr watts Shunt Regulator Peak Power kW 500 4 4 6 4 10 mSec 9360 9250 150 Continuous Power watts 440 640 1000 _ 2360 0250 0150 ERU sd Um 10 4250 109150 Regen Resistance 25 50 25 50 12 50 Bus Capacitance Energy Absorption joules 340 VDC Nominal BUS 15 5 15 5 20 75 VDC BUS with 4 000 uf 5 volt increase to 80 E m VDC Ens E Ripple 20 20 20 31 2 312 5 25 125 i At 75 VDC 0 4 0 2 aene 300 150 5 15 Maximum Motor Power Cable Length 18 AWG cable m 50 50 50 50 25 14 AWG cable m 50 50 50 50 50 Peak Output Current listed is for sine mode In six step mode the peak output currents are scaled to give the same output torque as in sine mode with a pure sinusoidal Back EMF motor To convert ARMS to A 0 pk multiply ARMS 1 414 Above 30 C ambient linearly derate between provided 40 C 50 C ratings At higher ambient temperatures above 30 C the S20360 drive needs to be mounted on a thermally conductive surface to limit the heatsink temperature to less than 75 C power to avoid excessive ac line front end currents See Appendix B Ca
46. 0 Amp Enable Dedicated Out 0 Brake Release 0 88 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 SynqNet Configuration Motor General _ Name Valid Configurations Purpose I O Bit 0 0 RS422 IN 0 Input 0 1 85422 IN 1 Input 0 2 RS422 IN 2 Input 0 3 RS422 IN 3 Input 0 4 RH 1 Input 0 5 RH 2 Input 0 6 RH 3 Input 0 7 PS OK Input 0 8 IO SHORT Input 0 9 DINP2 Input 0 10 DINP3 Input 0 11 DINP4 Input 0 12 HSINP1 Input 9 2 DRIVE MONITOR 9 2 1 Drive Monitor Table kollmorgen s200 h Drive Monitor Table 74 typedef enum S200MonitorAddressCMD IN 0x3938 Value of the output of the command processor block S200MonitorAddressHS TEMP 0x8726 Heat sink temperateure value S200MonitorAddressIFB 0x4544 Torque derotated current value S200MonitorAddressIDFB 0x4746 Non torque derotated current value S200MonitorAddressM TEMP 0x8700 Motor temperature A D value frm the SFD S200MonitorAddressPOS MTRN 0x5756 Multi turn feedback data S200MonitorAddressPOS 1585 Ox2E2D Lower 16 bits of the feedback S200MonitorAddressPOS FB MSBS 0x872F Upper 8 bits of the feedback S200MonitorAddressVBUS 0x3736 Motor power voltage S200MonitorAddressVEL FB OxlD1C Shaft veloci
47. 00 Maximum Output Line Frequency MHz 2 5 Max Recommended Speed at 32768 PPR 2200 rpm Max Recommended Speed at 16384 PPR 4600 rpm Max Recommended Speed at 4096 PPR rpm 18300 Marker Pulse Width 1 Quadrature Pulse General SFD Specifications 3 dB Bandwidth Hz gt 2000 45 Phase Lag Hz gt 1000 Max Tracking Rate rpm gt 48600 Max Recommended Rate rpm 25000 Max Tracking Acceleration rpm sec gt 16x10 Maximum Feedback Cable Length 50 m 164 ft 5200 Reference Manual M SM 200 01 13 Quick Start Guides 03 2006 Danaher Motion Kollmorgen 4 4 1 4 1 1 4 1 2 4 1 2 1 QUICK START GUIDES There are two types of Quick Start Guides depending on the Communication Mode of the drive If you are not using an S200 Base Unit Drive no SynqNet Option follow the 5200 Base Unit Drive Quick Start Guide If you are using an S200 SynqNet Drive follow the 5200 SynqNet Drive Quick Start Guide S200 BASE UNIT DRIVE This Quick Start Guide is designed to help a user quickly setup one of the following 5200 Drives See Drive Model Numbers and Descriptions for a complete list of 5200 drives e 20330 VTS S20630 VTS S20260 VTS S20360 VTS S20250 VTS 520350 VTS The setup consists of the following steps 1 S200 Tools Software Installation Hardware Setup 5200 Tools Communication Wizard Motor Feedback Configuration Sa
48. 00L gt 0 eyed S81 SH NI LNO 8 HO ul vo vo 002 une 5 epooeq 1 NI LO V H u jeec emjeJpenO L4 1 NI LNO V HO Jp 4 unooy sjunog no eeo p ieubiq 7 gr odo M epooeq Mt lt _ LANISH d ond das 4g banish 5200 Reference Manual M SM 200 01 72 Danaher Motion Kollmorgen 03 2006 Advanced Configuration 8 3 8 3 1 PARAMETERS AND VARIABLES Setup parameter values control the operation and configuration of an 5200 and read only variables give status information about the present operation of the drive The below defines the three types of parameters and variables e NV Parameter A type of variable stored in the non volatile NV permanent memory on the drive See NV Parameters for a complete list and descriptions e Status Variable Gives information about the present state of the drive Most of these variables are Read Only meaning that you cannot directly change them their value is controlled by the drive itself for example measured shaft speed See Status and Control Variables for a complete list and descriptions e Control Variable A variable that controls a particular function on the drive Control Variables are volatile erased when power is removed and are initialized at fixed default values every t
49. 08 A 2 1 Control Supply J1 1 to 1 2 ene 108 A 3 Multi Axis Considerations 108 4 Bus Energy amp Power Numerical Examples sse 109 A 4 1 Min External Bus Capacitance 109 A 4 2 Energy from Acceleration e 109 A 4 3 Capacitor Energy Absorb Deliver essem 109 44 Bus DC Input POWE oe eter erede et tiem 109 Appendix B Cables neus sud hed decreti esie seu Dv is 111 B 1 Long Cables depot etie Hd aseo eee a PR 111 B 2 Custom Composite Cables sss 111 Appendix C Voltage Sag Standard esee ener nnne 114 Appendix D Using a Voltage Doubler Mode Drive eene 115 D 1 S2xx50 AC Line Voltage Doubling Drive Power Specifications 116 Appendix E Regulatory Information ccccceceeeeeee cece ee eeeeeeee ee 117 E 1 Conformance 117 E 2 CE Approval A e Reade a axi YES ee EH unn 117 E 2 CE EMG Corniplianca Lente rd eee qe ee 117 2 21 etre nee 118 2 22 CE Test Setup iiit
50. 1 and S2 switches Configuring the drive with the S200Tools utility provides increased flexibility in setting parameters that are not available through the setup switches When using the S200Tools utility the configuration parameters should be saved to non volatile memory click the NV Save button to allow the configuration to be recalled on power up To configure the drive for SFD feedback set the following parameters Parameter Value CommMode SetupS2 2 Default value with switch S2 2 set to the down position labeled S on the drive or SFD CommOff 0 Degrees for AKM motor series Check with your sales representative for the correct commutation offset angle for other motor series OpMode Velocity or SetupS2 1 with switch S2 1 set to the up position labeled V as shown on the drive SelSFDParam SFD Default value recommended setting This setting automatically sets the motor parameters KVP is set for 75 Hz nominal velocity loop bandwidth with an unloaded motor To change KVP or other motor parameters refer to Configuring with SFD Feedback Motor Parameters ARFO Single pole filters in the velocity loop forward path Set to ARF1 accommodate the effects of mechanical resonance KVI Sets the velocity loop break out frequency from integral to proportional compensation CmdSrc Selects Analog PWM or Command variable for command CmdGain Sets the command gain for the c
51. 2 can set the operational mode and feedback types when enabled Setting the drive parameters as shown in the following table enables the switch and is the factory default configuration Switch positions 3 and 4 are reserved for future functionality and should be left in the down closed factory default position 58 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Basic Configuration Switch Parameter Switch State Position Setting Function Down Closed Up Open S2 1 OpMode Operational Torque Current Velocity SetupS2 1 Mode Control Control 52 2 CommMode Feedback SFD 6 Step SetupS2 2 Type 52 3 Reserved Default Reserved S2 4 Reserved Default Reserved NOTE flus 7 1 2 1 Drive parameter settings can override the S2 switch settings To enable S2 for setup verify that the following drive parameters are set as shown below The factory default is to ship the drive with the switches enabled Parameter Value OpMode SetupS2 1 CommMode SetupS2 2 51 Rotary Setup Switch Switch 51 is a 10 position rotary switch The function of switch 51 depends on the feedback mode in which the drive is configured 51 FUNCTION WITH SFD FEEDBACK When using the Smart Feedback Device SFD S1 sets the emulated encoder line count 51 Emulated Encoder S1 Position Emulated Encoder Posi
52. 3 4 four inputs that share a common terminal DINP on J4 1 The inputs operate over a wide input voltage range of 4 0 to MSINP1 30 V General purpose inputs are J4 5 maps compatible with either sourcing or sinking currents to provide maximum flexibility for Common Input interfacing to field wiring Terminal J4 1 40 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Wiring the Drive J4 1 DINP COM J4 2 DINP1 ENABLE J4 3 DINP2 INHIBIT J4 4 DINP3 INHIBIT J4 5 MSINP1 DIRECTION 4 64k Input current is a function of the input voltage and listed in the following table Input Voltage Input Current 4 0 volts 0 65 mA 5 0 volts 0 95 mA 12 volts 2 5 mA 24 volts 5 3 mA 30 volts 6 7 mA The response time for DINP1 DINP2 and DINP3 is less than 1 ms DINP4 has a response time of less than 100 ps For fastest response to an input configure the drive to respond NOTE when the input optoisolator is turned on current starts flowing in the photo diode 5200 Reference Manual M SM 200 01 41 Wiring the Drive 03 2006 Danaher Motion Kollmorgen 6 7 1 1 6 7 1 2 DEFAULT INPUT FUNCTIONS The list below describes the factory default functions for each of these inputs A logic input hardware is active when current is flowing through its photo diode Inactive logic input hardware is open circ
53. 4 BUS J1 5 J1 6 C2 CTRL VAC C1 CTRL VAC The BUS terminal is usually left open during normal operation In special multi axis applications drive buses can be wired in parallel to allow returned energy from one motor to power another and limit high regen powers The BUS terminal is used with the J1 2 REGEN terminal to add a regen resistor to the drive to absorb regenerated energy These terminals connect 120 240 VAC power to the drive s control voltage power supply 5200 Reference Manual M SM 200 01 31 Wiring the Drive 03 2006 Input Voltage Range RMS 85 VAC to 265 VAC single phase 47 to 63 Hz 120 VDC to 375 VDC Inrush Peak Current 10 A 0 p with 240 VAC Input Inrush pulse width 1 60 ms Fusing Bussmann MDA 75 For maximum ride through capability a 240 VAC input is recommended J1 7 J1 8 J1 9 L3 240 VAC L2 240 120 VAC L1 240 120 VAC These terminals connect 120 240 VAC power to the drive s output power stage BUS For single phase operation 120 240 use inputs J1 8 L2 and J1 9 L1 Input Voltage Range 90 to 265 VAC Phases 10r 3 Transformer 2to 3 KVA recommended KVA if transformer is required Maximum AC Line 100 KVA Inrush Peak Current a 140 A with 240 input Inrush pulse width 1 5 ms Maximum AC Line is specified to limit the mains surges to the drive
54. 74 DIpeak V Torque current Velocity I I t filtered value U phase voltage command VqCmd 134 5 Torque voltage VbusScale V command ICMD 0 8474 DIpeak Torque Current ARMS command Model Dependent Scale Factors Model Dipeak VBusScale Description User ARMS Relative x 520250 4 5 1 240 4 5 ARMS peak 520260 240 4 5 ARMS 520330 90 VDC 9 ARMS 520350 240 9 ARMS peak 520360 240 9 ARMS 520630 90 VDC 18 ARMS peak DPoles 0 62 Poles even numbers only DPoles sets the drive for the appropriate motor pole count Typically set to match the motor pole count With a feedback device that has multiple cycles per revolution DPoles is set to 78 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Advanced Configuration 4 WARNING twice the ratio of motor electrical cycles to feedback device electrical cycles per revolution Setting DPoles to zero turns electronic commutation off Binary 0 0 Poles Binary 1 2 Poles Binary 31 62 Poles When the DPoles setting does not match the actual motor pole count the motor s operation will be erratic and could be dangerous EncOut 128 to 32768 Lines See Chart Sets the J4 17 to J4 22 emulated encoder output signal s line count pulses per revolution when the EMU setup rotary switch S1 on the base drive is set to position 0 All other settings for
55. 8NXMPNbinNUinNT 5200 Reference Manual M SM 200 01 61 Basic Configuration 03 2006 7 2 CONFIGURING FOR BRUSH MOTORS The S200 Drive must be in Current Mode to drive a brush motor The S200 base unit when connected to a brush motor does not have velocity or position feedback and cannot close a velocity or position loop To drive a brush motor connect to the S200 as shown in the next figure c FEEDBACK c N MOTOR POWER To finish configuring the S200 to drive a brush motor set the following parameters using the S200Tools utility Once configured the parameters should be saved to non volatile MEMORY click the NV Save button to allow the configuration to be recalled on power up Refer to Advanced Configuration for detailed descriptions of the parameters The relevant No Connection 5200 Brush Motor Wiring parameters are listed in the table below Parameter Value CommMode Brush CommOff 0 Degrees OpMode Torque Current Or SetupS2 1 with switch S2 1 set to the down position labeled I on the drive KIP Set directly with the serial port when S1 is set to position 0 Or Set S1 to the appropriate position for the inductance of the motor be used refer to S1 Function with 6 Step Feedback I2TFO Set to the motor s thermal time constant I2TTrip Set to the motor s continuous current rating IImtPlus Set to the lower of 100 or t
56. 9 9 1 SYNQNET CONFIGURATION For S200 Series drives that support SynqNet the following sections explain proper drive configuration DRIVE FPGA TABLE Node Type Option Valid FPGAs 0x00030030 0x00000000 OxCOFEO0036 For more information about FPGAs visit Motion Engineering Inc s Technical Support site http support motioneng com Go to Hardware gt Drives gt FPGA Images Parameter Specification Node Type 0x00000000 Option 0x00000000 FPGA OxCOFE0036 Motor Count Drive Count Secondary Encoder Count SqNode Digital Out Count SqNode Digital In Count SqNode Analog Out Count SqNode Analog In Count 0 0 Parameter MotorO Capture Count Probe Count Pulse Count Dedicated In 0 Amp Fault Dedicated In 1 Brake Applied Dedicated In 2 Home Dedicated In 3 Limit HW Pos Dedicated In 4 Limit HW Neg Dedicated In 5 Index Primary Dedicated In 6 Feedback Fault Dedicated In 7 Captured Dedicated In 8 Hall A Dedicated In 9 Hall B Dedicated In 10 Hall C Dedicated In 11 Amp Active Dedicated In 12 Index Secondary Dedicated In 13 Warning Dedicated In 14 Drive Status 9 Dedicated In 15 Drive Status 10 Dedicated Out
57. E Guideline 72 23 EEC Low Voltage Directive Applied harmonized standards EN 50178 1998 CE Guideline 89 336 EEC EMC Directive Applied harmonized standards EN 61800 3 1997 Manufacturer s Contact Peter Deneault Compliance Engineer Danaher Motion GPS North America Pacific Scientific Issued By Steve McClellan Engineering Services Director Danaher Motion GPS North America Kollmorgen Industrial Drives Place Date Radford VA USA 03 05 2004 Legally binding Signature 22 Ch nh 120 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Appendix E Regulatory Information E 3 INSTALLATION AND COMMISSIONING Installation and wiring of the drive must be completed only by qualified personnel having a basic knowledge of electronics installation of electronic and mechanical components and all applicable wiring regulations Only qualified personnel having broad knowledge of electronics and motion control technology are to commission the machine utilizing the drives This manual should be read in its entirety This appendix contains important regulatory information not necessarily covered in earlier chapters The material in this section should be taken into consideration to ensure compliance with applicable regulatory requirements This section alone does not contain all the information needed to install and operate an 5200 drive General information on installation and wiring are explained in detail in
58. Enb AFBDivisorSrc AFBFBSrc Incremental A Quad B Disable Disable AuxFBbDivisor AQB Incremental A Quad B Enable Disable AuxFBDivisor AQB with Halls 1 Vp p Sin Cos Disable Disable AuxFBDivisor SCD Incremental EnDat 2 1 Disable Enable AuxPPR SCD 5200 Reference Manual M SM 200 01 75 Advanced Configuration 03 2006 Danaher Motion Kollmorgen See AuxFBDivisor to complete the setup of the Aux Feedback interface BatFDis Enable Disable This parameter enables or disables the Battery Low fault The Battery input on the command I O connector is an optional feature and is not required for proper operation of the drive It is only required if the battery backup of the multi turn information is required from the SFD If the feedback device is not an SFD then the battery does nothing 0 Enable Battery Fault 1 Disable Battery Fault CmdF0 1 518 93254 Hz CmdFO sets the break frequency in Hz for two cascaded single pole low pass filters on the hardware command input There are two ranges of values for from 2915 to 24873 Hz cannot be set The lower range is the active range suggested for velocity control and the upper range is used to effectively turn the filter off for velocity control or for use with torque current control This parameter is particularly useful when CmdSrc selects the PWM input for the command source CmdF0 should be less than the input PWM frequency divided by 10 and preferabl
59. KOLLMORGEN www DanaherMotion com 200 High Performance Compact Brushless Servo Drives SynqNet and Base Units Reference Manual M SM 200 01 Revision A D ovananer ww Revision History Date Issue Description 05 2004 Initial Release 03 2006 A Addition of SynqNet information 2006 Danaher Motion All rights reserved Printed in the United States of America NOTICE Danaher Motion is a registered trademark of the Danaher Corporation Danaher Motion makes every attempt to ensure accuracy and reliability of the specifications in this publication Specifications are subject to change without notice Danaher Motion provides this information AS IS and disclaims all warranties express or implied including but not limited to implied warranties of merchantability and fitness for a particular purpose It is the responsibility of the product user to determine the suitability of this product for a specific application Safety Symbols Warnings alert users to potential physical danger or harm Failure to follow warning notices could result in personal WARNING injury or death Cautions direct attention to general precautions Personal injury and or equipment damage could result if precautions CAUTION are ignored Notes highlight information critical to your understanding NOTE or use of the product Danaher Motion Kollmorgen 03 2006 Table of Contents Table of Contents 1 S200S
60. KPP Sets the proportional gain of the position loop KVFF Sets the feed forward gain of the derivative or the position command to the internal velocity command SelSFDParam SFD Default value recommended setting This setting will automatically set the motor parameters KVP will be set for 75 Hz nominal velocity loop bandwidth with an unloaded motor To change KVP or other motor parameters refer to Configuring with SFD Feedback Motor Parameters KVI Sets the velocity loop break out frequency from integral to proportional compensation ARFO Single pole filters in the velocity loop forward path Set to ARF1 accommodate the effects of mechanical resonance The following are optional parameters that can be set Parameter Function EncOut Sets the line count of the emulated encoder output NOTE Emulated Encoder Outputs are not available when the PosSrcCmd is set to AQuadB EnlnhibitCW s EnlnhibitCCW Enables the hardware over travel limits 68 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Basic Configuration 7 9 REVERSING MOTION DIRECTION In order to reverse the motion direction of the drive the command to the drive needs to be reversed In addition the emulated encoder output polarity needs to be reversed if an external controller is using the emulated encoder outputs for feedback To reverse the command to the dri
61. Loop Compensation KVP Range Depends on 0 00044 to 0 106 Ipeak 1 rad sec KVP Resolution 10 KVI Range Hz 0 0 0238 to 753 9 KVI Resolution 10 ARFO0 Range Hz 1 518 to 96382 ARF1 Range Hz 1 518 to 96382 Values for ARFO ARF1 from 3012 to 24873 Hz cannot be set 3 6 I O 3 6 1 Analog Command Maximum Differential Range volts 12 5 Maximum Single Ended Range volts 12 5 to 16 0 Full Scale Tolerance Worse Case 3 5 Typical 1 Linearity Full Scale lt 0 1 Monotonic to lt 26 Full Scale S N Ratio Referred to Full Scale bitSrms Full A D Bandwidth 14 800 Hz A D Bandwidth 16 25 Hz A D Bandwidth 18 Offset Adjustable to 0 Maximum Unadjusted Offset mV 50 Offset Drift uV C typ 250 CMRR gt 30 dB at 60 Hz 5200 Reference Manual M SM 200 01 Specifications 03 2006 Danaher Motion Kollmorgen 3 6 2 A Analog Output DacMon Maximum Range volts 0 5 4 5 Full Scale Tolerance Worse Case t5 Typical t1 Linearity 9o Full Scale 0 1 Monotonic to lt 26 Full Scale Offset mV 100 Offset Drift uV C typ 250 3 6 8 HSINP Step PWM Command HSINP J4 10 J4 11 Input Voltage volts 3 0 6 0 Input Current mA 9 0 24 0 Minimum Pulse Width ns 250 HSINP as Step Command Maximum Step Frequency MHz 1 5 HSINP as PWM Command PWM Frequency kHz 0 25 to 250 Pulse Width 0 100 Duty Cycle Pulse Width Distorti
62. OCK J14 4 5V I O J14 5 RTN J14 6 FCOMZ DATA J14 7 FCOMZ DATA J14 8 AUX PTC J14 9 VO RTN J14 10 5V I O J14 11 RTN J14 12 AUX A J14 13 AUX A J14 14 AUX B J14 15 AUX B Mating Connector Information 15 Pin Female High Density D Sub NorComp 180 015 102 001 Male D Sub connector solder NorComp 978 009 020 121 Metalized plastic back shell kit Refer to www norcomp net 6 13 1 Auxiliary Feedback Device Port Run FB Type X Incremental Encoder X X Incremental Encoder Halls AKM Motor Feedback Options ED EE DF EG EM EH EN EJ X 1 Vp p Sin Cos 65536x Interpolator X X 1 Vp p Sin Cos 65536x Interpolator Halls X X EnDat 2 1 Sin Cos Encoder AKM Motor Feedback Option DA X X EnDat 2 1 Sin Cos Encoder Multi turn Absolute AKM Motor Feedback Option DB Run Commutate the motor and close the servo loops FB Use as a secondary feedback 5200 Reference Manual M SM 200 01 57 Basic Configuration 03 2006 Danaher Motion Kollmorgen 7 7 1 7 1 1 BASIC CONFIGURATION When connected to a motor equipped with the Smart Feedback Device SFD the S200 drive will automatically configure most of its operating parameters For many applications requiring an analog torque or analog velocity block no additional set up beyond the setting of the two switches is required to f
63. Provide safety isolation with the external bus and control supplies from the power line The drive cannot be powered from an electrically Hot supply as it does not contain an isolation barrier The Ctrl and Bus voltages and non opto coupled I O grounds I O RTN are commoned inside the drive The Ctrl and Bus power supplies share a ground pin Bus Ctrl Gnd Join and connect to the negative terminals of the Ctrl and Bus power supplies The I O RTNs are normally connected to the signal ground of the system Some of the I O is opto coupled and have separate returns Be sure to thoroughly review this document for details The power supply negative terminal should be grounded somewhere in the cabinet The chassis should also be grounded In normal operation there should be no significant voltage between ground and the Bus Ctrl Gnd and I O RTNs The maximum voltage allowed between Bus Ctrl Gnd and chassis is 100 VDC Bus Capacitance There is a minimum requirement on the output capacitance of the bus power supply for the 5200 DC Input Drives This capacitor is needed to absorb energy during motor deceleration and motor disable It also helps provide energy during motor acceleration For multiple S200 drives operated from one supply the recommendation is to increase the capacitance according to the number of drives For example for four 6 A 18 ARMS DC S200 drives powered from one 75 VDC supply the recommended minimum bus output capacitance of t
64. RF ground 5200 Reference Manual M SM 200 01 117 Appendix E Regulatory Information 03 2006 Danaher Motion Kollmorgen E 2 1 Test Setup AC MODELS S2XX6X VTS 1 S200 AC DRIVE S20360 VTS 2 MOTOR FEEDBACK CABLE CF DA0111N 05 0 cF DA0111N 50 0 for conducted emissions 3 MOTOR POWER CABLE CP 102AAAN 05 0 CP 102AAAN 50 0 for conducted emissions 4 MOTOR KOLLMORGEN 00 5 LINE FILTER MTE RF30006 4 see below 6 CORDS FOR AC MAINS CONNECTION 7 5V POWER SUPPLY FOR ENABLE 8 PERSONAL COMPUTER 9 SERIAL CABLE for setup and diagnostics 10 SHIELDED I O CABLE WITH DSUB SHELL GROUNDED AT EACH END cable between filter and drive shielded with shield tied to PE with a 360 degree termination at each end of the cable E 2 2 CETest Setup DC MODELS S2XX3X VTS 1 S200 DC DRIVE S20630 VTS 2 MOTOR FEEDBACK CABLE CF DA0111N 05 0 cF DA0111N 50 0 for conducted emissions 3 MOTOR POWER CABLE 102 05 0 CP 102AAAN 50 0 for conducted emissions 4 MOTOR KOLLMORGEN 00 5 SAFETY ISOLATED DC BUS POWER SUPPLY 6 CORDS FOR AC MAINS CONNECTION 7 5V POWER SUPPLY FOR ENABLE OPTO 8 PERSONAL COMPUTER 9 SERIAL CABLE for setup and diagnostics 10 SHIELDED CABLE WITH DSUB SHELL GROUNDED AT EACH END 118 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Appendix E Regulatory Information E 2 3 Declarat
65. SFD If the feedback device is not an SFD then the battery does nothing J4 13 The I O RTN is the ground reference for the SFD input 5200 Reference Manual M SM 200 01 47 Wiring the Drive 03 2006 Danaher Motion Kollmorgen 6 7 5 6 7 6 DAC Monitors J4 14 DAC MON1 J4 15 DAC MON2 J4 13 16 23 26 RTN The DAC Monitors are general purpose analog monitor points The output range is 0 5 to 4 5 V with a source impedance of 2 9 kW which limits the short circuit to I O RTN to 2 mA Each DAC Monitor can be mapped by software to one of a number of internal variables O RTN is the ground reference for the DAC MON Analog Command Encoder output inputs and SFD These pins are electrically shorted together inside the drive Connect one of the I O RTN pins to an earth ground point in the cabinet reserved for single point grounding of all returns drives and supplies to control common mode voltage Encoder Outputs Inputs J4 19 CH A OUT IN J4 20 CH A OUT IN J4 21 CH B OUT IN J4 22 CH B OUT IN Outputs Channels A and B are RS 485 compliant differential I O that can be configured as either inputs or outputs Default is as outputs When configured as outputs and with high resolution feedback such as the SFD device Channels A and B provide position signals generated from the feedback device that emulate a quadrature encoder The outputs are buffered by 5 0 V 75LBC170 ty
66. al Time Constant in sec I2TTrip 0 to 1 19 DIpeak Sets the fault trip level for the I2T fault used to protect the motor from transient thermal overload caused by very high peak currents compared to the motor s continuous current capability It is typically set to be slightly larger than the motor s continuous current capability The motor s thermal sensor provides protection against small overloads ILmtPlus ILmtMinus of DIpeak IImtPlus and IL mtMinus are the clockwise and counter clockwise current limits respectively They set the maximum allowable torque current command in their respective directions They are a percentage of the drive s peak current rating DIpeak 80 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Advanced Configuration ITMode Fault Foldback Selects whether the drive faults on too much peak current for too long i e excessive I t or folds the current limits back by clamping them to 67 IFldBack or less If IImtPlus and IIlmtMinus are set to 67 or less fold back has no effect See FoldBack for related information 79 226 VBusScale DIpeak to 19014 VbusScale DIpeak V A KIP sets the proportional gain of the current loops The bandwidth of the current loop in Hz is KIP Motor l l L 21r See the drive specification section for recommended bandwidths KPP 0 379 93 99 Hz Not supported over SynqNet Sets KPP sets the proportional gain of the position loop in Hz Wh
67. anger of severe CAUTION burns if these regions are touched 5 Prevent Damage to the Drive Follow these guidelines to prevent damage to the servo drive during operation e Never plug or unplug connectors with power applied e Never connect or disconnect any wires to terminals with power applied e the drive indicates a fault condition find the cause of the fault and fix it prior to resetting the fault or power cycling the drive 124 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Appendix E Regulatory Information E 9 EMC COMPLIANCE WITH EN61800 3 Use in a Domestic Environment The products covered in this manual are of the restricted sales distribution class according to IEC 61800 3 In a domestic environment this product may cause radio interference in which case the user may be required to WARNING take adequate measures Because applications differ it is impossible for the drive manufacturer to guarantee machine EMC compliance In some applications it may be CAUTION necessary for the machine builder to incorporate more EMC mitigation E 10 techniques than Danaher Motion had to use in the EMC test setups General Suggestions to Improve Machine EMC Performance e Use Danaher Motion cables Danaher Motion cables have been designed with EMC considerations in mind Because subtle differences in cable construction can cause dramatic changes in EMC performance use of Danaher Motion s Kollmorgen mo
68. arameters provide robust performance of current and velocity loops with optimized settings to protect the motor from thermal overload For most applications these default motor parameter settings are recommended because they provide excellent performance and require no additional tuning To use the default motor parameters verify that SelSFDParam is set to SFD which is the factory default setting If the response time and or stability of the system needs to be further optimized for the specific application the motor parameters will need to be modified To modify the motor parameters set SelSFDParam to Drive This setting unlocks the motor parameters and allows the parameters to be individually set with the S200Tools utility The modified motor parameters will need to be saved to the drive s non volatile memory click the NV Save button to ensure that the changed settings are loaded when the drive is powered up Incorrect motor parameter settings can cause damage to the motor and or drive The motor parameters need to be set correctly to match the drive to the motor The correct parameter settings ensure e drive is matched to the motor inductance and pole count e Thecurrent and velocity loops are stable with good bandwidth e The motor is protected from thermal overload A good starting point to setting the motor parameters is to obtain the default motor parameters and then edit only the parameters that need to be changed e Using th
69. ation lines Shield all cables used with the S200 drives with the shields connected to PE EMC testing was performed using a single drive with standard wiring When a machine incorporates several drives or is designed for use in an environment requiring very low emissions additional steps may be necessary to reduce the overall machine emissions and or susceptibility High frequency grounding of cable shields may help reduce radiated and conducted emissions as well as protect against susceptibility to external and self generated noise High Frequency Grounding of Cable Shields e When a cable with a separate inner foil shield and outer braided shield is used EMC performance may be improved by connecting the foil shield to the PE location on the connector and removing about 10 mm 0 5 in of the outer cable jacket close to the drive within 0 6 m 2 ft of the drive to expose the braided shield and clamping the outer braided shield to the ground plane with a 360 type clamp e ground plane is available at the motor end of these cables similar use of a conductive clamp at that end to connect the shield to the ground plane may help as well Clamping the cable shields to PE typically reduces the level of emissions and increases the level of immunity to interference Example of 360 clamping of cable shields 126 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Appendix E Regulatory Information E 11 A
70. atus indicator This signal is actually the inverse of the FAULT DOUT1 output of the drive on the Command I O connector J4 Current flows through DOUT1 when DriveOK is active or logic one 0 Drive fault see FaultCode 1 Drive not faulted EMUAI 0 1 This variable indicates the state of the emulated encoder channel A pin on the Command connector J4 0 Input CH A OUT more positive then CH A OUT 1 Input CH A OUT more positive then CH A OUT EMUBI 0 1 This variable indicates the state of the emulated encoder channel B pin on the Command connector J4 0 Input CH B OUT more positive then CH B OUT 1 Input CH B OUT more positive then CH B OUT Enabled Off On This variable indicates the enable state of the drive power stage This signal is the inverse of the active on RUN DOUT2 output of the drive on the Command I O connector J4 Current flows through DOUT2 when Enabled is active or logic one 0 Drive disabled power stage OFF 1 Drive enabled power stage ON EnDatDistMT 0 to 65535 Supported over SynqNet If an EnDat encoder is present this variable holds the number of distinguishable multi turns the encoder can resolve EnDatPPR 0 to 2 1 Supported over SynqNet If an EnDat encoder is present this variable holds the number of signal periods per revolution for a rotary encoder or signal period length in nm 0 001um for linear encoders ExtFaults Status Value This variable gives the
71. better The S200 drives are not considered portable and are to be mounted in the intended manner in a motor control cabinet having adequate strength and thickness with acceptable spacing for the end product classification accessible by qualified personnel only The enclosure cabinet shall meet at least the requirements of Protective Type IP2X according to 5 1 of EN 60529 If the top surface of the enclosure cabinet is easily accessible it shall meet at least the requirements of the Protective Type IPAX Care shall be taken to ensure that the larger device or enclosure that accommodates the built in device provides protection against direct contact The S200 drives may be erected in closed electrical operating areas if a protection against direct contact is available or assigned for by means of obstacles and or a distance according to IEC 364 4 412 3 and IEC 364 4 412 4 Follow IEC 536 2 and IEC 1140 for installation protection against electric shock Installation shall be performed in accordance with local electric codes local accident prevention rules EN 50178 and EN 61800 3 Never connect or disconnect any drive connectors or terminals while the power is switched on Due to high leakage current permanently install this drive hard wired or fixed type The PE connection shall be made by two separate protective conductors satisfying the requirements for protective conductors as given in 543 of HD 384 5 54 S1 between the earth ground and the PE t
72. bles for voltage loss vs cable length Single phase operation of the S20660 requires derating of continuous output 3 2 AC INPUT DRIVES CONTROL AND POWER 3 2 1 AC Control Power Supply Input Voltage Range RMS 85 VAC to 265 VAC single phase 47 to 63 Hz 120 VDC to 375 VDC Ride Through Time for AC 85 VAC 60 Hz 0 78 60 Hz cycles Line Drop 120 VAC 60 Hz 3 3 60 Hz cycles 240 60 Hz gt 18 5 60 Hz cycles 6 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Specifications 3 2 2 3 2 3 3 2 4 3 2 5 3 2 6 AC Motor Power Supply Input Voltage Range RMS 90 to 265 VAC Phases 10r 3 Transformer Suggested KVA 520260 1 5 to2 kVA 520360 2 0 to 3 kVA 520660 3 0 to 5 kVA Maximum AC Line 100 Maximum AC Line is specified to limit the mains surges to the drive AC Bus Voltage and Faults 240 VAC Input Nominal Bus 320 VDC Voltage 120 VAC Input Nominal Bus 155 VDC Voltage BUS Undervoltage Fault Factory Default is None BUS Overvoltge BusOV Fault 407 5 BUS Regen Voltage 0 974 BusOV 397 VDC Nominal AC Inrush Current amp Fusing 520260 520360 520660 Worse Case Inrush Peak 140 A 0 140 A 0 p 240 A Current at 240 VAC Inrush pulse width 1 5 ms
73. ccessing Drive Parameters over 90 9 3 1 lntroductiori toit eei ted aes e ted e Ee 90 9 3 2 Memory Operations on Drive 90 9 3 3 Accessing Individual Parameters 91 9 3 4 Accessing an Entire Parameter 91 Accessories Connector Kits and nnn nnn nnns 95 10 1 ACCESSONGS cedi eee a abe o eene 95 10 2 Connector Kifs e E i tee i te ERE 95 10 3 Cables iade Re ete qu e Cete tdem e eene 96 Diagnostics and Troubleshooting 97 111 DrveFault Godes o oU Rer nete 97 11 27 DiagnostiCs i oe ee abo oa es 99 11 21 ete tei daten d etse aaRS 102 5200 Reference Manual M SM 200 01 Table of Contents 03 2006 Danaher Motion Kollmorgen Appendix A Power Supply ennt enne ne nennen anni nnne 103 1 ease tet e ecd etes 103 A 1 1 Single Power Supply Operation sses em 103 A 1 2 Main Supply Output Capacitance J1 3 to 1 2 105 A 2 Two Power Supply Operation esses 1
74. ck 0 Not in fold back Not asserting fault 1 Fold back I t fault HallInp 0 7 Decimal This variable reads back the state of the Hall inputs to the drive on the drive feedback connector Input Bit Description IN8 Hall A IN9 Hall B IN10 Hall C Inputcw Inputcu InputCV HallInp Value 1 1 1 7 1 0 6 1 0 5 1 a __ 0 4 0 1 3 0 D 1 2 0 0 1 0 0 0 0 HSInp1 Inactive Active Indicates the state of the hardware input HSInp HSInp on the Command I O connector J4 For OpMode Position PosCmdSrc Step Dir this input is the Step input Input transitions from LED current to no LED current yields a step count while input transitions from no LED current to LED current yields no action 0 Active state current flows in opto isolator input diode 1 Inactive state no current flow HSOT 50 to 137 6 HSOT reads the temperature at which the drive will generate a Heat Sink over temperature fault Comparing HSOT minus ambient temp to HSTemp minus ambient temp can give an 5200 Reference Manual M SM 200 01 85 Advanced Configuration 03 2006 Danaher Motion Kollmorgen indication of the amount of head room from thermal overload that the drive has during normal operation HSOT desired trip temperature 25 0 6768 50 76 For example HSOT 85 decimal yields 75 6 C trip temperature HSTemp 41 1 C to 125 8 C HSTemp reads back the heat s
75. commendations and warnings detailed in this manual are complied with and that the applicable regulations for safety machine directives etc and noise suppression EMC Directives are observed while operating the drive At the end of its lifetime dispose of or recycle the drive according to the regulations applicable at that time E 2 CE APPROVAL The CE initials confirm that the 5200 drives satisfy all requirements of CE Directives However the equipment is not ready to operate without additional installations cable motor etc Thus all necessary tests and measurements had to be made on a typical installation The test installation with all peripheral devices as well as the test results and measurements are recorded in detail in documentation that is available from the manufacturer on request E 2 CE EMC COMPLIANCE If the connection method on your machine is different from the ones pictured in this manual or in the event of use of components other than those specified adherence to CE interference limit values cannot be guaranteed The machine builder should incorporate good EMC installation and wiring practices in the machine design Some machine designs NOTE require more EMC consideration than others For example a multi axis machine generates more noise than a single axis machine Therefore multi axis machines may require additional noise reduction techniques such as a metal enclosure or clamping of cables shields to an
76. composite cable Some of the PWM ampere level spikes tend to return in this adjacent shield affecting the power stage voltage and current drive the feedback shield nearest to the power wires In a single shielded feedback cable this driven shield is also around the feedback data wires so some coupling can occur With double concentric feedback shields the driven shield is the outer of the two feedback shields and interposed between the driven shield and feedback data wires is the inner feedback shield Typically the inner feedback shield is isolated from the connector shells and is connected to the return for the power supply powering the feedback device A raw cable with two pairs of twisted shielded feedback sections inside a composite cable is electrically the same as single feedback shielding There may physically be two feedback shields in such a cable but these shields are not concentric There is only one shield between the power and feedback wires Whereas the double concentric feedback shields have two shields between the power and feedback wires 2 SFD 5and Gnd Resistance Spec To insure that the SFD 5 V at the SFD inside the motor is within specification the voltage drop total in the SFD 5 V wire and SFD 5 V RTN wire must not be greater than 0 5 V at 150 mA For this reason a cable requirement is that the total resistance of the feedback SFD 5 V wire plus SFD 5 V RTN wire must be 3 33 o at 20 C In practice th
77. e However unlike Download NV these parameters are only saved to the drive s temporary RAM and will not be recalled at a power up cycle It is recommended that you use the Download Drive button when testing settings Once you are satisfied with the settings click the Download NV button to permanently save the settings to the drive e Save Save As You can also save the settings of a drive as a configuration file S2C Remember saving a configuration file does NOT save the settings to the drive Configuration files can be helpful for saving multiple drive setups You can easily download a setting to a drive by opening the configuration file in the Offline mode and clicking the Download NV Drive buttons once the proper drive is selected in the Online mode It is recommended that you save a configuration file for each setup 5200 SYNQNET DRIVE Follow the instructions below if you are using one of the following S200 Series Drives e 20250 SRS S20260 SRS S20350 SRS 20360 SRS S20330 SRS S20630 SRS 20250 SDS S20260 SDS 520350 505 20360 SDS S20330 SDS 520630 505 The setup consists of the following steps 1 MDK and SynqNet Controller Installation 5200 Tools Software Installation Hardware Setup 5200 Tools Communication Wizard SynqNet Configuration Motor Feedback Configuration Save Options NO aR WN MDK and SynqNet Controller Installation Before you can use an S200 SynqNet Drive you must first install the Motion Develop
78. e S200 Tools set SelSFDParam to SFD this loads the default motor parameters e Next set SelS FDParam to DRIVE This will allow the motor parameters to be edited Change only the parameters you are looking to optimize When finished setting the motor parameters and any other parameters save the parameters to NV Memory by clicking the NV Save button The following drive setup parameters controlled by SeISFDParam Parameter Value KVP Velocity loop proportional gain KIP Current loop proportional gain DPoles Drive pole pairs I2TFO Speed of response for motor transient thermal protection I2TTrip Fault trip level for motor transient thermal protection IImtPlus Clamps drive maximum lout based on motor limtMinus 5200 Reference Manual M SM 200 01 65 Basic Configuration 03 2006 Danaher Motion Kollmorgen 7 4 2 Torque Current Mode The 5200 can drive a brushless motor in Torque Current Mode using SFD Feedback The drive can be configured either with the S200Tools over the serial port or configured using the 51 and S2 switches Configuring the drive with the S200Tools utility provides increased flexibility in setting parameters that are not available through the setup switches When using the S200Tools utility the configuration parameters should be saved to non volatile memory click the NV Save button to allow the configuration to be recalled on power up To confi
79. e of models off the shelf for the fastest possible delivery Danaher Motion sales engineers are conveniently located to provide prompt attention to customer needs Call the nearest office for ordering and application information and assistance or for the address of the closest authorized distributor If you do not know who your sales representative is contact us at Danaher Motion 203A West Rock Road Radford VA 24141 USA Phone 1 540 633 3400 Fax 1 540 639 4162 Email customer support danahermotion com Website www DanaherMotion com 5200 Reference Manual M SM 200 01 127
80. e phase AC bus power a full torque acceleration of the motor to high speed during an F47 mandated voltage sag has the potential to drag the bus voltage down If only the internal bus capacitors of a 3 A 9 ARMS S200 are supplying the full 3 kW peak output power the bus voltage sag rate is 13 V ms A single 10 to 20 ms motor acceleration during a 5096 F47 voltage sag has the potential to drop the bus voltage about 5096 Options to handle this problem are a Limited hold up time of 20 to 30 ms is achieved by adding additional capacitance on the bus Wire an external 1 500 uf or higher 450 VDC aluminum cap across the bus to bus In this case simply wire a rectifier or surge limiter between the drive AC terminals and the cap to help charge the external capacitance at power up The bus voltage does not return to normal until the line returns to normal so multiple accelerations during the sag are a problem with this option b Monitor the line voltage and quickly pause the machine when the voltage sags c Combination of a and b d A robust costly option to ride through all F47 mandated voltage sags when three phase 240 VAC is not available is either to double the peak power capability of the motor drive system or to derate the motor s maximum speed 50 If a motor s top speed can be achieved with a 5096 low bus voltage the worse case F47 voltage sag of 50 is tolerated with little or no effect on motor performance e Ifthree phase powe
81. e regen resistor may exceed 70 When using an external regen resistor if regen cabling is accessible during normal machine operation regen resistor cable should be rated at 450 VDC and shielded with shield connected to PE 122 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Appendix E Regulatory Information Consult the factory before using this product on a circuit protected by a residual current operated protective device RCD All covers shall be closed during operation The 5200 drives should be used within their specified ratings E 7 UL AND CUL CONFORMANCE The 5200 drives are UL and cUL Recognized to UL 508C under UL File number E137798 Consider the following points to ensure that final installation meets UL requirements The drive should be used within its specified ratings The drive should be mounted in the intended manner in an enclosure having adequate strength and thickness with acceptable spacing for the end product classification The spacing from the exposed live metal parts to the enclosure wall should be in accordance with the requirements for the overall equipment These drives shall be used in a pollution degree 2 environment in order to comply with the spacing requirements of UL 840 and UL 508C The UL temperature tests were done with a metal heat plate with overall dimensions 6 in x 12 in x 1 8 in The machine builder is responsible for ensuring adequate heat sinking capabi
82. e rev There are 24 bits within one rev but the displayed value is scaled for 65536 counts per rev i e bits 17 through 24 show up as a fractional count after the decimal point See PosFBMtrn for integral revolutions PWMLo Base Half Base Indicates whether the drive has switched to half base PWM frequency The drive switches to half base PWM frequency when the measured motor current is above 0 53 and the electrical commutation frequency is less than 2 9 Hz The PWM frequency returns to base if the measured motor current reduces below 0 32 Dlpeak or the drive speeds up beyond 4 77 Hz commutation electrical frequency 0 Drive uses base PWM frequency 1 Drive uses half base PWM frequency SetupS1 0 9 This variable reads back the state of the rotary user setup switch S1 that determines the line count of the emulated encoder EMUA and EMUB outputs with SFD feedback or the current loop proportional gain KIP for 6 step feedback See Configuring with SFD Feedback 86 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Advanced Configuration SetupS2 0 15 decimal This variable reads back the state of the 4 position DIP setup switch S2 on the drive Switch position 1 is LSB Open high Closed low SFDExtFaults Status Value This variable gives the detailed fault code of the SFD FaultCode Status 000 No Fault 001 Sensor Error 010 No Fault 011 Multi tu
83. ei a ae i 8 34 27 Offset E 9 3 5 Velocity Loop 3 5 1 Velocity Loop Compensation esesseeeem emen 9 3 6 or EE 9 3 6 1 Analog Command sse eene emen nennen nere enne nnns 9 3 6 2 Analog Output DacMon ssesseeee eee eene nnne nns 10 3 6 3 HSINP Step PWM Command sse eene 10 3 6 4 SINP Direction Command seen enm emen enne 10 3 6 5 Quadrature Input cicer iet tete dee Hore Ede nent 10 3 6 6 General Purpose lInputs 5 2 annar ee eee tete 10 3 6 7 General Purpose Outputs ssssssseeeeeeene nennen 11 3 6 8 Quadrature Outputs eene eene nnne nns 11 3 7 Mechanical 3 uh ad Reo eed en ed Ge a eia 11 3 8 Environment l 3 eR e tert 11 3 9 Smart Feedback Device nnne 12 3 9 1 Position Signal ipte REI eR beer tie 12 3 9 2 MVelocity Signal rape te qe SU RD 12 3 9 3 Emulated Encoder Output Signals sssseeee 13 3 9 4 General SFD Specifications 13 4 Quick Start 4 1 S200 Base Unit Drive 4 1 1 5200 Tools Software Installation sse 14 4 1 2 Hardware Setup rsrsr ata ne
84. elocity operating mode OpMode Description 000 Torque Current Mode 001 Velocity Mode default 010 Setup DIP switch S2 position 1 SetupS2 1 0 Velocity 011 Position Mode PosCmdSre Step Dir AQuadB Not supported over SynqNet selects the source of the position command It selects between using Command I O connector J4 optically isolated inputs for Step Dir and the emulated encoder port used as an A quad B differential input J4 10 11 and J4 5 for Step Dir and J4 19 20 and J4 21 22 for A quad B inputs See the Control Block Diagram for more information 0 AQuadB 1 Step Dir default SelSFDParam SFD or Drive 5200 Reference Manual M SM 200 01 81 Advanced Configuration 03 2006 Danaher Motion Kollmorgen Determines whether the SFD motor parameters or drive setup values are used for the following parameters KVP Velocity loop proportional gain KIP Current loop proportional gain DPoles Drive poles I2TFO Response speed for motor transient thermal protection I2TTrip Fault trip level for motor transient thermal protection ILmtPlus Sets the drive maximum lout based on motor ILmtMinus Sets the drive maximum lout based on motor Ipgak SFDSpan Span or No Span Sets how the drive handles single sample communication errors with the SFD Span interpolates SFD feedback position for isolated single sample communicatio
85. en OpMode Position the net velocity command VelCmd in rad sec is VelCmd KPP 2z PosErr KVFF 100 d dt PosCmd KVFF 0 199 Sets the feed forward gain from the derivative of the position command directly to the velocity command of the velocity loop and has the units of percent When OpMode Position the net velocity command VelCmd in rad sec is VelCmd KPP 2x PosErr KVFF 100 d dt PosCmd KVI 0 0 0238 753 9 Hz KVI adjusts the velocity loop integral compensation It sets the break out frequency between predominantly integral compensation and predominantly proportional compensation Higher KVI values give higher integral gain and shorter time constants A value of below 0 19 Hz turns off KVI There is no integral compensation only proportional from KVP See the Control Block Diagram for more information KVP 221 0e 6 DIpeak to 25 09 DIpeak ARMS rad sec KVP sets the proportional gain of the velocity loop and has the units of ARMS rad sec The idealized velocity loop bandwidth in Hz is KVP KT JTOT 21r where KT is the motor s torque constant JTOT is the total shaft inertia and the units of KT JTOT should come out to rad sec2 ARMS See the Control Block Diagram for more information OpMode Current Velocity SetupS2 1 Position Not supported over SynqNet OpMode selects between current torque velocity and position control modes or whether the SETUP1 hardware switch is used for selecting between current torque or v
86. ependent Scale Factors The Model Dependent Scale Factors are used to calculate limits for some of the drive parameters The following table lists the model dependent scale factors Model Dependent Scale Factors Model Dipeak VBusScale Description User ARMS Relative x 520260 4 5 1 240 VAC 4 5 ARMS peak 520360 240 9 ARMS peak 520660 240 18 ARMS peak 520330 90 VDC 9 ARMS peak 520630 18 0 25 90 VDC 18 ARMS 74 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Advanced Configuration 8 3 3 Read Write NV Parameters 1 518 96382 Hz ARFI 1 518 96382 Hz and ARF1 set the break frequency Hz for the two single pole anti resonance low pass filters in the forward path of the velocity loop They are used to help accommodate mechanical resonance in the system introduced by the load connected to the motor See the Control Block Diagram for more information AuxFBDivisor 1 to 2 147 483 647 Supported over SynqNet This parameter is the divisor used to scale the raw incremental encoder counts or the Sin Cos encoder interpolated counts from the Aux Feedback interface to the Aux position word If the Aux Feedback device is used only for controller feedback then this parameter may be set to any value convenient for the application If the Aux Feedback device is used to commutate the motor then it must be set to a specific value For
87. er Identification and Configuration section Depending on the firmware version there may be more than one parameter section The format is described below A sample map file for the S200 SynqNet drive is shown in the Sample Drive Map File The file header contains one line MPI Drive Parameters Drive Identification Section This section contains one line which describes the name of the manufacturer the model number and the drive firmware versions that are compatible with the drive parameter list d Manufacturer and Model drive firmware version file specific For S200 SynqNet the Manufacturer and Model text will always be Kollmorgen 5200 Examples 4 Kollmorgen S200 2 0a Parameter Identification Section This section contains definitions of the parameters that are valid for the firmware version s listed in the Drive Identification section The section begins with the following header line fparameters Each line in this section contains the following parameter identification information Parameter Identification Name Description number Drive parameter number in hex name Drive parameter name or command string read write access Read write rw or read only ro data type One of the pre defined data types see the Data Types table values List of valid values range of valid values or an address default value Parameter value to be u
88. er s Kit Software package and SynqNet controller from Motion Engineering Inc For more information about installation please see MEI s Technical Support website S200 Reference Manual M SM 200 01 17 Quick Start Guides 03 2006 Danaher Motion Kollmorgen 4 2 2 4 2 3 4 2 3 1 200 Tools Software Installation Follow the installation instructions from the CD ROM or zip file See S200 Tools Software Installation Guide 5200 Tools supports the following Operating Systems Windows 2003 Server Windows XP All Service Packs SP Windows 2000 SP2 Windows XP embedded Windows NT4 SP6 Hardware Setup DRIVE SETUP NOTE The drive serial port J5 is disabled on SynqNet drives If you are using an S200 SynqNet Drive you need to establish SynqNet communication link between the 5200 SynqNet Drive and the SynqNet motion controller 1 2 Plug one end of an Ethernet communications cable to J11 SynqNet IN of the 5200 drive and the other end to the SynqNet controller s OUT port One Drive Node Use another Ethernet communications cable to connect J12 SynqNet OUT of the 5200 drive to the XMP SynqNet controller s SynqNet IN port Host Computer S200 uz jour iN SynqNet Controller Ethernet m Cables Multiple Drives Nodes Connect an Ethernet communications cable from the XMP SynqNet controller s OUT port to the SynqNet IN port J11 of the first drive node Connect an Ethernet cable from the node s SynqN
89. er terminals of multiple drives parallels the internal bus capacitors of the drives 200 uf per drive This allows the PWM currents of the drives to spread out thereby NOTE lowering the temperature of the capacitor in the hottest drive 108 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Appendix A Power Supply Design A 4 4 1 4 2 A 4 3 A 4 4 Bus ENERGY amp POWER NUMERICAL EXAMPLES The energy flows in the drive bus are e In Motoring mechanical energy Motor losses motor accelerates e Out Regenerated mechanical energy Motor losses motor decelerates e Out Regenerated motor inductive energy disable or fault Min External Bus Capacitance Inductance in AKM motors mated to S200s can be as high as 5 mH line to line The inductive energy stored in a 5 mH motor at 18 ARMS is calculated as E winding 0 75 x Inductance line to line x lays X 0 75 x 0 005 henry x 18 pus x 18 nus 1 2 joules The bus capacitor needed to absorb the regenerated energy Erecen is sized using the general rule that the energy stored in the capacitor be a minimum of 5 Erecen This limits the voltage increase on the bus due to regeneration to 10 of the DC value Using this general rule to find the minimum bus capacitance for the motor in the above example for simplicity ignore that a fraction of regenerated inductive energy is dissipated in the motor E bus cap 5 x 1 2 joules 6 jo
90. ergy flows See the A 4 Bus Energy amp Power Numerical Examples Bus capacitance can be tweaked experimentally Increase bus capacitance if there are overvoltage trips In general there is sufficient bus capacitance if the bus voltage variation 15 5 V from 75 VDC during the machine cycle Check the bus voltage with an oscilloscope Scope ground on J1 2 Bus Ctrl Gnd and probe on J1 3 bus Hor 5 ms div Some bus voltage variation is normal and required for the output bus capacitor to supply or absorb energy T 8 Bus over voltage fault non latching If regeneration is too high while bus capacitance is too low the bus voltage rises to the bus over voltage fault threshold and disables the drive transistors It typically takes 1 to 2 ms for the motor current and torque to go to zero After it has reached zero there is no further rise in the bus voltage When the bus capacitors discharge to below the over voltage threshold by a hysteresis value the over voltage fault is cleared and normal operation resumes While this protects the drive by limiting the bus voltage rise it may not be desirable because it interrupts normal motor torque Unregulated power supply External bus capacitance requirements are usually met by the output capacitor in an unregulated power supply as long as there is no diode between the drives and bus capacitor The same capacitor that filters the 120 Hz or 360 Hz line ripple also provides energy
91. eries 1 1 1 ot ir Wear 2 1 2 Drive Model Numbers and Descriptions sss eene 2 2 Before You Beglh eon cite ri aoa Eaa Naaa i a 4 2 1 Salely Mie bens DE sto Et S t 4 2 2 Unpacking and 4 3 Specifications aie ep 5 3 1 Drive Family POWER p D e VE EAT t e RP REUS 5 3 2 AC Input Drives Control and 6 3 2 1 AC Control Power Supply essseeeene emm eene enne 6 3 2 2 AC Motor Power Supply winiarni iiaii 7 3 2 3 AC Bus Voltage and eene 7 3 2 4 AC Inrush Current amp FUSING eee emm eene 7 3 2 5 Control Inrush Current amp em 7 3 2 6 AC Power On Delay cedet due ed needed ee ve deed redeas 7 3 3 DC Input Drives Control and Power essent 8 3 3 4 DC Control Power Supply teet ii 8 3 3 2 Bus Voltage and Faults ssssee eee 8 3 3 3 DC Power On Delay e due cc dep ud e be dated ed 8 3 4 Motor Current Control petu ER Bees 8 3 4 1 Current Loop Bandwidth is
92. erminal s on the drive or by a protective conductor having a cross section of at least 10 Cu The S200 drives are designed to Protective Class l The discharge time for the bus capacitors may be as long as 5 minutes After disconnecting the drive from the ac mains be sure to wait 5 minutes before removing the drive s cover and exposing live parts The finished installation shall comply with the requirements of the IEC 364 4 41 series of standards The cables and leads except the protective conductors used in the erection of the 5200 in an installation which are accessible for contact without opening or removing a barrier or are laid on extraneous conductive parts shall have double or reinforced insulation between the core and the surface or shall be surrounded by a metal screen having a satisfactory current carrying capacity in the event of a short circuit between the core and the screen When installing the 5200 into its operating location it shall be ensured that any existing protective separation according to 5 2 18 of EN50178 is maintained throughout the entire length of the circuit in question In installations the compliance for of the measures for protective separation shall be checked by visual inspection Refer to Sections 1 and 4 of this manual for external fusing information Motor cable shield must be connected to protective earth During periods of extreme regeneration or excessively high input voltage the temperature of th
93. es 6 step commutation with CU CV 110 CommOff 180 Degrees Offsets the origin for the electrical commutation angle in degrees Normally set to zero Non zero allows matching non standard motors or systems In 6 step mode this parameter must be set to WARNING 0 for proper operation See also CommMode Dinp1Pol Invert or Normal This parameter selects the polarity of the Dinp1 When this parameter is set the input to the FPGA is inverted before it is used by the logic This parameter affects the sense of the enable I O input The following describes the different values for this parameter 0 Normal 1 Invert Dinp2Pol Invert or Normal This parameter selects the polarity of the Dinp2 When this parameter is set the input to the FPGA is inverted before it is used by the logic This parameter affects the sense of the InhibitCW I O input The following describes the different values for this parameter 0 Normal 1 Invert Dinp3Pol Invert or Normal This parameter selects the polarity of the Dinp3 When this parameter is set the input to the FPGA is inverted before it is used by the logic This parameter affects the sense of the InhibitCCW I O input The following describes the different values for this parameter 0 Normal 1 Invert Dinp4Pol Invert or Normal This parameter selects the polarity of the Dinp4 When this parameter is set the input to the FPGA is inverted before it is used by the logic This param
94. es with the AC mains is necessary It is the responsibility of the machine builder to choose filter s appropriate for the application Danaher Motion is willing to assist in this choice Often the decision is made to filter the machine as a whole instead of filtering the individual drives Mount the line filter as close as possible to the point where incoming power enters the machine cabinet Locate the drive s as close as possible to the line filter To provide maximum high frequency filtering remove any paint from between the filter the drive and the conductive surface ground plane to which they are bonded For maximum benefit separate input wiring to the line filter and output wiring from the line filter from each other During CE testing three 3 line filters were qualified for use with 50 m motor and feedback cables to represent worse case conducted emissions compliance The following filters were used Corcom 6EQ1 single phase Corcom 36FCD10 three phase MTE RF30006 4 three phase Information on these and other filters can be found at 5200 Reference Manual M SM 200 01 125 Appendix E Regulatory Information 03 2006 Danaher Motion Kollmorgen AN CAUTION A CAUTION Corcom Inc MTE Corporation USA 1 800 468 2023 or 847 680 7400 USA 1 800 455 AMTE Germany 49 89 857920 International 1 262 253 8200 http www cor com http www mtecorp com For complete i
95. et OUT port J12 to the SynqNet IN port J11 of the next node Connect another cable from the SynqNet OUT port J12 of the last node in the topology to the SynqNet IN port of the XMP SynqNet controller S200 Node 1 14 Host Computer OUT 5200 NodeO J11 Ethernet Cables 112 OUT IN m f D SynqNet Controller IN ju 18 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Quick Start Guides NOTE Although you can connect other SynqNet supported nodes drives on the SynqNet network you will only be able to configure the S200 Series Drives with the 5200 Tools software S200 Tools will only communicate with 5200 Series Drives 4 2 3 2 MOTOR SETUP Depending on the type of motor feedback that is used you will need to use the appropriate feedback connector Motor Feedback J3 Feedback J14 AUX FB SFD X SinCos with Endat 2 1 SinCos with Halls ComCoder Incremental Halls lt KY 4 2 4 S200 Tools Communication Wizard 4 2 4 1 LAUNCH S200 TOOLS Launch the S200 Tools program by clicking the desktop icon or from the Windows Start button Programs gt Danaher Motion gt S200Tools The default location for S200Tools exe is C Program Files Danaher Motion S200Tools Deve SASM t me Opasan Mode When the S200 Tools program is launched for the first time no drives should be listed under the Online or
96. eter affects the sense of the MSInp1 I O input The following describes the different values for this parameter 0 Normal 1 Invert 5200 Reference Manual M SM 200 01 77 Advanced Configuration 03 2006 Danaher Motion Kollmorgen DM1Map DM2Map See Chart Selects the variable sent to DACMon1 DACMon2 analog output pins on Command I O connector J4 The DACMon1 2 output pins have a 2 0 V range centered around a 2 5 V bias that is the output varies from 0 5 to 4 5 V and is 2 5 V when the selected DAC signal is zero These DAC outputs are not clamped at maximum analog range When the signal reaches maximum analog output further signal increases cause it to extreme DM1Map wrap around to the opposite range Parameter Value Definition VelErr 286 rpm V PosFB 0 25 rev V IdFB 0 8474 DIpeak ARMS V VelFB 2288 rpm V VelFB 9155 rpm V PosErr 0 0625 Rev V VdCmd 134 5 VBusScale V PosFB 244 1e 6 rev V Velocity error Position big bits Non torque current Velocity little bits Velocity big bits Position loop position error Quadrature voltage command Position little bits DM2Map Parameter Value Parameter Value Definition Velocity mode Torque mode VBus 380 VBusScale Bus voltage V V CmdIn 9155 rpm V Command IFB 0 8474 DIpeak V VelFB 1144 rpm V DTFilt0 7152 DIpeak VU 812 VBusScale V 0 84
97. extended fault status of the drive Each bit represents an individual fault that is logically OR ed with other faults Note that this variable remembers its last active value and can be used as a one deep fault log Code Extended fault Extended fault 1 SFD UART parity error 9 Drive under temperature 10 Drive short circuit Drive output over current Option card read timeout Option card watchdog timeout Step size overflow Position error overflow 16 Drive over temperature AuxFB Fault 84 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Advanced Configuration FaultCode Status Value This variable gives the fault status of the drive The below table lists the possible fault states and gives the number of blinks that the drive s front panel Status LED will blink to indicate the fault See also ExtFaults for further specifics on a given fault C Status Status 1 Not Assigned 11 Hall Fault 2 SFD Configuration Error 3 13 SFD Shor 4 SFD Motor Data Error 5 SFD Sensor Failure 6 SFD UART Error 7 17 SFD Communication Error 8 Option card Watch Dog timeout 9 Position error too large 10 Output Over Current 20 Open Card Fault FoldBack Normal Foldback Indicates whether the drive is actively folding back the peak current limits because of excessive 14 ITMode can be set to fault the drive on either excessive 1 or fold ba
98. gure the drive for Current Mode with SFD feedback set the following parameters Parameter Value CommMode SetupS2 2 Default value with switch S2 2 set to the down position labeled S on the drive or SFD CommoOff 0 Degrees for motor series check with your sales representative for the correct commutation offset angle for other motor series OpMode SetupS2 1 with switch S2 1 set to the down position labeled I on the drive or Current SelSFDParam SFD Default value recommended setting This setting will automatically set the motor parameters To change motor parameters refer to Configuring with SFD Feedback Motor Parameters CmdSrc Sets the source of the command CmdGain Sets the command gain for the command input CmdOffset Sets the command offset for the command input CMDFO Sets the filtering on analog input commands The following are optional parameters that can be set Parameter Function EncOut Sets the line count of the emulated encoder output EnInhibitCW dee EnInhibitCCW Enables the hardware over travel limits 66 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Basic Configuration 7 4 3 Velocity Mode The 5200 can drive brushless motor in Velocity Mode using SFD Feedback The drive can be configured either with the 5200 tools over the serial port or configured using the S
99. h currents can cause heating of wires and capacitors The simplest way to squelch bus ringing is to lower or change the inductance of the bus wiring with the following a Move the external bus capacitor closer to the drive or b Twist the bus and ground wires between the drive and supply or c Add extra capacitance 470 uf or more near the drive bus terminals 12 Recommended External Bus Capacitors Aluminum electrolytic computer grade screw top cans are available with panel mount hardware The voltage rating should exceed the maximum bus voltage Choose a cap 5200 Reference Manual M SM 200 01 107 Appendix A Power Supply Design 03 2006 Danaher Motion Kollmorgen with a 100 V rating for operation at 75 V bus nominal The important capacitor parameter is capacitance energy storage so an 85 C general purpose type such as are listed below is acceptable Panasonic G AA series 1 375 x 4 125 8 200 uf 100 V EEGAA2A822CKE 2x4 125 22 000 yf 100 V EEGAA2A223FKE 3 x4 125 47 000 uf 100 V EEGAA2A473HKE Cornell Dubilier DCMC series 1 375 x 4 125 8 600 uf 100 V DCMC862U100AC2B 2x4 125 20 000 yf 100 V DCMC203U100BC2B 3x 4 125 49 000 pf 100 V DCMC493U100DC2B United Chemicon U36D series 1 375 x 4 625 8 200 yf 100 V U36D100L G822M35X117HP 2x4 625 18 000 uf 100 V U36D100LG183M51X117HP 3 x 4 625 47 000 pf 100 V U36D100LG473M76X117HP A 2 Two POWER SUPPLY OPERATION Powering the drive control power separately from the bus power has t
100. h of the outputs DOUT1 Output 1 This output provides the FAULT state of the FAULT drive When the drive is powered and not faulted the output transistor is turned ON When the drive is faulted or not powered the output transistor is turned OFF DOUT2 Output 2 This output provides the RUN state of the drive RUN When the drive is powered not faulted and enabled the output transistor is turned ON When the drive is faulted not enabled or not powered the output transistor is turned OFF This output indicates when the drive is capable of running the motor OUTPUTS DRIVING TYPICAL LOADS Both the collector and emitter of the phototransistor are on J4 providing the capability to drive either sinking or sourcing loads Sinking Load External Current Limiting Resistor Power Suppl 50 mA MAX 30 VDC MAX An optoisolator is being driven in this example The current through the output needs to be limited to 50 mA or less which is accomplished by selecting an appropriate current limiting resistor The voltage of the external power source needs to be 30 VDC or less and can be the same source used to provide power to the inputs Sourcing Load Relay Coil Current Limiting Resistor 50 mA MAX External Power Suppl 30 VDC MAX In this example a relay coil is being driven The current through the coil needs to be limited to 50 mA or less which is accomplished by selecting an appropriate value of current limiting resistor
101. he AuxFB faults AuxFBEnDatFIt AuxFBPTCFIt or AuxFBSCDFIt Check to make sure that the drive is set up for the correct feedback device and that the device is functioning correctly If ExtFaults is No Extended Fault then this was a fault induced by the controller such as SynqLost 5200 Reference Manual M SM 200 01 101 Diagnostics and Troubleshooting 03 2006 Danaher Motion Kollmorgen 11 2 1 Fault Generation The following sequence occurs when the protection circuits generate a fault One or more faults are detected by the control logic The fault source is latched only for latched faults The output stage is disabled The LED indicates the appropriate fault code For non latched faults When the fault condition is cleared the drive re enables automatically Latched faults are cleared by setting the Enable input to the disable state or by cycling off on the Control Power NOTE The large bus capacitors store substantial energy To use the control power to reset a fault the power should be removed for at least 30 seconds to ensure that the fault resets Self resetting faults disable the drive and do not return it to normal operation until 50 100 ms after the fault condition clears When multiple faults occur the highest priority fault is reported After the fault is cleared and the drive is reset by cycling the enable input the next highest priority fault that still exists will be displayed
102. he advantage that fault and status information is preserved when bus power is down for safety Wire the control supply positive terminal to J1 1 CTRL and the control supply negative terminal to J1 2 Bus Ctrl Gnd Wire the main supply positive terminal to J1 3 and its negative terminal to J1 2 J1 2 is a shared ground for control power and main power Separate ground wires from the two supplies should join at or near the shared drive ground pin J1 2 The drive can be damaged if the supply voltage exceeds NOTE 90 V even briefly A 2 1 X Control Supply 1 1 to J1 2 The voltage range of the control supply is 10 to 90 V This supply can be either unregulated or regulated However it must be isolated from the power line as its negative terminal is typically earthed for safety and commoned with main power negative terminal For reliable starting the control supply should have a peak power rating of at least 20 W A typical continuous control power drawn by an S200 DC drive is 2 to 8 W A single relatively low power low voltage supply 12 V or 24 V can provide control power and power for multiple drives A 3 MULTI AXIS CONSIDERATIONS In multi axis applications the drive s power terminals can either be wired separately to the power supplies or paralleled locally daisy chained and then wired to the power supplies In the latter case increase the wire size to handle the higher current Locally paralleling the main pow
103. he percent of the motor s peak ILmtMinus current rating divided by the drives peak current CmdSrc Selects Analog PWM or Command variable for command CmdGain Sets the command gain for the command input CmdOffset Sets the command offset for the command input CMDFO Sets the filtering on analog input commands ED LIC Enables the hardware over travel limits 62 M SM 200 01 Danaher Motion Kollmorgen 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Basic Configuration 7 3 7 3 1 7 3 2 CONFIGURING CURRENT MODE WITH 6 STEP HALL FEEDBACK The base S200 Drive must be in Torque Current Mode when using 6 Step feedback Torque Block with 6 Step Feedback Wiring c FEEDBACK c N MOTOR POWER Setting Drive Parameters for 6 Step Operation In 6 Step mode with Hall or Hall equivalent feedback the drive can be configured either using the S200Tools utility or the 51 and S2 switches Configuring the drive with the 5200 Tools provides the advantage of setting the drive s current limits and motor thermal protection When using S200Tools the configuration parameters should be saved to non volatile memory to allow the configuration to be recalled on power up 5200 Reference Manual M SM 200 01 63 Basic Configuration 03 2006 Danaher Motion Kollmorgen To configure the drive for 6 Step feedback set the following parameters
104. he supply is 4 x 4 000 yf 16 000 uf Bus capacitor voltage rating should be 100 V Bus capacitor type is aluminum electrolytic Bus Switching and Fusing Do NOT put E Stop switches or contactors between the drive bus pin J1 3 and the power supply bus capacitor There is a risk of damage to the drive if the bus is disconnected from the power supply capacitor when the drive is enabled The motor does not need to be rotating to regenerate energy The motor windings store magnetic energy that regenerates back to the supply when the drive is disabled E stop switches can safely be located in series with the primary winding of a step down transformer If individual axis E Stop switches are required connect a local unswitched capacitor 1 000 uf 100 V across the drive bus terminals J1 3 to J1 2 If the buses of individual drives are to be fused select the fuse type and rating for high margin S20330 3 amp S20630 6 amp 7 A Slo Blo Bussmann MDA 7 15 A Slo Blo Bussmann MDA 15 5200 Reference Manual M SM 200 01 37 Wiring the Drive 03 2006 Danaher Motion Kollmorgen 6 5 J2 MOTOR POWER CONNECTOR J2 is a 4 pin pluggable connector J2 Connector view from front of drive Pin Description J2 1 5200 AC Input Drives PE Physical Earth S200 DC Input Drives BUS CTRL GND J2 2 Motor Phase W J2 3 Motor Phase V J2 4 Motor Phase U Mating Connector Informat
105. high voltage even when the motor is not rotating Never disconnect or connect the product while the power source is energized After removing the power source from the equipment wait at least 5 minutes before touching or disconnecting sections of the equipment that normally carry electrical charges e g capacitors contacts screw connections To be safe measure the electrical contact points to each other and to electrical safety earth with a meter before touching the equipment 2 2 UNPACKING AND INSPECTING Open the box and remove all the contents Check to ensure there is no visible damage to any of the equipment A Use proper procedures when handling electronic components to avoid damage to equipment CAUTION Remove all packing material and equipment from the A shipping container Be aware that some connector kits and CAUTION other equipment pieces may be quite small and can be accidentally discarded Do not dispose of shipping materials until the packing list has been checked Upon receipt of the equipment inspect components to A ensure that no damage has occurred in shipment If damage is detected notify the carrier immediately Check all shipping material for connector kits documentation diskettes CD ROM or other small pieces of equipment NOTE 4 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Specifications
106. ide a good connection to PE Remove the paint on the mounting surface over an area extending at least 12 mm 0 5 in from the mounting bolts to achieve good electrical connection over a large area between the drive and grounded mounting surface e Ensure that the environment within the cabinet meets the requirements listed in the Specifications MOUNTING DIMENSIONS AC INPUT DRIVES DC INPUT DRIVES AC1 AC2 DC w Option Drive 20260 VTS S20660 XX S20330 VTS 520330 20360 VTS S20630 VTS 520630 Drive Dimensions Drive Height A 175 0 mm 175 0 mm 152 4 mm 152 4 mm 6 90 in 6 90 in 6 00 in 6 00 in Drive Width B 54 8 mm 64 0 mm 28 7 mm 48 3 mm 2 16 in 2 52 in 1 13 in 1 90 in Drive Depth C 131 6 mm 131 6 mm 100 8 mm 100 8 mm 5 18 in 5 18 in 3 97 in 3 97 in Clearance Requirements Top and Bottom D 25 4 mm 25 4 mm 12 7 mm 12 7 mm 1 0 in 1 0 in 0 50 in 0 50 in Side to Side E 25 4 mm 25 4 mm 12 7 mm 12 7 mm 1 0 in 1 0 in 0 50 in 0 50 in Mounting Dimensions Horizontal Mounting Offset 25 6 mm 25 6 mm 24 6 mm 24 6 mm F 1 01 in 1 01 in 0 97 in 0 97 in Vertical Mounting Offset 4 3 mm 4 3 mm 4 1 mm 4 1 mm G 0 17 in 0 17 in 0 16 in 0 16 in Vertical Mounting Height 166 4 mm 166 4 mm 144 3 mm 144 3 mm H 6 55 in 6 55 in 5 68 in 5 68 in Drive to Drive Mounting J 80 3 mm 87 3 mm 41 40 mm 60 96 mm 3 16 in 3 16
107. ime that the drive is turned on See Status and Control Variables for a complete list and descriptions The next section gives more details on the memory structure of the drive and how values are initialized The succeeding two sections give detailed lists and descriptions of NV Parameters and Status Control Variables respectively The functionality of the drive may be updated from time to time which may add to these lists Parameter and Variable Storage The 5200 has two types of memory non volatile memory and RAM 5200 non volatile memory NV memory is similar to disk memory in a personal computer in that it can be written to and read from and maintains its settings without power The 5200 memory RAM is temporary memory When control power is applied all NV parameter values are automatically copied from NV memory into 5200 RAM memory The 5200 operates out of temporary memory that is the temporary memory parameter values set the S200 configuration and adjustments 5200 Tools configuration software changes 5200 settings which include both parameters and variables In the Offline branches of S200Tools configuration software changes made to a setting are made only in the PC S200Tools memory on the PC Clicking the Download Drive button sends the values to the drive s temporary memory Clicking the Download NV button sends the values to the drive s NV permanent memory In the latter case the drive s control power must be cycled to get the drive
108. in 1 63 in 2 40 in Mounting Hardware M4 8 or 8 8 8 Drive Weight 0 77 kg 0 85 kg 0 40 kg 0 5 kg 1 69 Ib 1 86 Ib 0 88 Ib 1 10 Ib 1 Depth measurement is for drive only Add approximately 50 8 mm 2 in to depth given in the table to accommodate mating connectors and wire bend radius 5200 Reference Manual M SM 200 01 23 Mounting the Drive 03 2006 Danaher Motion Kollmorgen Horizon tial Top Clearance Mounting Offset P D Drive Width F B 4 Vertical Mounting Offset G For Drive Mounting use or 8 Hardware Height Vertical A ounting Height H For Drive Side Clearance Mounting E use or 8 4 gt Hardware lt ______ gt Bottom Drive to Drive Mounting Clearance J D Side Clearance E Mounting Dimensions Front View See the preceding table for mounting dimensions 24 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Mounting the Drive 5 2 5 2 1 MECHANICAL OUTLINE DRAWINGS Base AC Drive 0008008080 5 18 131 57 EN 0 18 4 57 RECOMMENDED MOUNTING HARDWARE 8 OR M4 4 57
109. ink temperature HSTemp determines how close the drive is to thermal shut down by comparing the temperature rise above ambient to the potential rise above ambient at the drive over temperature fault trip which can be read as HSOT IFB IdFB DIpeak to DIpeak These variables read back the torque IFB and non torque IdFB derated current values IFB Motor torque current IdFB Motor non torque current LogicVer 0 15 Decimal LogicVer gives the version number of the drive logic as a 4 bit unsigned integer Versions are assigned sequentially and if necessary the numbers wrap around if there are more than 16 versions Model 0 31 Decimal Model is the base unit identity code for the drive There are only 4 codes defined Other codes are configuration errors Base Model 20260 240 VAC 4 5 ARMS 20360 240 VAC 9 ARMS 520660 240 18 ARMS 520330 90 VDC 9 ARMS 520630 90 VDC 18 ARMS MTemp 0 864 870 Ohms This variable reads back the motor temperature A D value from the SFD The value is read back as the thermal sensor resistance Using the motor thermal sensor specification this value can then be converted to a winding temperature PosFBMTrn 2048 to 2047 Turns This variable reads back an instantaneous sample of the shaft position multi turn from the SFD feedback port J3 PosFB 0 to 65535 9961 Counts This variable reads back an instantaneous sample of the shaft position within on
110. input impedance of gt 300 and a single ended impedance of 150 kO The recommended full scale differential command input range is 10 V but the input can handle up to 12 V to accommodate noise and overshoot spikes Default setup has 10 V corresponding to lpeak or maximum velocity depending on the OpMode The offset gain including polarity and low pass filter bandwidth of this input are set by the following NV Parameters CmdGain CmdOffset and CmdF0 respectively and can be adjusted by the PC setup software Defaults are x10 V range 0 offset 1500 Hz bandwidth Positive ANA CMD yields clockwise torque when looking at the shaft at the front of the motor J4 24 2 5 CMD 332k 130k gt 100 pf 2425 AID OMD 33 2k _1_ 130k J4 26 O RTN 5 4 2 Always connect I O J4 26 to the signal ground of the source Failure to do so may result in erratic operation Both J4 24 and J4 25 need to be wired For single ended operation connect the unused input to the signal ground of the source Best signal fidelity uses a separate wire all the way back to the source for the unused input connection to the source s signal ground The direction of rotation of the motor can be changed by swapping the ANA CMD input connections or changing the sign of the CmdGain NV Parameter 50 M SM 200 01 5200 Reference Manua
111. ion Screw Terminal Connector 12 24 AWG Wire Range Phoenix MSTB2 5 4 STF 5 08 BK OR Spring Cage Clamp Connector 12 24 AWG Wire Range Phoenix 2 5 4 SFT 5 08 BK OR Crimp Connector Crimp Shell 14 20 AWG Wire Range Phoenix MSTBC 2 5 4 STZF 5 08 BK Crimp Contact 14 16 AWG Wire Range Phoenix MSTBC MT 1 5 2 5 Crimp Contact 18 20 AWG Wire Range Phoenix MSTBC MT 0 5 1 0 Refer to www phoenixcon com J2 1 PE On S200 AC Input Drives this point is connected to Motor Case Chassis Ground Ground On S200 DC Input Drives this point is connected to BUS CTRL GND In either case this termination provides a convenient point for the motor ground connection and motor power wire shield Local electrical code may require using the Earth Ground Chassis stud for this function J2 2 3 4 These three terminals provide the 3 phase power Motor Phases output to the motor on the motor etc NOTE For nonstandard motor drive combinations consult the factory for proper phase orientation Observe motor polarity connect phase the drive to phase U 38 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Wiring the Drive 6 6 J3 FEEDBACK CONNECTOR J3 is a 6 pin pluggable IEEE 1394 style connector for the feedback device Although this connector mechanically accepts standard IEEE 1394 cables it is electrically not a 1394 interface The base drive accepts either SFD Smart Feedback Device or Hall in
112. ion of Conformity In our Declaration of Conformity we affirm our compliance with Directive 73 23 EEC Low voltage Directive and with Directive 89 336 EEC EMC Directive EMC testing was done according to EN61800 3 1997 with the incorporation of amendment A11 2000 Emission limits according to chapter 6 3 1 of that regulation First environment restricted distribution for the following drives e 20260 VTS S20360 VTS S20330 VTS 20630 VTS S20260 SRS S20360 SRS 20330 SRS S20630 SRS S20260 SDS 20360 SDS S20330 SDS S20630 SDS e Currently undergoing conformity testing 20660 VTS S20660 SRS S20660 SDS During assembly of our product in a machine startup that is normal operation is prohibited until the end product complies with Directive 89 392 EEC Machine Directive and directive 89 336 EEC EMC Directive The machine manufacturer must prove that the complete system conforms with all relevant European Directives Drive conformance to specified standards is certified by the Declaration of Conformity in this manual 5200 Reference Manual M SM 200 01 119 Appendix E Regulatory Information 03 2006 Danaher Motion Kollmorgen CE Declaration of Conformity This is to certify that Kollmorgen Industrial Drives 201 Rock Rd Radford VA 24141 Declares that the product s Designation DIGITAL SERVO DRIVE Type S20260 VTS S20360 VTS S20330 VTS and S20630 VTS comply with the following relevant regulations C
113. is means that for long cables the AWG wire gage needs to be considered NOTE The inner shield of the a double concentric feedback cable when isolated from the terminating connector shells can also A function as a conductor to carry some or all of the SFD 5 V RTN current This is useful to keep the total SFD 5 and RTN resistance within specification on long cables without having large diameters NOTE 3 Feedback Characteristic Impedance Danaher Motion s S200 feedback cables are designed to have a feedback data pair differential impedance of 81 o at 1 MHz Impedances in the range of 50 to 100 o while not tested will likely work properly with the 5200 Two suggestions simplify the design of customer composite cable 1 Purchase the raw composite cable from Danaher Motion The cable has good shielding properties 2 Purchase a composite feedback cable built by Danaher Motion Review its construction and test its performance There are many ways to connect the multiple shields of a composite cable A good way to understand how the Danaher Motion composite cable is built is to buy a short Danaher Motion S200 composite cable open it up and see how the shields at both the motor and drive end are connected 5200 Reference Manual M SM 200 01 113 Appendix C Voltage Sag Standard 03 2006 Danaher Motion Kollmorgen APPENDIX C VOLTAGE SAG STANDARD Semiconductor 47 and F42 standards relate to the ability of equipment to
114. istance is usually a small fraction of the available nominal bus voltage For 5200 DC Input Drives with long cables and demanding dynamics the 14 AWG cable is preferred over the 18 AWG cable Cable voltage drop vs cable length is shown in the table below Cable Voltage Drop vs Length Cable V line line peak Vioss in cable as Length 2x Rphase at 0 866 x 18 a percent of 75 V bus meter ohm ARMS18 AWG cable 18 cable 14 cable 3 0 126 2 77 3 7 96 1 5 10 0 413 9 09 12 1 4 8 96 25 1 03 22 7 30 3 12 0 50 50 m not recommended with N A 24 0 96 6 18 ARMS CusTOM COMPOSITE CABLES A composite cable has both feedback and power wires in one cable One of the critical requirements for a composite cable is to provide a high degree of isolation between the power and feedback wires For 240 VAC connected drives the power wires can have up to 400 fast switching PWM waveforms that can couple to the feedback wiring causing communication errors between the Drive and the Smart Feedback Device SFD 5200 Reference Manual M SM 200 01 111 Appendix B Cables 03 2006 Danaher Motion Kollmorgen Danaher Motion has developed and sells a composite cable that has very good isolation between the power and feedback sections It is strongly recommended that this raw cable be used for custom composite cable designs Contact your Danaher Motion sales representative for additi
115. it breakers in the J1 AC motor power lines to comply with local electrical codes The control input power required is between 5 and 10 watts The AC input motor power depends on output power and losses in the power stage On AC input drives J1 is a 9 pin pluggable connector J1 Connector view from front of drive Pin Description J1 1 PE Protective Earth J1 2 REGEN J1 3 BUS J1 4 BUS J1 5 C2 CTRL VAC J1 6 C1 CTRL VAC J1 7 L3 240 VAC J1 8 L2 240 120 VAC J1 9 L1 240 120 VAC Mating Connector Information Screw Terminal Connector 12 24 AWG Wire Range Phoenix MSTB2 5 9 STF 5 08 BK OR Spring Cage Clamp Connector 12 24 AWG Wire Range Phoenix 2 5 9 SFT 5 08 BK OR Crimp Connector Crimp Shell 14 20 AWG Wire Range Phoenix MSTBC 2 5 9 STZF 5 08 BK Crimp Contact 14 16 AWG Wire Range Phoenix MSTBC MT 1 5 2 5 Crimp Contact 30 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Wiring the Drive 18 20 AWG Wire Range Phoenix MSTBC MT 0 5 1 0 Refer to http www phoenixcon com A To avoid damage to the connector and drive NEVER plug or unplug J1 with power applied CAUTION J1 1 PE This chassis ground point must be connected to Protective Earth J1 2 REGEN Protective Earth ground The connection at the Protective Earth ground end must be hard wired do not use a pluggable connection A ground fault
116. ive will appear configured in the interface but the SynqNet Options tab will not appear under the Drive Setup options 6 8 1 1 STATUS LED J5 1 SERIAL 5 The Status LED is located below the Serial Port connector located at J5 Please see the Drive Fault Codes section for descriptions S200 Reference Manual M SM 200 01 51 Wiring the Drive 03 2006 Danaher Motion Kollmorgen 6 8 2 Serial Interface Specification Parameter Specification Baud rate 19 200 Electrical Interface RS 232 Full duplex Transfer format UART 1 start bit mark 8 data bits odd parity bit and 1 stop bit space 6 8 3 RS 232 Wiring Cable wiring diagrams for connecting to either 9 or 25 pin serial ports of most computers are also shown Pinouts vary among computer manufacturers Check the hardware NOTE reference manual for your machine before wiring To PC 9 Pin Female To J5 on Drive To J5 on Drive To PC 25 Pin Female 52 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Wiring the Drive SYNQNET OPTION CARD WIRING AUX CU AUX CV CLOCK AUX CW CLOCK 5 1 0 VO RTN FCOMZ DATA FCOMZ DATA AUX PTC RTN 5V I O VO RTN AUX AUX A AUX B AUX B yi AUX FB OINP COM OINP1 HOME IN OINP2 POSLIMIT IN OINP3 NEGLIMIT IN OINP4 NODE DISABLE GP RS422 IN3 GP RS422 IN3 OOUT1 OOUT1 VO
117. k is enabled the drive peak output current automatically reduces to 0 67 of DIpeak If foldback is not enabled the drive will fault Mechanically jammed motor Motion profile acceleration requires peak current for too long of a time duration Machine load on the motor increased by friction Wiring problem between drive and motor yielding improper motion Motor commutation error Drive under sized for application friction or load Motor I I t Too High Motor current amplitude squared multiplied by time has exceed allowed limits Mechanically jammed motor Motion profile acceleration requires peak current for too long of a time duration Machine load on the motor increased by friction Motor commutation error Motor under sized for application friction or load Optional Battery low Optional fault used to indicate SFD battery supply voltage is low Battery low fault enabled and battery is not installed SFD Battery backup voltage is low 5200 Reference Manual M SM 200 01 99 Diagnostics and Troubleshooting 03 2006 Danaher Motion Kollmorgen Status PED Fault Description Possible Cause Blink Code 7 Bus Over Voltage AC Line voltage AC unit or DC bus power supply Self Resetting voltage DC unit is too high Regenative energy during deceleration is causing The BUS voltage has the BUS to rise exceed the upper On AC Drive
118. l Danaher Motion Kollmorgen 03 2006 Wiring the Drive 6 8 J5 SERIAL PORT CONNECTOR J5 a 6 pin RJ 12 RJ 11 connector provides RS 232 serial communication to the drive The RS 232 transceiver is an industry standard RS 232 configuration using the MAX3221 Pin Description J5 1 No Connection J5 2 RX232 J5 3 RTN J5 Connector view J5 4 from front of drive J5 5 TX232 J5 6 No Connection Mating Connector Information RJ12 RJ11 Phone Style Standard RJ12 RJ11 plug J5 1 J5 6 These terminals are not used or connected to the drive No Connection J5 2 RS 232 receiver input to the drive This terminal connects to RX232 the user s RS 232 transmitter output 25 3 5 4 These terminals are the common ground connection for the llo RTN RS 232 serial port The ground from the user s RS 232 needs to connect to this terminal Cable shielding is also connected to this point J5 5 RS 232 Transmitter output from the drive This terminal TX232 connects to the user s RS 232 receiver input A Do NOT use the serial connector cable when using an S200 SynqNet Series Drive SynqNet cables not a serial cable should be used for CAUTION communication between the drive and SynqNet motion controller If you connect to an S200 SynqNet Series Drive using a serial cable and select Serial instead of SynqNet as the Communications Mode in the S200Tools Communication Wizard the dr
119. l communication cable Customers are responsible for ordering the proper connector kit s and other accessories necessary for drive setup For assistance in proper selection please contact a sales representative 10 1 ACCESSORIES Part Number Description P7S2 232 9D RS232 serial communication cable DB 9 to Mod Jack 6 feet 768 026902 01 Terminal Block adaptor for I O connector MSM20001 200 Base SynqNet User Manual 200 UP 200 Base unit control logic upgrade kit for Base and CAN Indexing drives 200 SQ UP 200 Base unit control logic upgrade kit for SynqNet drives 10 2 CONNECTOR KITS Part Number Description CK S200 MF Motor power and feedback mating connectors for S200 AC or DC units CK S200 IP DC and input power mating connectors for base S200 DC drive CK S200 IP DC TB and input power mating connectors for base S200 DC drive and terminal block adaptor for I O connector CK S200 IP AC I O and input power mating connectors for base S200 AC drive CK S200 IP AC TB and input power mating connectors for base S200 AC drive and terminal block adaptor for I O connector CK S200 SQ Option card SynqNet SRS SDS I O Aux Feedback mating connectors CK S200 SQ TB Option card SynqNet SRS SDS terminal block adaptors for I O Aux Feedback CK S200 CNDN Option card CD DN and mating connecto
120. led recommendations 424 V 48 V 75 a Regulated AC Cbus Supply Line Gnd e AC Optional Regulated Isolated Supply 5200 Reference Manual M SM 200 01 103 Appendix A Power Supply Design 03 2006 Danaher Motion Kollmorgen s 10 ft max TENE LA pee nte ue e pef us P 24 V 48 V 75 v AWG 3 Ctrl va EN na T Diode S ok p7 see below Cibus Rectifier 2 C Line X J Bus Ctrl Gnd i Gnd T RIEN J1 2 16 Isolating DC Input S200 Transformer Unregulated Isolated Supply Bus How to Size Cbus J1 3 Ctrl __3 cont 5200 __ __6 Agus cont 5200 ns 2 000 uf drive at 75 V bus 7 4 000 yf drive at 75 V bus 4 000 uf drive at 48 V bus 8 000 uf drive at 48 V bus 16 000 uf drive at 24 V bus 32 000 uf drive at 24 V bus Bus Ctrl Gnd e 7 J1 2 Local Cap only required for stand alone 6 S200 that runs warm DC Input S200 CAUTION 2777 PE 470 uf 100V lowers aluminum within 1 ft of drive if HsTemp gt 65C WIRING MULTIPLE DC DRIVES An appropriately sized output capacitor in the main power supply is the key to economically delivering high peak power In most applications the capacitor supplies much of the peak power needed to accelerate the motor and inertia under 20 ms
121. lity in the final installation The thermal protective device s provided integral to the motor drives were not evaluated by UL The terminals are suitable for factory wiring only These motor drives have not been evaluated to provide solid state overload or over speed protection The DC models were evaluated by UL for use with an isolated power supply rated no more than 150 V open circuit secondary voltage and 10 secondary power This combination shall be maintained to satisfy UL requirements 5200 Reference Manual M SM 200 01 123 Appendix E Regulatory Information 03 2006 Danaher Motion Kollmorgen E 8 ADDITIONAL SAFETY PRECAUTIONS Motor Case Grounding Insure that the motor s case is connected to PE ground The fourth wire in the motor cable connecting J2 1 to the motor case accomplishes this If the motor is not properly grounded dangerous voltages be present on the motor case due to capacitive coupling between the CAUTION motor windings and case Requirements for Safe Operation of the Drive It is the machine builder s responsibility to insure that the complete machine complies with the Machine Directive EN60204 The following requirements relate directly to the servo controller 1 Emergency Stop If personal injury can result from motor motion the user must provide an external hardwired emergency stop circuit outside the drive This circuit must simultaneously remove power from the drive s moto
122. marily motor and feedback parameters the drive will be in a Not Configured state and will require the execution of CONFIG to configure the drive tend Designates the end of the parameter map file DRIVE CONFIGURATION FILE The drive configuration file contains the actual parameter values The file has a one line header that identifies the following e node number e drive number e drive identification e firmware version number The drive configuration file must match the map file the firmware version of the drive being addressed and the location of that drive on the SynqNet network Here is an example of the header line sqNode 3 drive 0 Kollmorgen S200 2 0a This header shows that the file contains data for the S200 SynqNet drive that is located on Node 3 The header also specifies that the drive has firmware version 2 0a If the drive does not have this version an error message will be displayed The rest of the file consists of parameter command strings followed by their values For an example see the Sample Drive Map File The easiest way to create a template for the drive configuration file is to read a file of data from a drive It is important that the map file exists and is valid 94 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Accessories Connector Kits and Cables 10 ACCESSORIES CONNECTOR KITS AND CABLES S200 drives are not shipped with a connector kit or seria
123. mmand on the drive that does not need any data A few examples from the CD SynqNet and the PicoDAD are 0x01 MBEMFCOMP rw signed 16 0 100 0 Back EMF compensation percentage 0x02 DICONT ro signed 16 10 1100 0 Drive rated continuous current 0x03 DIPEAK ro signed 16 10 1100 0 Drive rated peak current 0x04 ICONT rw signed 16 0 1000 0 Application rated continuous current Parameter Configuration Section The Configuration Section lists the parameters that will be downloaded to a drive from a drive configuration file or uploaded from a drive to a configuration file using the sqDriveConfig Utility The section begins with the following header line config The header is followed by a list of drive parameter names names only not values For example ARFO ARF1 DIS CMD FO Indicates a comment and the line is ignored by the parser 5200 Reference Manual M SM 200 01 93 SynqNet Configuration 03 2006 Danaher Motion Kollmorgen File Footer 9 3 4 2 The sequence of names does not need to correspond to the sequence in the Parameter Identification section However it does need to follow the sequence of parameters required by the drive The configuration section typically ends with a 1 This code is used to instruct the sqDriveConfig Utility to execute a drive CONFIG after the parameters have been downloaded After changing certain drive parameters pri
124. mmunications and diagnostics to continue during emergency stop conditions with no power to the motor It also allows rapid recovery from emergency stops Optically isolated inputs and outputs positive locking connectors and full fault protection promise long machine life and immunity to accidental damage The single motor power or feedback cable option simplifies connectivity All connectors and LED status indicators are easily accessible from the front of the drive 5200 Reference Manual M SM 200 01 1 S200 Series Drives 03 2006 Danaher Motion Kollmorgen 1 1 MODEL NUMBER S2 03 3 0 VT S 002 S2 200 Servo Family L Customization omit for standard drives 000 019 Reserved for factory use 020 999 Reserved for customers Feedback Support S SFD Halls Base Unit SFD Comcoder CAN Option card Smart Feedback Device SFD SynqNet Option Card Sine encoder SynqNet Option Card EnDat 2 1 SynqNet Option Card Current Rating 02 1 5 ARMS continuous 4 5 ARMS peak 03 3 ARMS continuous 9 ARMS peak 06 6 ARMS continuous 18 ARMS peak Functionality VT Velocity Torque modes CN Position Node w CANOpen Interface SD SynqNet option card w micro D connectors SR SynqNet option card w standard RJ connectors Voltage 3 20 90 VDC 5 120 doubler 240 VAC 1 ph 6 120 240 VAC Electrical Option 0 No Electrical Option 1 2 DRIVE MODEL NUMBERS AND DESCRIPTIONS Here is a list of the va
125. nal of the power source 4 0 to 30 VDC The input DINP 1 4 is connected to the sourcing logic output on the field device as shown in the diagram below Sourcing Logic Output from Field Device External 4 30 VDC Power Supply J4 1 TTL and CMOS The following are examples of driving with TTL or Drivers CMOS output devices 5 VDC 5200 Reference Manual M SM 200 01 43 Wiring the Drive 03 2006 Danaher Motion Kollmorgen 5 VDC oe SOURCING CMOS 6 7 2 General Purpose Outputs General DOUT1 and 00072 are optically isolated outputs that Purpose provide information about the state of the drive The Outputs outputs are Darlington phototransistors with a 33 V zener diode wired in parallel to clamp voltage transients J4 6 7 J4 7 DOUT1 FAULT DOUT1 FAULT J4 8 9 33V DOUT2 J4 6 RUN DOUT1 J4 9 DOUT2 RUN J4 8 33V DOUT2 The following table lists the maximum output rating Maximum Voltage 30 VDC Maximum Current 50 mA Von 1 0 V at 10 mA 1 2 V at50 mA lorr 5 pA Response Time 1 ms Clamp Voltage 33 V nominal A The outputs are not short circuit protected Configure the application to ensure the maximum current is not exceeded CAUTION 44 M SM 200 01 S200 Reference Manual Danaher Motion Kollmorgen 03 2006 Wiring the Drive 6 7 2 1 6 7 2 2 DEFAULT OuTPUT FUNCTIONS The list below describes the factory defaults for eac
126. ns errors No Span faults the drive on any SFD communication error Recommended default setting is Span 0 No Span 1 Span SWCIrFault Not Clear or Clear This parameter will clear the fault logic 0 Not Clear default 1 Clear 82 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Advanced Configuration 8 3 4 Status And Control Variables AuxFBComAng 180 to 180 Supported over SynqNet This register is the value of the commutation position from the AFB interface It is used to generate the commutation angle in the drive AuxFBEnDatFlt Fault No Fault Supported over SynqNet This bit indicates that the Aux Feedback interface encountered an error when trying to read data from an EnDat device Sources of error are 1 EnDat device recover timeout from last transaction 2 EnDat device calculation timeout 3 EnDat CRC fault AuxFBHallFIt Fault No Fault Supported over SynqNet This bit indicates the AuxFB Halls are in an illegal state of either all ones or zeros 0 No Fault 1 Fault AuxFBPTCFIt Fault No Fault Supported over SynqNet This bit indicates the AuxFB PTC has generated a fault 0 No Fault 1 Fault AuxFBSCDFIt Fault No Fault Supported over SynqNet This bit indicates that the amplitude of the sum of the sine and cosine signals is not with in 30 of the nominal 1 0 Vp p 0 No Fault amplitude in range 1 Fault amplitude not with 30 CmdIn DIpeak
127. ns such as semiconductor fabrication electronic assembly packaging medical and woodworking equipment among others Danaher Motion s S200 servo drives are the first all digital industrial drives with a velocity loop bandwidth up to 800 Hz offering unmatched system throughput and simplified tuning High resolution 24 bit feedback and high performance 3 5 kHz current loop bandwidth provide smooth motion and rapid start and stop action to optimize machine performance Smart feedback and industry leading high bandwidth deliver fast and accurate plug and play commissioning by eliminating the need for servo loop tuning in most applications Base S200 servo drives come standard with torque or velocity control as well as with factory options that support SynqNet or add pre settable Indexing with CANopen communications The factory option cards also add interfaces to additional motor feedback devices such as Comcoder 1 Vp p Sin Cos and EnDat 2 1 The drives operate with AC 120 240 VAC or DC 20 90 VDC power sources and have current ratings from 1 5 ARMS continuous to 18 ARMS peak Their compact footprint ranges from 1 1 in 28 7 mm wide and 6 0 in 152 4 mm tall to 2 44 in 62 mm wide and 6 9 in 175 mm tall with depths ranging from 3 9 in 100 8 mm to 5 2 in 131 6 mm allow them to fit into tight spaces They are UL 508C recognized CE marked and conform to EN50178 and EN61800 3 standards Separate Keep Alive control power input allows co
128. nstructions on wiring an AC version S200 drive refer to AC Input Drive Wiring of this manual For complete instructions on wiring a DC version S200 drive refer to the DC Input Drive Wiring Motor Power Cable Filtering In typical applications the S200 drives do not require additional filtering in the motor leads Machines with many drives and long motor power cables may require an external balun in series with the power motor power cable to reduce the machine s conducted emissions Additional information can be found in Pacific Scientific Application Notes 106 Reducing Motor Drive Line Noise and 107 Reducing Motor Drive Radiated Emissions Balun PN 104 090003 01 Current Rating 60 A sinewave pk 42 ARMS 5 sec 20 A sinewave pk 14 ARMS cont Inductance 340 yh nominal Energy Rating 7 200 uJ nominal Resistance 0 021 O nominal Gap 10 mil Ground Cable Shields The Motor Power J2 Feedback J3 Command I O J4 and Serial Port J5 cables must be shielded and the shields should be connected to PE The safety PE connection can be made through connector pin or shell All cables used with the S200 drives should be shielded with the shields connected to PE Dangerous voltages resulting from cable capacitance exist on some cable shields if the shields are not connected to PE ground Avoid Crosstalk To avoid the risk of crosstalk keep the motor and feedback cables away from sensitive signal cables i e telephone and intercommunic
129. o 90 Altitude lt 1500 m 5000 feet 3 9 SMART FEEDBACK DEVICE SFD 3 9 1 Position Signal Resolution Rev arc min 24 bits 0 0013 Repeatability arc min RMS lt 2 Rev 0 04 Noise No Filtering arc min RMS lt 2 Rev RMS 0 16 150 Hz Single Pole Filtered arc min RMS lt 28 Rev RMS 0 08 10 Hz Single Pole Filtered arc min RMS lt 2 Rev RMS 0 02 DC Offset Temperature Drift lt 278 C 0 08 arc C Absolute Accuracy AKM arc min 2793 Rey 17 2 or 3 4 arc min 21 10 Communications Update Period ys 51 2 3 9 2 X Velocity Signal Resolution rpm 0 001 Quanta rpm 0 07 Noise No Filtering rnm RMS 4 150 Hz Single Pole Filtered rnm RMS 0 6 10 Hz Single Pole Filtered rom RMS 0 06 DC Accuracy Typical at 25 C 96 0 01 Worse case 96 0 05 Ripple AKM1 96 p p at 1200 rpm 2 5 2 3 4 at 1200 rpm 1 5 Offset rpm 0 0001 Communications Update Period us 51 2 Hardware Interpolation Period us 0 1 12 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Specifications 3 9 3 3 9 4 Emulated Encoder Output Signals Available Resolutions PPR Binary 128 512 1024 2048 4096 8192 16384 32768 Decimal 125 500 1000 2000 2500 5000 10000 200
130. o the drive s permanent memory and are recalled during a power up cycle e Download Drive This button will save the parameter settings displayed in S200 Tools to the selected drive node However unlike Download NV these parameters are only saved to the drive s temporary RAM and will not be recalled at a power up cycle It is recommended that you use the Download Drive button when testing settings Once you are satisfied with the settings click the Download NV button to permanently save the settings to the drive e Save Save As You can also save the settings of a drive as a configuration file S2C Remember saving a configuration file does NOT save the settings to the drive Configuration files can be helpful for saving multiple drive setups You can easily download a setting to a drive by opening the configuration file in the Offline mode and clicking the Download NV Drive buttons once the proper drive is selected in the Online mode It is recommended that you save a configuration file for each setup 22 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Mounting the Drive 5 MOUNTING THE DRIVE The S200 drives are designed for operation in a cabinet using the following installation instructions e Mount the drives vertically inside a cabinet on a flat solid electrically conductive mounting surface that is connected to PE Protective Earth Ground and capable of supporting the weight of the unit e Prov
131. o the ratings in Voltage Sag Standard for 240 VAC single phase operation 5200 Reference Manual M SM 200 01 115 Appendix D Using a Voltage Doubler Mode Drive 03 2006 Danaher Motion Kollmorgen D 1 S2xx50 AC LINE VOLTAGE DOUBLING DRIVE POWER SPECIFICATIONS 120 VAC Voltage Doubling 5203550 520250 Peak Output Current ARMS 0 to 40 9 0 4 5 Ambient Minimum Peak Current TimeStarting 3 0 from 0 Amps Cont Output Current ARMS 0 to 40 1 5 Ambient Continuous Output Power Watts 350 Peak Output Power Watts 1200 RMS Line Current at Continuous 5 Output Power RMS Fusing Line Inputs MDA 15 MDA 10 S200 units with the voltage doubling option manufactured before June 2004 have the function of L1 and L3 reversed Using 240 VAC on old voltage doubled units with this new documentation WARNING will lead to catastrophic failure of the drive Requirements for Safe Operation of the Drive It is the machine builder s responsibility 116 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Appendix E Regulatory Information APPENDIX E REGULATORY INFORMATION E 1 CONFORMANCE REQUIREMENTS The equipment described herein has been developed produced tested and documented in accordance with the corresponding standards During use conforming with requirements the equipment is not dangerous for people or equipment Use conforming with requirements means that the safety re
132. ommand input CmdOffset Sets the command offset for the command input CmdF0 Sets the filtering on analog input command The following are optional parameters that can be set Parameter Function EncOut Sets the line count of the emulated encoder output EnInhibitCW 33 EnlnhibitCCW Enables the hardware over travel limits 5200 Reference Manual M SM 200 01 67 Basic Configuration 03 2006 Danaher Motion Kollmorgen 1 4 4 Position Mode The base 5200 can drive a motor in Position Mode using SFD Feedback The source of the command can either be Step and Direction or differential quadrature signals The drive needs to be configured using the S200Tools utility The configuration parameters should be saved to non volatile memory click the NV Save button to allow the configuration to be recalled on power up To configure the drive for SFD feedback set the following parameters Parameter Value CommMode SetupS2 2 Default value with switch S2 2 set to the down position labeled S on the drive or SFD CommOff 0 Degrees for AKM motor series Check with your sales representative for the correct commutation offset angle for other motor series OpMode Position PosCmdSrc Selects the source of the command either Step Dir or AquacB Sets the distance the shaft moves for each input position GearOut command pulse count
133. on ns 250 maximum 3 6 4 SINP Direction Command MSINP J4 5 J4 1 Input Voltage volts t 4 0 30 0 Input Current mA 0 65 6 7 Direction Setup Time ys 100 Minimum Pulse Width us 200 3 6 5 Quadrature Input Quadrature Input CHA J4 19 20 CHB J4 21 22 Type RS 422 RS 485 Input Voltage Differential 0 2 to 12 volts Common Mode 7 to 12 volts Input Termination None internal to the drive Maximum Line Frequency kHz 625 corresponds to 2 5 MHz quadrature pulse rate 3 6 0 General Purpose Inputs DINP1 DINP2 DINP3 J4 2 3 4 Input Voltage volts t 4 0 30 0 Referenced to DINPCOM J4 5 Input Current mA 0 65 6 7 Response Time 1 0 ms 10 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Specifications 3 6 7 General Purpose Outputs DOUT1 DOUT2 J4 6 7 and J4 8 9 Maximum Output Voltage volts 0 30 to 30 0 Clamp Voltage volts 33 V 6 Maximum Output Current 50 mA On voltage volts 1 0 V at 10 mA 1 2 V at 50 mA Response Time ms 1 0 3 6 8 Quadrature Outputs Quadrature Out
134. onal information If this cable does not meet your specifications the following are some guidelines for custom composite cable development Due to the complexity of modeling and understanding cable coupling a new composite cable needs to be prototyped and tested to have confidence that it will be reliable 1 Composite cable should have double concentric feedback shields one shield within another The raw composite cable that has been tested and is known to work well with the S200 has the following structure double concentric shields around the feedback wires plus an outer shield around the whole cable see diagram below This type of raw cable is strongly recommended Testing shows double concentric shielding is ten times better than single shielding at reducing coupling from the power wires to the feedback data wires SFD 5 VDC Outer Jacket Feedback gE Outer Shield Outer Shield X Motor Connector Shield Connect to SFD Shelly Feedback Inner Shield Motor Wires Connect to Logic GND SFD Communication B twisted pair amp WUT 8 PE Wire Optional Foil Shield Shield iA SFD Return Inner Drain Wire E and inner shield Jacket Inner Jacket Composite Cable Cross Section 112 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Appendix B Cables There can be substantial capacitance between the power wires and adjacent feedback shield in a
135. orgen 03 2006 Diagnostics and Troubleshooting 11 DIAGNOSTICS AND TROUBLESHOOTING The S200 drive incorporates Output motor short circuit protection line to line line to neutral and line to PE Internal monitoring of the power stage heat sink temperature for drive over temperature Bus over voltage and under voltage detection Control under voltage detection Excessive current I t fault foldback Depending on drive setup when excessive is detected either the peak output current limit is dropped to 6796 of maximum or the drive faults Excessive motor current I t protection Invalid smart feedback device SFD shaft feedback signal Motor over temperature on SFD equipped motors 11 1 DRIVE FAULT CODES The Drive Status LED is located on the front panel The drive status and fault codes are communicated by the state of the LED Status LED Drive Status ON Drive is enabled not faulted Output stage is enabled and controlling power to the motor OFF Drive control input is not powered or has insufficient voltage applied Fast Blinking Drive is not enabled not faulted Output stage is not enabled no power to the motor Slow Blinking Drive is blinking a fault code pause The number of blinks corresponds to the fault code as follows ME Fault Code 1 Not Fault 2 Motor Over Temp 3 Drive Over Under Temp 4 Drive 14 Too High 5 Motor Too High 6 Optional Battery low 7 Bus Over Voltage 8
136. pe RS 422 compatible line drivers Recommended load current is x20 mA which corresponds to a line to line load resistance of 100 These outputs can handle shorts to I O RTN indefinitely without damage The resolution of the Encoder Outputs number of pulses per motor revolution is set by S1 rotary switch as follows 48 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Wiring the Drive 51 Position Pulses Revolution 0 User settable factory default 500 512 1000 1024 2000 2048 4096 5000 8192 10000 User settable non volatile PPR via the serial port Possible PPR are 128 512 1024 2048 4096 8192 16384 32768 125 500 1000 2000 2500 5000 10000 20000 The maximum output line frequency is 2 5 MHz Limit line frequency to below 1 25 MHz which corresponds to quadrature count frequency below 5 MHz for robust operation X oo 1 o 5 Go Po gt The emulated encoder output is only available when A using a high resolution feedback device such as the SFD feedback to the base unit or Encoder feedback to the NOTE option card The emulated encoder outputs have no signals when there is only base unit 6 step feedback Inputs Channels A and B can be configured as inputs by setting NV Parameter PosCmdSrc to AQUADB With NV Parameter OpMode set to Position and PosCmdSrc to AQUADB the motor shaft posi
137. pending on the position command source selected by PosCmdSrc See Also GearOut and OpMode GearOut 32768 32767 Not supported over SynqNet GearOut is used to scale the input position command when configured as a position controller OpMode Position This parameter is the dividend used to calculate the revs per step for the position mode Typically this parameter is 256 which allows Gearln to be numerically equal to the number of steps per rev GearOut negative reverses the direction of motion for a given command The formula for calculating motor shaft revs per input step is GearOut Gearln 256 revs per input step There is 1 input count per step input or per input quadrature count depending on the position command source selected by PosCmdSrc See Also Gearln and OpMode HSInp1Pol Invert or Normal This parameter selects the polarity of the HSInp1 When this parameter is set the input to the FPGA is inverted before it is used by the logic This parameter affects the sense of the HSInp1 I O input I2TFO 23 16 6 1 470 Hz Sets the break frequency in Hz for the I2T filter used to protect the motor from transient thermal overload caused by very high peak currents compared to the motor s continuous current capability Typically set to between 4 and 10 times faster than the motor s bulk thermal time constant published in the data sheet Given a desired time constant set the I2TFO value to I2TFO 1 21r Motor Therm
138. put CHA J4 19 20 CH B J4 21 22 CHZ J4 17 18 Type RS 422 RS 485 Output Voltage volts 5 0 V Differential Output Unloaded Hysteresis 1 2 Quadrature Count corresponding to 1 8 Encoder Line Count 3 7 MECHANICAL 200 AC INPUT DRIVES 200 DC INPUT DRIVES Base Drive w Option AC3 Base Drive w Option Card Card 20260 VT 520260 520660 20630 VT 520630 20360 VT 520360 20330 VT 20330 XX Drive Dimensions Drive Height A 175 0 mm 175 0 mm 175 0 mm 152 4 mm 152 4 mm 6 90 in 6 90 in 6 90 in 6 00 in 6 00 in Drive Width B 54 8 mm 54 8 mm 64 0 mm 28 7 mm 48 3 mm 2 16 in 2 16 in 2 52 in 1 13 in 1 90 in Drive Depth C 131 6 mm 131 6 mm 131 6 mm 100 8 mm 100 8 mm 5 18 in 5 18 in 5 18 in 3 97 in 3 97 in Mounting or 8 or 8 or 8 or 8 or 8 Hardware Drive Weight 0 77 kg 0 85 kg 0 82 kg 0 40 kg 0 5 kg 1 69 Ib 1 86 Ib 1 80 Ib w 0 88 Ib 1 10 Ib option card 1 97 1 Depth measurement is for drive only Add approximately 50 8 mm 2 in to accommodate mating connectors and wire bend radius 3 8 ENVIRONMENTAL Operating Temperature C Full Rating 0 to 40 Operating Temperature C Derated Linearly Derate Continuous Current to 67 of 40 to 50 40 C Rating 5200 Reference Manual M SM 200 01 11 Specifications 03 2006 Danaher Motion Kollmorgen Pollution Degree 2 Storage Temperature C 20 to 70 Humidity non condensing 10 t
139. puts 3 J3 Connector view from front of drive 5 Pin Description J3 1 SFD 5 V 200 mA J3 2 SFD 5 RTN J3 3 SFD COM J3 4 SFD COM CU J3 5 NC CV J3 6 NC CW Shell Shield Connection Mating Connector Information IEEE1394 Firewire type 2 0 mm plug set 22 AWG Max Molex 55100 0600 Refer to www molex com for assembly instructions J3 1 This terminal provides a 5 VDC output to power SFD 5V the feedback device For example motors equipped with SFD Halls or a commutation encoder The load current should not exceed 200 mA J3 2 This terminal is the return connection for the 5 SFD 5 RTN VDC supply An inner feedback cable shield can be connected to this point Outer shields should connect to the shell which is PE J3 3 SFD serial communications port when using the SFD COM SFD feedback device No connection when using Hall feedback J3 4 SFD serial communications port when using the SFD CU SFD feedback device CU Commutation Phase U input when using open collector Hall feedback This input has a 2 21 kW pull up resistor to 3 3 V J3 5 No connection when using the SFD feedback NC CV device CV Commutation Phase V input when using open collector Hall feedback This input has a 2 21 kW pull up resistor to 3 3 V J3 6 No connection when using the SFD feedback NC CW device CW Commutation Phase W input when using open collector Hall feedback This inpu
140. r is available within the plant but at higher voltage than 240 VAC consider adding a power transformer to step it down to 240 VAC for use as AC bus power for the S200 drives in the machine This is also a robust option 114 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Appendix D Using a Voltage Doubler Mode Drive APPENDIX D USING A VOLTAGE DOUBLER MODE DRIVE J1 9 L1 120VAC Hot 240VAC J1 8 L2 240VAC J1 7 L3 120VAC Neutral Figure 1 Main Power Line Connection of the S2xx50 AC Input Voltage Doubler Drive In the S2xx50 AC input voltage doubler drives AC line L3 is shorted to the center point of the two series connected bus capacitors as shown in Figure 1 For voltage doubling connect single phase 120 VAC to J1 9 L1 and J1 7 L3 On the same unit connecting 240 VAC to J1 9 L1 and J1 8 L2 gives standard single phase full wave rectification In both cases the result is a 320 VDC nominal bus voltage Three phase AC line operation is not possible with the S2xx050 AC input voltage doubler models In fact connection to a three phase source will damage the drive Please use the standard S2xx60 AC input version of the product When doubling a 120 VAC line the drive continuous power specification is derated to about 7096 of standard single phase ratings The following table gives the power specifications for 120 VAC voltage doubled operation Refer t
141. r power terminal J2 2 J2 3 and J2 4 and disable the drive by open circuiting the connection CAUTION R to J4 pin 2 a The motor will coast under this condition with no braking torque z If braking torque is required to quickly stop the motor a dynamic brake can be added that loads the motor s windings resistively The motor should not be loaded until the servo drive is disabled The holding brake optional on Danaher Motion motors is not intended to stop a spinning motor It is CAUTION k designed to prevent a stopped motor from rotating due to an applied torque gt 2 Avoid Unexpected Motion Always remove power from J1 and wait 5 minutes before working on the machine or working anywhere where injury can occur due to machine motion p CAUTION 3 Avoid Electrical Shock e Never power the servo drive with the cover removed or with anything attached to circuitry inside the cover e Ifthe drive must be removed from the cabinet wait at least five minutes A after turning off power before removing any cables from the drive or removing the drive from the mounting panel e Never connect or disconnect any wiring to the drive while power is applied Always power down and wait five minutes before connecting or disconnecting any wires to the terminals 4 Avoid Burns CAUTION The temperature of the drive s heat sink and housing as well as an external regen resistor may exceed 60 C Therefore there is a d
142. r to change the factory default NOTE For S200 drives with the SynqNet option the base drive INHIBIT function is turned off by EnhibitCW Off Over travel limit switch inputs must be wired directly to J13 on the SynqNet option card Input 3 This input operates symmetrically to DINP2 with the INHIBIT control function preventing further motion in the counter clockwise shaft motion direction This function can be turned on or off by setting EnInhibitCCW DInp3Pol sets the control logic polarity Input 4 This input is the direction input when the drive is in Position Mode with the set to Step amp Direction Open circuit no LED current positively increments the position command motor goes CW Set up time for direction is 100 us Minimum pulse width is 200 us Refer to DInp4 DRIVING THE GENERAL PURPOSE INPUTS Sinking Logic For compatibility with sinking outputs the DINP COM terminal is connected to the positive terminal of a power source 4 0 to 30 VDC The input DINP1 4 is connected to the sinking logic output of the field device as shown in the diagram below 42 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Wiring the Drive J4 1 DINP COM 4 2 3 4 5 DINP1 4 External 4 30 VDC Power Supply Sinking Logic Output from Field Device Sourcing Logic For compatibility with sourcing outputs the DINP COM terminal is connected to the negative termi
143. ride through voltage dips of various magnitudes and duration F47 requires that semiconductor equipment tolerate transient voltage sags or dips on the AC power line voltage dip to 5096 of nominal for 200 ms 7096 of nominal for 0 5 second and 80 of nominal for one second F42 specifies how to test for compliance with F47 To robust the S200 for F47 type voltage sags power the S200 using AC line voltage and phasing as described below AC S200 Control Power 240 VAC one phase AC S200 Bus Power Three Phase 240 VAC DC S200 DC power supply operated from three phase 240 AC line AC Control Power The use of 240 VAC single phase nominal for control power results in the control voltage remaining within the drive control voltage specification 85 VAC to 265 VAC during an F47 5096 sag deepest F47 specified sag Powering the control with 240 VAC also maximizes the ride through time for larger amplitude sags because more energy is stored in the control bus capacitor AC Bus Power If three phase 240 VAC is available for bus power it provides much better F47 ride through than either single phase 240 VAC or 120 VAC because F47 and F42 standards mandate that in a three phase system only one phase of the three phases is sagged at a time If the AC S200 is powered by three phase 240 VAC it keeps its bus capacitors reasonably well charged by pulling power from the one line to line voltage that does not sag With singl
144. rious S200 Series Drives e CNS CAN Indexer option card e SRS SynqNet option card with RJ 45 connectors e SDS SynqNet option card with Micro D connectors e VTS Analog Velocity Torque Base Drive AC Drive Description 20260 VTS 200 120 240 VAC 1 3 phase 1 5 4 5 ARMS Base Unit 20360 VTS 200 120 240 VAC 1 3 phase 3 9 ARMS Base Unit 20250 VTS 200 120 VAC doubler 240 VAC 1 ph 1 4 4 5 ARMS Base Unit 20350 VTS 200 120 VAC doubler 240 VAC 1 ph 3 9 ARMS Base Unit 20260 SRS 200 120 240 VAC 1 3 phase 1 5 4 5 ARMS SynqNet with RJ 45 connectors 20360 SRS 200 120 240 VAC 1 3 phase 3 9 ARMS SynqNet with RJ 45 connectors 20250 SRS 200 120 VAC doubler 240 VAC 1 ph 1 4 4 5 ARMS SynqNet with RJ 45 connectors 20260 SDS 200 120 240 VAC 1 3 phase 1 5 4 5 ARMS SynqNet with Micro D connectors 20360 SDS 200 120 240 VAC 1 3 phase 3 9 ARMS SynqNet with Micro D connectors 20250 SDS 200 120 VAC doubler 240 VAC 1 ph 1 4 4 5 ARMS SynqNet with Micro D connectors 20350 SDS 200 120 VAC doubler 240 VAC 1 ph 3 9 ARMS SynqNet with Micro D connectors M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 S200 Series Drives DC Drive Description 20330 VTS 200 90 VDC 3 9 ARMS Base Unit 20630 VTS 200 90 VDC 6 18 ARMS Base Unit 20330 CNS 200 90 VDC 3 9 ARMS Base Unit CAN Indexer option card
145. rn Fault 100 No Fault 101 No Fault 110 No Fault 111 No Fault SixStep SFD 6 Step This variable indicates whether the drive is in 6 step or sinusoidal current control SWEnable Disable Enable Serial communications channel motor power enable Both the hardware enable input on the command I O connector and SWEnable must be active for power to flow to the motor Base units have SWEnable active at power up This variable is provided for convenience when working with a PC set utility 0 Disables drive 1 Enable set by state of hardware enable input default VBus 0 to 523 volts AC Input Drives 0 to 131 volts DC Input Drives This variable reads back an instantaneous sample of the voltage of the bus supplying power to the motor VelFB 18 310 rpm to 18 310 rpm This variable reads back an instantaneous sample of the shaft velocity feedback It has a resolution of 0 5588 rpm When measuring speed use Velocity for least noise and maximum accuracy Velocity 18 310 rpm to 18 310 rpm This variable reads back a filtered version of the shaft velocity feedback It has the same units as VelFB but it is much more precise for careful measurements of shaft speed because the filtering greatly lowers noise VerLW 0 0 to 255 9z VerLW gives the version number of the drives logicware as three integer bytes 5200 Reference Manual M SM 200 01 87 SynqNet Configuration 03 2006 Danaher Motion Kollmorgen
146. rotary switch S1 have fixed line counts EncOut 4 the number of quadrature counts per revolution EncOut Line Count EncOut Line Count 0 500 8 8192 10000 125 128 16384 20000 32768 5000 15 2500 1 2 3 4 5 6 7 EnInhibitCCW On or Off Not supported over SynqNet Enables or disables the hardware input that prevents motion in the counter clockwise direction When enabled and the hardware input is active current torque operation clamps the current command to 0 or positive clockwise With a velocity loop function enabled and the hardware input active the velocity command is clamped to 0 or positive clockwise When both InhibitCCW and InhibitCW are enabled and both hardware inputs are active the motion command is clamped to O 0 OFF 1 ON EnInhibitCW On or Off Not supported over SynqNet Enables or disables the hardware input that prevents motion in the clockwise direction When enabled and the hardware input is active current torque operation clamps the current command to be 0 or negative counter clockwise With a velocity loop function enabled and the hardware input active the velocity command is clamped to be 0 or negative counter clockwise When both InhibitCCW and InhibitCW are enabled and both hardware inputs are active the motion command is clamped to 0 0 OFF 1 FBSrc Base Unit Feedback Option Card Feedback Supported over SynqNet Enables When this bit is set to
147. rrents also flow in the Control or Bus terminal Size the ground wire to the drive to be no smaller than the positive Bus wire A larger wire size yields a cleaner ground If a separate control supply is used connect the control supply ground and main bus supply ground together at or near the drives not at the supplies Bus wire inductance and bus resonance The time domain of motor related energy flow is measured in milliseconds The inductive voltage drop in the bus and ground wiring for these times is small For this reason the energy leveling bus capacitor does not need to be located near the drive and a single bus capacitor can be shared by multiple drives Be aware of bus resonance NOTE Current can oscillate between capacitors in any distributed DC power system with the capacitor located apart and connected in parallel with wires The capacitors and wiring inductance form an underdamped LC circuit that can ring when excited by PWM currents The easiest way to monitor the current in the bus wiring of the drive is with a current probe The ringing occurs if the current probe shows a large 10 A quasi sinusoidal current in the 1 to 10 kHz range While more difficult to see in voltage it does cause small sinusoidal voltage few volts to occur across the drive positive Bus J1 3 to Gnd J1 2 terminals Occasional bursts of bus ringing are usually not too serious but sustained or too frequent ringing is undesirable because hig
148. rs for S200 CK S200 CNDN TB Option card CD DN and mating connectors terminal block adaptors for I O and feedback connector for S200 5200 Reference Manual M SM 200 01 95 Accessories Connector Kits and Cables 03 2006 Danaher Motion Kollmorgen 10 3 CABLES Part Number Description P7S2 232 9D RS232 serial communication cable DB9 to Mod Jack 6 feet CF DA0111N XX X Feedback Cable value series Euro connector at the motor end to IEEE1394 connector at the drive end for Smart Feedback Device support CP 102ACN XX X Power Cable value series Molex connector at the motor end to S200 crimp pin pluggable connector at the drive end CP 102AAAN XX X Power Cable value series Euro connector at the motor end to S200 crimp pin pluggable connector at the drive end CC D01CO2N XX X Composite Cable value series Single Molex connector at the motor end to IEEE1394 connector and S200 crimp pin pluggable connector at the drive end for Smart Feedback Device and power support in the single cable CC D01AO2N XX X Composite Cable value series Euro style connector for power and feedback at the motor end to IEEE1394 connector and S200 crimp pin pluggable connector at the drive end for Smart Feedback Device and power support in a single cable Only available on AKM3 and series motors 96 M SM 200 01 5200 Reference Manual Danaher Motion Kollm
149. rs set to their default values Parameters are identified by their command string and index The index is used when accessing a parameter over SynqNet Drive parameters are implemented for particular drive models and firmware versions NOTE Supported parameters for a drive may be different depending on the version of firmware The MPI library contains a general drive parameter interface that is able to handle any set of drive parameters independent of the MPI library version It uses a drive parameter map file to determine the valid drive parameters Individual drive parameters can be set or read using MPI methods or with the sqDriveParam Utility A list of drive parameters can also be set or read using methods or with the sqDriveConfig Utility The following sections describe the syntax of utilities used when accessing parameters These utilities are typically executed from a DOS window in the XMP bin WinNT directory Memory Operations on Drive Parameters The drive firmware operates by using parameters stored in RAM However these parameters can also be saved in non volatile memory E2PROM where they are loaded into RAM upon power up The non volatile memory can also be cleared Parameters may 90 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 SynqNet Configuration 9 3 3 9 3 4 be reset to their default values and a set of saved parameters may be loaded from the non volatile memory into
150. s If there are additional S200 nodes on the network they are automatically discovered When using a network with multiple SynqNet nodes use the SynqNet controller node pulldown bars to select a particular node on the network to display in the Online mode 20 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Quick Start Guides 4 2 5 4 2 6 4 2 6 1 4 2 6 2 Controller 0 5 Node 0 SyngNet Node 0 Node 1 Loop Gains General Info SynqNet Node 2 SyngNet Node 3 SynqNet Node 4 SyngNet Node 5 SyngNet Node 6 SyngNet Node 7 NOTE for SynqNet Although the 5200 Tools software maintains communication with all properly connected S200 drives drives on the SynqNet network only one SynqNet node will be displayed at a time under the Online display SynqNet Configuration The next step is to set the proper drive and motor feedback configurations Under the SynqNet Options tab select the source for motor feedback Feedback Source Select Base Unit Feedback if the motor feedback is connected to J3 on the S200 Drive Select Option Card Feedback if the motor feedback is connected to J14 on the S200 Drive Summary Control Mode Motor Command Control 10 Setting Loop Gains General Info H m Feedback Settings 4 Auxilary Feedback Type Incremental A Quad B AuxFBDivisor 16782216 counts per mechanical
151. s NOT an S200 drive gt NEN No Connection Currently connected with a 5200 Drive Base Unit Troubleshooting If you receive the No Connection message check the hardware connections After you have confirmed your setup click the OK button i a 125200 Tools Unit 52026 240 1 5 4 5Arms Status Drive Setup Motor Summary Offline The installed S200 drive s will now be listed as Online and will list its configuration and status options 16 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Quick Start Guides 4 1 4 4 1 5 4 2 4 2 1 Motor Feedback Configuration The 5200 Base Unit drives only support SFD motor feedback If you are using SFD motor feedback no further configuration is needed If you want to use SinCos or ComCoder as motor feedback you must use the AUX FB J14 connector which is not available on Base Unit drives Save Options There are three types of Save options It is important to know how to use each type to ensure that configurations are not lost e Download NV This button will save the parameter settings displayed in S200 Tools to the selected drive These parameters are saved to the drive s permanent memory and are recalled during a power up cycle e Download Drive This button will save the parameter settings displayed in 5200 Tools to the selected drive nod
152. s add regen resistor threshold limit On S200 DC input drives external BUS capacitor is too small add capacitance 8 Bus Under Voltage On 5200 DC input drives Self Resetting BUS voltage is too low BUS voltage is pulled down during high acceleration S200 DC drive fault loading only External BUS capacitor is too small BUS voltage is below specified 20 VDC minimum 9 Motor or l n Short Motor power wiring short circuit line to ground neutral 7 Motor cable short line to line Line to Line Line to Neutral or Line to PE Motor power cable length exceeds the data sheet short on the motor specification causing excessive motor line to earth output causing an ground neutral capacitance instantaneous over Internal motor winding short circuit current 10 Output Over Current Insufficient motor inductance KIP or KII improperly set causing excessive output current overshoots 11 Hall Fault Invalid configuration Motor overspeed Valid only when drive Invalid hall state isset for 5 Hall Invalid hall transition feedback operation 12 SFD Configuration SFD UART error during SFD initialization Error Bad motor data check sum The drive will attempt to initialize the SFD up to 4 times If it fails this error is reported 13 SFD Short Excessive loading on SFD 5 supply Short in the feedback cable on SFD 5 J3 1 to Excessive current ground drain on SFD 5 supply output 14 SFD Motor Data Error Motor and Drive are no
153. se When using a 2 pair cable these pins are left unconnected in the cable Mating Connector Information 8 Pin Male PN 5 557315 not shielded 8 Pin Male PN 5 569552 3 shielded 6 10 1 SynqNet LEDs Pin Meaning Description ON Tx and Rx active cyclic phase STAT Network Status Activity BLINK Tx only active discovery phase OFF Idle shutdown phase ON Link Active OFF Link Inactive LNK Link Activity 54 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Wiring the Drive 6 11 J12 SYNQNET OUT PORT CONNECTOR na SQ OUT e 8 1 J12 is a Standard CAT5 connector J12 Connector view from front of drive Pin Description J12 1 CONN_RD1 J12 2 CONN_RD1 J12 3 CONN_TD1 J12 4 CONN_RTERM1 J12 5 CONN RTERM1 J12 6 CONN TD1 J12 7 CONN_TTERM1 J12 8 CONN TTERM1 SHLD UUP1 and UUP2 are unused pair 1 and 2 When using a standard CAT5 cable these pairs are connected to the two unused pairs in the 4 pair 8 wire cable NOTE Standard 5 design practice is to terminate these pairs on the PCB to reduce noise When using a 2 pair cable these pins are left unconnected in the cable Mating Connector Information 8 Pin Male PN 5 557315 not shielded 8 Pin Male PN 5 569552 3 shielded 6 11 1 SynqNet LEDs
154. sed if value is not specified help string Simple string to provide help to user 92 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 SynqNet Configuration All service commands and drive parameters are accessed over the service channel as 32 bit quantities but the 32 bits of data can represent different types of data To support various data types with generic software tools the supported data types have been predefined Here are the data type names that are supported for the drive parameter map file Data Types Name Description unsigned8 An 8 bit unsigned binary number unisigned16 A 16 bit unsigned binary number unsigned32 A 32 bit unsigned binary number signed8 An 8 bit binary twos complement number signed16 An 16 bit binary twos complement number signed32 An 32 bit binary twos complement number hex32 An 32 bit unsigned hexadecimal number same as unsigned32 but displayed as hexadecimal enumerated A list of numbers 1 2 3 4 where each number has a specific meaning same as unsigned32 but displayed as a selectable list mask A set of bits 1 2 4 8 where each bit has a specific meaning same as unsigned32 but displayed as a set of selectable flags character An ASCII character Single A 32 bit floating point number according to IEEE754 action A write only parameter where the data is always zero Performs an action co
155. t Use the sqDriveConfig Utility for reading or writing an entire set of drive parameters The utility uses a Drive Parameter Map File that contains definitions and properties of the drive parameters The map file needs to match the drive processor firmware version in terms of version number and in terms of the set of supported parameters Syntax for reading an entire set of parameters to a file SqDriveConfig server ip address node x drive y get destination file name map map file name 5200 Reference Manual M SM 200 01 91 SynqNet Configuration 03 2006 Danaher Motion Kollmorgen 9 3 4 1 File Header Syntax for writing an entire set of parameters from a file SqDriveConfig server ip address node x drive y set source file name map map file name Map files for each drive are delivered with the MPI installation and can be found in the XMP bin subdirectory In addition the map file matched to a specific version of drive firmware can be downloaded from the Drive Firmware section Simply select the drive and retrieve the appropriate firmware and map file information DRIVE PARAMETER MAP FILE The drive parameter map file is a text file that contains a list of valid drive parameters for a particular drive model The file contains five sections File Header Drive Identification Parameter Identification Configuration and File Footer Each Drive Identification section is matched with a Paramet
156. t compatible Auto setup Motor data SFD is Calculation yielded a desired parameter value outside drive limits Outside valid range is inconsistent Incorrect inconsistent motor data loaded into the SFD 15 SFD Sensor Failure Internal SFD failure Excessive electrical noise in the drive environment causing communications interference 16 SFD UART Error Internal SFD failure 100 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Diagnostics and Troubleshooting Status LED Blink Code Fault Description Possible Cause 17 SFD Communication Error Feedback cable not connected at the drive or at the motor Feedback cable shield not connected Defective feedback cable Internal SFD failure Excessive electrical noise in the drive environment causing communications interference 18 Option Card Watch Dog Time out Communication error between option card and main board 19 Position Error Too Large Check ExtFaults ExtFaults Step size over flow means GearOut GearIn is too large ExtFaults Position error over flow means that the following error PosErr has exceeded 128 revs Check if the motor is stalling or if the commanded speed is higher than the motor can achieve at the present bus voltage 20 Option Card Fault Check ExtFaults If ExtFaults is AuxFBFault then the AuxFB device is in error Check t
157. t has a 2 21 kW pull up resistor to 3 3 V Shell Outer shield connection wired to PE in the drive 5200 Reference Manual M SM 200 01 39 Wiring the Drive 03 2006 Danaher Motion Kollmorgen 6 7 J4 COMMAND I O CONNECTOR d rcc Lom J4 is a 26 Position High Density D 9DOOOO00O00O00O00 subminiature female connector 3000000000 2000000001 J4 Connector view from front of drive Pin Description Pin Description J4 1 DINP COM J4 14 DAC MON1 J4 2 DINP1 Enable J4 15 DAC MON2 J4 3 DINP2 Inhibit J4 16 J4 4 DINP3 Inhibit J4 17 Encoder Output Channel Z J4 5 MSINP1 Direction J4 18 Encoder Output Channel E J4 6 DOUT1 J4 19 Channel A Encoder Output Input J4 7 DOUT1 Fault 4 20 Channel Encoder Output Input J4 8 DOUT2 J4 21 Channel B Encoder Output Input J4 9 2 RUN J4 22 Channel Encoder Output Input J4 10 HSINP1 Step PWM J4 23 J4 11 HSINP1 J4 24 Analog Command Input J4 12 SFD BAT J4 25 Analog Command Input J4 13 VORTN J4 26 RTN Mating Connector Information 26 Pin Male High Density D Sub with Back shell Kit 24 AWG Max NorComp 180 026 102 001 D Sub Connector NorComp 978 015 010 03 1 Back shell Kit Refer to www norcomp net 6 7 1 General Purpose Inputs General Purpose The general purpose inputs are a bank of Inputs DINP1 3 7 J4 2
158. the Option Card Feedback position it disables both the SFD and Hall feedback faults and device interfaces on the base unit This bit also forces the feedback position word from the SFD to be zero The drive is set for sine commutation In this mode writing to the CommOff parameter will change the motor position This mode is 5200 Reference Manual M SM 200 01 79 Advanced Configuration 03 2006 Danaher Motion Kollmorgen used when an Option card is attached and the primary feedback device is a Comcoder 0 Base Unit feedback device connected 1 Option card feedback device connected FitDiag Off or Diagnostic Blink Code FitDiag selects between the DOUT1 Fault line being static low for no fault and static high for drive off and or faulted to low for no fault and toggle high low N number of times with the diagnostic LED fault blink code The DOUT 1 line output is still static high for drive off See FaultCode entry for a chart giving the blink counts for each fault 0 OFF default 1 Diagnostic Blink Code GearIn 0 65535 Not supported over SynqNet Gearln is used to scale the input position command when configured as a position controller OpMode Position This parameter is the divisor used to calculate the revs per step for the position mode The formula for calculating motor shaft revs per input count is GearOut Gearln 256 revs per input count There is 1 input count per step input or per input quadrature count de
159. the RAM The operations described above are executed using SynqNet Direct Commands which are listed in the table below The command string is used to identify the specific command It also indicates the syntax of the command used when communicating with the drive over the serial port SynqNet Direct Commands Tor Command SynqNet Direct Description String Command Notes Save SAVE 0x1C Save all parameters to Parameters non volatile memory Accessing Individual Parameters Use the sqDriveParam Utility for accessing individual parameters The syntax follows the conventions listed below xis the node number Nodes are numbered starting from zero e y isthe drive or axis number on that node Drives are numbered starting from zero Xparameter index identifies the parameter being accessed e data value is the data being written to the parameter Syntax for reading drive parameters Sqdriveparam server ip address node x drive y read parameter index Syntax for writing drive parameters Sqdriveparam server ip address node x drive y writ lt parameter index data value Examples To read the value of the drive rated peak current Sqdriveparam server ip address node x drive y read 0x3 Set the encoder resolution to 2048 Sqdriveparam server ip address node x drive y write 0 7 data 2048 Accessing an Entire Parameter Se
160. tion Lines Revolution Lines Revolution User settable 0 factory default 5 2048 500 1 512 6 4096 2 1000 7 5000 3 1024 8 8192 4 2000 9 10000 151 position 0 allows setting the non volatile line count via the drive parameter EncOut to any of the following values 128 512 1024 2048 4096 8192 16384 32768 125 500 1000 2000 2500 5000 10000 20000 The value written replaces the factory default value listed in position 0 of the table The emulated encoder output is only available when using SFD feedback to the base unit or a high resolution feedback device connected to the option card 5200 Reference Manual M SM 200 01 59 Basic Configuration 03 2006 Danaher Motion Kollmorgen 7 1 2 2 tls 51 FUNCTION WITH 6 STEP FEEDBACK In 6 step mode S1 sets the current loop proportional gain KIP Set S1 to the value listed in the table for your drive type and motor inductance Consult the factory if the motor inductance is lower or higher than what can be accommodated by 51 An incorrect setting of KIP can cause current loop instability or oscillation potentially resulting in damage to the drive or application Motor Inductance Table for 6 Step Commutation L in mH AC Input Drive DC Input Drive S1 520260 520360 520660 520330 520630 Position User User User User User Settable Settable Settable Settable Settable
161. tion command comes from the quadrature decode of channels A and B input scaled by the ratio of NV Parameters GearOut over Gearln In Input mode Channels A amp B accept quadrature position commands The command signals need to be differential quadrature signals Channel A leading B generates a CW position command while Channel B leading A generates a CCW position command The magnitude of the command position is set by Gearln and GearOut The maximum input line frequency for reliable operation is 625 kHz which corresponds to a maximum quadrature pulse rate of 2 5 MHz 5200 Reference Manual M SM 200 01 49 Wiring the Drive 03 2006 Danaher Motion Kollmorgen 6 7 7 4 17 18 CH Z OUT CH Z OUT Encoder Phasing The CH Z Output is only available when using SFD Feedback These two terminals function as a differential TTL marker pulse The output pulse occurs once per motor shaft revolution starting at feedback device position O Its width is one line width or two quadrature encoder widths The CH Z uses the same differential driver as described for CH A and CH B Ex qp held Eod 4 QE T CE Encoder Phasing for Clockwise Motor Rotation Analog Command Input ANA J4 24 25 Inputs NOTE This differential input accepts the analog command from the user It has a maximum single ended input range with respect to I O on either input of 12 5 to 15 5 VDC a differential
162. tor power and feedback cables is recommended e When joining or splicing sections of cable be sure to maintain the integrity of the cable shield along the entire length of the finished cable e Separate cables according to type AC Mains input motor power and signal cables should be separated from each other by at least 100 mm 4 in to avoid cross coupling between them If cables of different types have to cross they should do so at a 90 angle e Route wiring close to machine frame It is a good practice to run wires along the machine frame local ground whenever practical this couples some high frequency noise signals that could otherwise be troublesome directly to the local ground e Remove paint from all drive filter and cable clamp mounting locations e Add clamp on ferrites to cables Adding clamp on ferrites to noisy cables can reduce emissions by absorbing RF energy before it is radiated e Use the appropriate line filter A line filter is required for CE applications more information on line filter selection can be found in D 10 e Add a balun to the motor power cable adding a balun in series with the V and W phases of the motor power cable can attenuate both conducted and radiated emissions e Ensure that cables shields have a good RF ground more information on this can be found in D 10 AC MAINS CONDUCTED EMISSIONS Line Filter To meet the CE conducted EMC requirements an external line filter in seri
163. ty drive the high speed Differential input differentially from 5 V logic through twisted pair Drive wiring The differential driver needs to deliver a minimum of 3 0 V to the input terminals on J4 A CMOS driver is recommended Twisted Pair J4 10 Wiring HSINP1 3 0 V Min Y 5 V Differential J4 11 Driver CMOS HSINP1 46 M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Wiring the Drive Sinking Load For single ended operation both terminals of the high speed input are available on J4 allowing the input to be connected to either sinking or sourcing logic The following diagram shows the connections to drive the high speed input from sinking logic J4 10 HSINP1 External 4 30VDC Power Supply External Current Limiting Resistor for supply gt 5 0 V Sinking Logic Output from Field Device Sourcing Load The following shows the connections to drive the high speed input from sourcing logic The power supply can be the same power source used to provide power for the general purpose inputs Sourcing Logic Output from Field Device External Current Limiting Resistor for supply gt 5 0 V O External 4 30VDC gt Power Supply O J4 11 HSINP1 6 7 4 SFD BAT J4 12 The SFD BAT terminal is an optional feature and is not SFD required for proper operation of the drive It is only required if battery backup of the multi turn information is required from the
164. ty feedback S200MonitorAddress 9 2 2 Monitoring Real time Data from Drive Some data from the drive is not part of the standard MEI I O However it can be monitored in real time from the drive For more information on how to monitor real time data from the drive see Drive Monitor List of real time monitor fields This is a partial list of supported fields Consult your drive manual for a complete list 5200 Reference Manual M SM 200 01 89 SynqNet Configuration 03 2006 Danaher Motion Kollmorgen 9 3 9 3 1 9 3 2 e e HSTemp e FB e dFb e MTemp e Pos PosFbMTrn e PosFbLSBS PosFb e PosFbMSBS PosFb VBus VelFB ACCESSING DRIVE PARAMETERS OVER SYNQNET Introduction The drive s functionality is designed to use various drive parameters and instructions which are communicated over SynqNet Some parameters have read only access whereas other parameters may have read write access The parameters can be stored in non volatile memory on the drive and are used on each power up cycle Examples of read only drive parameters are e drive command value CMD IN e drive model number MODEL e drive bus voltage V BUS Examples of read write drive parameters are e commutation offset value COMM OFF e proportional gain of the current loop motor pole count D POLES Drives are shipped from the factory with motor parameters set to zero and application paramete
165. uited has no photo diode current The active control logic polarity of each input can be set by the corresponding DInpXPol NV Parameter In other words depending on the state of DinpXPol a given hardware input driven active will activate or not activate a drive control function DINP1 ENABLE DINP2 INHIBIT DINP3 INHIBIT DINP4 DIRECTION Input 1 The ENABLE control function mapped to this input enables disables the drive and resets the latched drive faults With default logic polarity DInp1Pol Normal the drive can enable when input 1 is activated current flowing in the photo diode and will be disabled when open circuited This input will disable a drive independent of any other parameters Successful enabling requires no drive faults and SWEnable SynqNet drive enable active as appropriate Setting this input to the inactive state clears any latched drive faults Input 2 The INHIBIT control function mapped to this input prevents further motion in the clockwise shaft motion direction when activated by current flowing in the photo diode This input has no effect on motion in the counter clockwise direction This function can be turned on or off by setting EnhibitCW DInp2Pol sets the control logic active polarity for this hardware input This input is useful for a clockwise over travel limit switch Broken wire failsafe over travel limit switch operation requires that DInp1Pol be set to Invert by the use
166. ules E bus cap 1 2 Cbus x DC voltage x DC voltage Assume the bus DC voltage is 75 volts Cbus 2 x Ebus cap 75 V x 75 V 2 x 6 joules 75 V x 75 V 2 133 UF The internal S200 bus capacitance is 200 uf which is less than 10 of the required capacitance for energy absorption Energy from Acceleration Time The bus supply for a group of S200 drives must have enough total capacitance to handle brief high current bus transient flows positive and negative a few milliseconds without excessive bus voltage variation The peak output power of a 6 18 ARMS DC S200 can be as high as 1 5 kW 1 5 kW 18 ARMS x rt 2 x 60 V emf IR This is an energy flow of 3 joules for 2 ms or 15 joules for 10 ms Mechanical energy is estimated by considering the load to be pure inertia and measuring the velocity transition times A full torque acceleration or deceleration of an inertia load yields a triangle power pulse with an energy in joules half of the peak power in watts multiplied by the velocity ramp time in seconds from zero speed Monitor the motor acceleration by mapping velocity and torque to DAC monitor pins J4 14 15 and then looking at them with a scope Set DM1Map to VelFB and DM2Map to IFB See the I O Setting tab in S200Tools At a peak power flow to the shaft of 1 kW 25 A x 40 V EMF the energy delivered vs acceleration time is 5 ms 2 5 joules 10 ms 5 0 joules 15 ms 7 5 joules Capacitor Energy Absorb Deliver The capacitor
167. ully commission the drive For such cases connection to a computer to commission the drive is not required The quick setup is useful for simplifying machine field upgrades repairs and for reducing spare part inventory See Configuring with SFD Feedback The drive can also be configured for a simple analog Torque Current control with 6 Step Hall Feedback type by simply setting the switches See Configuring Current Mode with 6 Step Hall Feedback The 5200 drive has many advanced capabilities to aid machine design through its diagnostic and measurement capabilities accessed through the Windows compatible S200Tools GUI utility The drive also has many advanced motion capabilities that can be set up through the S200Tools utility For example if desired the settings of the switches can be overridden in drive non volatile memory to eliminate any accidental miss adjustment of the drive in the field See the Advanced Configuration section for more details SWITCH SETTINGS The configuration switches S1 and S2 are located on the top of the drive Although the drive can be configured to not use the switches the factory default configuration uses the switches for selecting Torque Current versus Velocity operational mode SFD or 6 step feedback device and emulated encoder line count 51 N 23 gt Down Closed e o 8L 52 DIP Setup Switch S2 is a 4 position DIP switch Switch positions 1 and
168. ve Options Of ON 5200 Tools Software Installation Follow the installation instructions from the CD ROM or zip file 200 Tools supports the following Operating Systems e Windows 2003 Server e Windows Service Packs SP e Windows 2000 SP2 e Windows XP embedded e Windows NT4 5 6 Hardware Setup DRIVE SETUP To establish a communication link between the host computer and the S200 Base Unit drive connect a serial communication cable between the drive and host computer 1 Plug one end of a serial communications cable to J5 SynqNet IN of the 5200 drive and the other end of the cable to the host computer s serial COM port NOTE The serial communications cable is not shipped with the drive It must be ordered separately M SM 200 01 5200 Reference Manual Danaher Motion Kollmorgen 03 2006 Quick Start Guides 4 1 2 2 4 1 3 4 1 3 1 4 1 3 2 Host Computer Serial Port Serial Cables Serial Port S200 MOTOR SETUP If you are using an S200 Base Unit drive use the J3 connector for motor feedback Only SFD motor feedback is supported on Base Unit drives If you want to use SinCos or ComCoder as motor feedback you must use the AUX FB J14 connector which is not available on Base Unit drives See Drive Model Numbers and Descriptions for a complete list of S200 drives 200 Tools Communications Wizard LAUNCH S200 5 Launch the S200 Tools program by clicking the desktop icon
169. ve in Torque or Velocity Modes either change the wiring or change the parameters CmdSrc Setting Wiring Method Parameter Method Analog Command Swap the analog command connections J4 24 and J4 25 Change the sign of CmdGain Command Variable None Change the sign of Command PWM Input Swap the PWM connections J4 10 and J4 11 Change the sign of CmdGain To reverse the command to the drive in Position Modes PosCmdSrc Setting Wiring Method PosCmdSrc AQuadB and J4 20 Reverse the Ch A input to the drive by swapping J4 19 Step Dir The Direction command J4 5 to the drive needs to be inverted by the user s controller To reverse the Emulated Encoder Outputs from the drive Reverse the Emulated Encoder Outputs if the external control loops use the emulated encoder outputs for feedback Swap the CHA and CHA emulated encoder outputs J4 19 and J4 20 going to the external controller 5200 Reference Manual M SM 200 01 69 Advanced Configuration 03 2006 Danaher Motion Kollmorgen 8 ADVANCED CONFIGURATION The S200 is shipped with a factory configuration that is designed to work with a Smart Feedback Device SFD equipped motor to implement an analog commanded Torque Current block The 10 V input factory configuration yields a maximum clockwise torque current The 10 V input
170. y divided by 50 or more See the Control Block Diagram for more information CmdGain See Chart CmdGain sets the scale factor from the user input on the Command I O connector J4 to the internal servo loop command CmdGain can be negative or positive which allows the direction polarity to be changed Because the input to the command processing block can be an analog voltage or a digital duty cycle and the servo loop could be Torque Current or velocity there are four combinations of units listed below See CmdSrc and OpMode for these settings See CmdOffset for adding an offset to the command Expressed as an equation Cmdlin User Input CmdOffset CmdGain NOTE The Range of CmdGain is clipped by the value of CmdOffset The chart below gives CmdGain units and numerical range assuming that CmdOffset is 0 50 CmdSrc OpMode CmdGain Units CmdGain Range Analog Torque Current ARMS V ARMS V Analog Velocity krom V krpm V PWM Torque Current ARMS 96 ARMS 96 PWM Velocity krpm krpm Cmd Offset Volts or Percent CmdOffset is added to the user input on the Command I O connector to allow any constant offset present in the source to be cancelled Because the input to the command processing block can be an analog voltage or a digital duty cycle there are two possible units See CmdSrc for this setting and CmdGain for scaling the gain of the input command Expressed as
171. yields a maximum counter clockwise torque current By adjusting the rotary switch 51 to set the emulated quadrature encoder output completed setup of the drive is now ready for many applications To configure the drive as an analog velocity loop with medium velocity loop bandwidth stiffness adjust the DIP switch S2 so that pin 1 is in the up position S2 123 4 If this functionality serves the application need the factory setup can be used as is in an application For applications other than the two standard configurations described above such as using a PWM digital line for the command or implementing a position loop with Step and Direction command the drive configuration will have to be customized through the Windows PC compatible setup software called S200Tools The rest of this chapter describes the S200 configuration options through diagrams of the control loops reference lists of setup parameters with their definitions and range and further explanations of drive capabilities 70 M SM 200 01 5200 Reference Manual 03 2006 Advanced Configuration Danaher Motion Kollmorgen CONTROL BLOCK DIAGRAM 8 1

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