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1. ISCALE 10r3 ServoStar MotionLink Off Line OF File Edit View Configure Tune Options Help BE Offline SEG3 160 volts Operation Mode Serial Torque IE Current f 1 2 Gearing anru anny Encoder E LIT Feedback Or PTU Device e System Motor Device Select B 202 4 pen x Set C Disable lt Enable Exit Figure 5 1 Serial Torque Mode w MotionLink MSU024D SERVOSTAR CD Product Family 5 7 System Operation Kollmorgen 5 5 2 Analog Torque The SERVOSTAR is most often configured to operate as an analog torque loop controller OPMODE 3 In this case the current loop receives its input from the analog to digital A D conversion system After conversion the input command signal is processed through an algorithm which adjust the signal ANOFF ANDB ANZERO filters it ANLPFHZ and then scales it ISCALE before developing the current command ICMD The current or torque command is then checked against peak IMAX ILIM and continuous FoldBack features ICONT current clamp limits Sinusoidal commutation modulation is added to the command and then fed to the three phase current loop regulator which calculates a current error This error is then fed through a digital pole placement compensation algorithm The output of the compensator is converted
2. KOLLHORGEH Axis Disable Enable 2 Figure 4 1 MotionLink Screen MSU013D e Setting Drive Variable Parameters From the Configure menu click the Drive option The same screen appears as described the SERVOSTAR Startup screen section Click Exit to return to Main MotionLink Screen e Setting Motor Variable Parameters selecting the Motor option under the Configure menu the user can obtain the same parameter screen found in the SERVOSTAR Startup screen Click Exit to return to Main MotionLink Screen e Customizing to Application By dropping down the Operational Mode listing the user can select the mode of loop control desired position velocity torque Clicking the Tune button the user can select the system bandwidth the type of loop control and the filtering necessary for the application These are the same parameter screens found in the SERVOSTAR Startup screen Click Exit to return to Main MotionLink Screen e Saving Variable Parameters to EEPROM At the top of this screen the user can click the button labeled RAM E to save the modified variables from RAM to EEPROM e Saving Variable Parameters to SSV file Occasionally the user may desire to backup the variable parameters from one drive for use in another To do this the user must pull down the Edit menu and 4 8 SERVOSTAR CD Product Family Kollmorgen System Startup select Backup Variab
3. Regen circuit turn off Vdc Vmax Regen circuit turn on Vdc Table 2 1 SERVOSTAR Regen Information For guidance on application sizing of Regen Kits see Applicatin Note on the PSP CD ROM SERVOSTAR CD Product Family Kollmorgen System Description 2 1 5 Product Family Control Specifications Product Model SERVOSTAR CD Control Specifications Current Loop Commutation Loop Velocity Loop Position Loop Update Rate 62 5 uS 16kHz Bandwidth Update Rate lt 2000Hz 62 5 uS 16kHz Output Waveform Update Rate Sinusoidal 250 uS 4kHz Bandwidth lt 400Hz Speed Command Resolution Serial Analog 12Bit Optional 14 Maximum Minimum Speed 500Hz Serial 1 RPM or Analog 1 2048 VMAX Long term Speed Regulation Update Rate 01 clock tolerance 500uS 2kHz T O Connector by pinout Analog Input 2 3 Fault Output Relay 5 6 Remote Enable 7 8 Configurable Inputs 7 9 10 11 Configurable Digital Output 7 12 Configurable Analog Output 13 4 amp Complements 1 2 4 5 7 8 Maximum Voltage 13 V differential Input Resolution 12 Bit Optional 14 Bit Sensitivity 4 9mV 12Bit Voltage Range 8 to 8V Standard 10 to 10 V Rescaled Input Impedance CMR gt 10K ohms 50 dB Long term Drift Max Capacity Input Frequency
4. e ete c tine 2 5 2 Analog TON cct ere eite eee ii SERVOSTAR CD Product Family Kollmorgen Table of Contents 23 5 3 Current Sampling cy ND ec go tre 5 9 E 5 9 5 6 I Drive FoldBack a As cen eee DER 5 9 5 6 2 FoldBack eee cade eere une coepere create Dade ca 5 9 SECTION 6 SERVOSTAR HELPS cscsssssccsssssscscssssesececececececesesessscssssssssscececececscsnsesssesesececececesesessscacacaseseseseseeee 6 1 6 I TECHNICAL INFORMA TION beoe ee a TERTIA 6 1 6 2 TROUBLESHOOTING TOOLS Pee YEA TR SAVA TE ads ee 6 1 BS CODES LC 6 1 6 3 1 FATAL FAULT ERROR GODES i e a a E E A AE E E E a E 6 2 6 3 2 NON FATAI ERROR CODES foe d reos a toe pet e a EE 6 2 6 3 3 NO MESSAGE FAULTS 6 4 6 4 FAULT MONITORING SYSTEM 5 o ceci cte erede ee haee ener eee eese 6 5 6 5 FIRMWARE UPGRADES lote ve voee V R S Y K yu ve tue VD 6 6 6 6 CUSTOMER SUPPORT xe teet e NO ed eode ie feodi 6 7 SECTION ZINDEX CE 7 1 SERVOSTAR CD Product Family iii Kollmorgen Safety Instructions Only qualified personnel are permitted to transport assembly commission and maintenan
5. 1 3AVH LSNW SHOLOW NOILOALOYd QVO TH3AO Hardware Installation 80101510 3ULIIAA x eqpoo MSA 873 9 9 3NIS HOF SLNANI 339 A9 NOWWOO athe 0 81 TWH TANNVHO TIVH TWNOLLdO 33 OL 38 1Sn LVLSOWYSHL YOLOW OLLWY X 570 33 OL 38 1SNW LVLSOWYSHL SOLON IH 3NIS eui 02 ANY 5 21 33S AVIN HOLIMS LVLSOWYSHL G3sn 1SnIN QVO TH3AO 010 WWNYALXS NOLLO3LOBd TWWYSHL 1VHO3LNI 3AVH 15 3010 NOILOALOYd QVO TH3AO S3HO LIMS 305 S THINNVHO TIVH LNOHLIM 9NILVH3dO N03 SNOISIAOYd Al1V3H9 AVA SNOILdO S3dAL H3000N3 NOISS3A 3NIS H3QOON3 NOISH3A H3A1OS3H HL1ON31318v9 LYOHS ONISN SH3009N3 LNIYYNO NI ISN 38 G33N 13S 3NO AINO NI dOHQ 39 VL1OA 3ZIWINIW OL SHV SNOILOSNNOO H3009N3 OML SALON o o o o o o o o o o o o o 9 o o o o ovadaa4 o N O yoeqpss uiajs S SERVOSTAR CD Product Family 12 Kollmorgen H
6. Mating Connector Hardware CK100 Kit Includes C1 C2 C4 C7 plus 2ft 0 69m of stranded bus ribbon C3 Kollmorgen A 93899 013 Vendor Info Weidmuller BL3 5 13 Cat No 161574 C5 Kollmorgen A 81014 004 Vendor Info PCD ELFP04110 Connector Screw Torque 2 25 15 0 25Nm 24V Logic optional PCD ELFP02210 or equivalent Table 3 1 5 Cx Hardware Specifications SERVOSTAR CD Product Family Kollmorgen Hardware Installation 3 2 2 2 Cx unit 2xQD 10 0 0 39 HEAT SINK 33 7 1 33 163 0 6 42 2 0 0 08 256 0 216 0 10 08 8 50 Figure 3 1 Cx Outline Dimension MSU031D SERVOSTAR CD Product Family Hardware Installation Kollmorgen 3 3 INSTALLATION PRACTICES The environment that any electronic control system lives in can effect its operation Kollmorgen recommends that the SERVOSTAR system be operated and stored under the environmental conditions stated in the product specification tables see 2 1 3 Cx Electrical Specifications on page 2 8 The system may be operated in higher temperature ambient conditions with a derating applied Please check with the factory for derating information Attention to proper installation and field wiring are of prime importance to ensure long term and trouble free operation Users should familiarize themselves with and follow the installation and wir
7. 100 ppm 0 075 C 1A 24 Vde 2 5kHz Opto isolated Input Voltage Range 12 to 24 V Nominal Min On Max Off 10V 1V Current Demand per Input Output Voltage max 0 to 48 Nominal Bi directional Open Collector Min On Max Output Current Max Output Current 1mA internal series resistance Sensitivity Resolution 4 9mV 12 Bit Voltage Range Encoder Equivalent Output Output Voltage high level 25 C 10 to 10V C4 by pinout 2 5 min 20mA Output Voltage low level 25 5 max 20mA RS 485 Line Drive Type DS26C31TM Remote Encoder Input C8 by pinout amp Complements 1 2 4 5 7 8 Input Voltage high low level 25 C 5V 0V nominal 2 2V Input Impedance 100 Q RS 485 Line Receiver Type SN75173 See section 5 4 2 4 Position Loop on page 5 6 for features using this input Table 2 1 SERVOSTAR Control Specifications SERVOSTAR CD Product Family System Description Kollmorgen 2 2 FEEDBACK DEVICES The SERVOSTAR can receive resolver encoder with or without halls or sine encoder feedback Kollmorgen offers a variety of motors with options for these various feedback devices The device preference and the associated model number must be determined when the order is placed The following provides general information on the feedback requirements of the drive 2 2 1
8. Controller Routed to Motors Routed to Motors Figure3 1 Filter Bonding System Diagram MSU034D SERVOSTAR CD Product Family 3 17 Hardware Installation Kollmorgen Filter Bonding System Diagram Notes 1 Input power Enters enclosure from metal conduit 2 Single point ground bus bar ground bus 15 an excellent way to achieve this 3 High frequency ground between conductive back panel and enclosure Also a high frequency ground is required between the enclosure and earth ground 4 EMI filter grounding Safety grounds must be provided on the filters Potentials can exist even when the power Is off because of the capacitors internal to the filters 5 Bonding of motor cables The use of armored screened motor cables that are bonded as close to the drive as possible are essential for CE compliance and strongly recommended to better the overall performance and reliability of the system 6 Feedback cable bonding is required for CE compliance As with the motor cables the feedback cables should be bonded to the back panel This bonding will do two things First it will cut down r
9. SV S39VL S31VH3dO QO YVLSOAYAS JHL SNINSHVAA MOI HOLON SI SOVLIOA LNANI 99159 ama 7 SALNNIN OL 151 AVIN SOVLIOA N7 aanadns 5 9 r HEWE pt 31ON 22S L ILON 33S OWA 082 911 aH e 2 01 1 15 ANIOd YVLS OL didus LAdNI NIVIN NU E Q 01 31ON 33S SERVOSTAR CD Product Family 3019914095 H3MOd 3ZIOH3N3 OL NOLLNSHSNd AYVLNSWOW YOLOVLNOD NIV Wous LOVLNOO 340 ATTVWNHON nn 1 GNNOYS LON YOLSISSY LVLSOWYSHL 9Z HY3 N3938 SAILSISSY WNYSLXS 9018 3 10 5 e Kollmorgen Hardware Installation Figure 3 7 System Wiring Diagram notes Note 1 FUSE 2 and contactor may not be required if input power line is neutral Also see Note 9 Note 2 Allow 30 seconds after turning power off before reapplying power Note 5 All AC Line wires should be twisted pair Note 6 The ground of the drive and motor best minimizes ground currents and noise when connected in a star point configuration Note 9 See 2 1 3 Cx Electrical Specifications on page 2 8 for recommended line input fusing REFFORMATVERBINDENSEITENREFNote 10 Cables should be properly bonded to the backpanel and implemented as close to the drive si
10. Monitoring and Troubleshooting Tools performance recording RECDONE RECING RECOFF RECORD RECRDY RECTRIG system status checking STAT STATUS STATUS2 control loop monitoring 1 current torque I IA IC ICMD IMAX ICONT DICONT DIPEAK 2 speed V VCMD VE 3 position PCMD PFB PE HALLS HWPOS INPOS PRD PEXT PEINPOS analog output ANOUT with 12 bit resolution and scaling flexibility PSCALE that can be configured to monitor speed torque current power velocity error following error and position feedback PFB Should be used as a monitoring tool only dual state digital output 01 OTMODE OIRST O1TRIG that toggles according to various absolute current speed and position parameter settings Also can be used to communicate occurrences of FoldBack motor braking and the status of the Remote Enable hardware switch Status Display TESTLED indicator that communicates operational and fault characteristics real time reading of the 10 position DIP switch DIP DIPEN software status switch indicator provided for Configurable Inputs INx INXMODE IN SERVOSTAR CD Product Family 2 5 System Description Kollmorgen Fault and Safety Detection General watchdog faults general faults ACKFAULT STAT STATUS configurable UnderVolts protection UVMODE UVTIME UVRECOVER Speed and current protection VOSPD VLIM ACC DEC ILIM ILIM2 fatal and non fatal error coding with text explanation to the hos
11. has a seven segment indicator called a Status Display that indicates four types of states Power up Steady State Flashing State and Momentary State The decimal point directly relates to the global drive enable Status Display DRIVE STATE DISPLAY APPEARANCE Momentarily illuminates all display segments forming an 8 and the decimal point Steady State Displays the operational mode OPMODE of the drive 0 8 No Faults Used to indicate an abnormal operating state If the position hold feature is active the OPMODE number will flash at a 1 Hz rate If a fault was detected a flashing code will be displayed to identify the fault Some codes Flashing State consist of a sequence of two or more digits see Troubleshooting section In general these faults will cause a latched disable sometimes controllable through software switches To clear fault toggle remote enable except for OverCurrent If the encoder initialization function ENCSTART is active the OPMODE number will flash at a 3 Hz rate Displays a character momentarily for 500 ms before returning to the steady state The Momentary Fault timer is resetable C Communications Error Drive 15 in FoldBack mode Table 5 1 Status Display States Status Display Decimal Point DECIMAL POINT STATE DRIVE STATUS Steady OFF Steady ON Drive enabled power to the motor Flashing Drive enabled power to the motor but a motor safety feature has been disabled for ex
12. MTANGLP MTANGLF MTANGLH defined as speed and torque optimization through commutation angle advancing of the drive s output current waveform with respect to the motor s back EMF waveform firmware and serial number information VER SERIALNO MOTOR via terminal SERVOSTAR CD Product Family Kollmorgen System Description 2 1 2 Part Number Description MODEL NO C R 0 3 0 0 0 2 G 2 04 A SERVOSTAR Amplifier Family C C Series Compact Drive Feedback R Resolver E Encoder B Sine Encoder Motor Information g i Rated Current Amps Voltage Level E 0 No Comp C peries 03 06 1 115 Vac 160 Vdc 2 230 Vac 325 Vdc J low inductance motors w SSV Variable file only C Series Hardware Options Y Special Compensation 260 Standard w 24V logic input three digit extension follows 261 SERCOS w 24Vlogic input the Y designator SERVOSTAR CD Product Family 2 7 System Description Kollmorgen 2 1 3 Cx Electrical Specifications Product Model Cx03 Main Input Power Logic Input Power SoftStart Protection Functions Rated Main Output Ma Mb Mc Protective Functions Environment Voltage Nominal 10 110 230 230Vac 19 36 1 3 Line Frequency 47 63 230 10 230084 0 89 1 39 1 8 2 79 Continuous Current amps at 230 1 3 3 9 3 5 Peak Current amps for 50
13. STOPMODE ISTOP See AppNote ASU005H on the PSP CD ROM for a comprehensive discussion on this feature e separate accel decel linear ramping control in velocity and position mode ACC DEC PROFMODE e S curve accel decel ramping control PROFSCRV PROFMODE in the position mode OPMODE 8 e controlled decelerating DECSTOP DISSPEED DISTIME with acceleration feed forward when the drive is left enabled STOP HOLD CWLIM CCWLIM LIMDIS or becomes disabled K S ACKFAULT DIS Also can be used in conjunction with the Electronic Braking feature e torque compensator for coulomb friction and weight counter balancing IFRIC IGRAV Motor Controllability e provides linear and rotary motor control MOTORTYPE MPITCH MENCRES with automatic unit conversion e configurable back EMF characteristics for effective current loop controller design and command MBEMF MBEMFCOMP e Kollmorgen s patented Torque Angle control to maximize motor output power MTANGLC MTANGLP MVANGLF MVANGLH e motor speed and current limits MSPEED MICONT MIPEAK e thermal protection control MFOLD MFOLDD MFOLDDIS MFOLDR MFOLDT adaptable to any motor e AutoConfig feature ACONFIG ACONFIGST MFBDIR automatically configures the motor s power and feedback cables It checks warns and corrects for incorrect wiring of these cables e configurable positive motion direction DIR Feedback Devices e device zeroing mode that rotates the motor to an e
14. command LOAD command or Power up SAVE command operating parameters MICRO PROCESSOR Figure 4 1 Memory Flow Diagram MSU029D The PC transmits serial data to the drive and stores it in dynamic RAM However any variable data that is changed from the PC will be lost when logic power is lost if it is not saved into non volatile EEPROM Each variable listed in the VarCom Reference Guide indicates whether it can be saved to the EEPROM For the user who configures the same system on similar applications the variables can be saved on disk in an SSV file for convenient downloading into other drives See Section 4 2 Initial Startup 4 1 4 MotionLink Installation 4 1 4 1 Installing on PC e Insert the SERVOSTAR PSP CD ROM to load MotionLink for Windows e The CD ROM should autorun If not select Start Run or browse your CD ROM drive e Type D autorun exe and hit the Enter key this assumes your CD player has a D letter designation e Select a product and follow the instructions on the screen 4 1 4 2 Running the Program e to your Start Programs listing and select SERVOSTAR MotionLink from the menu or click on the SERVOSTAR MotionLink icon if loaded on the desktop 4 4 SERVOSTAR CD Product Family Kollmorgen System Startup 4 2 INITIAL STARTUP Review and be familiar with this section completely before applying power to the system WARNING Most drives are shipped from the
15. 1 2 MotionLink Screen 4 2 1 3 Terminal Rp ee aen 4 2 2 MultiDrop Communication 4 2 3 Power Up eine entente eene ance reete eget ee ete sete nere 4 2 4 Enabling the System SECTION S SYSTEM OPERATION eer tnn roo pron ene ro o EW e Kek V Le KK V ona 5 1 Del STATUS DISPLAY D E 5 1 2 2 OPERATIONAL MODES 5n ae reri n HERE ETE GU TREE sporty uceusets uty seats any 5 2 5 9 9 YS TEM dd 5 2 3 32 Analog ANIN aq wale ER ets cede deret Rege ade BRL 5 2 5 3 2 Remote Enable Input 5 3 5 3 3 Configurable Inputs IN1 IN2 5 3 5 3 4 Configurable Outputs ANOUT 5 3 5 3 5 Fault Output Relay RELAY RELAYMODE sse nennen eene nennen nennen 5 4 5 3 6 Motor Thermostat Input THERM 5 4 5 4 CONTROL LOOPS ina 5 4 524 1 COPE i s nte celi 5 4 3 4 2 Servo Loop Description 5 4 2412 T Current Loop xoci c ROG PR UE 5 4 2 2 Commutation Loop 5 4 2 3 Velocity Loop 5 42 4 Position eto tat dne toe tene Ve d aya 5 5 TORQUE LOOP OPERATION 2 51 Serial FOTQUe
16. 2 3 2 6 Position Mode SWEN 2 6 4 10 4 11 Serial 5 2 System I O 5 2 See Configurable I O PRD 2 3 2 5 5 7 5 8 2 1 5 2 PROMPT 2 4 Terminal dumb 4 9 See MotionLink PSCALE 2 2 2 4 MultiDrop communications 4 10 RDRES 2 3 2 10 2 11 saving variables to EEPROM 4 9 READY 2 6 4 10 4 11 setting variable parameters 4 9 RECDONE 2 5 TESTLED 2 5 RECING 2 5 TF 2 2 RECOFF 2 5 THERM 2 6 5 4 RECORD 2 5 THERMODE 2 6 5 4 6 5 RECRDY 2 5 THERMTIME 2 6 5 4 RECTRIG 2 5 THERMTYPE 2 6 5 4 SERVOSTAR CD Product Family 7 3 Index Kollmorgen Torque Loop See Current Loop TRUN 2 6 TUNE 2 2 UL v UNITS 5 3 UVMODE 2 6 UVRECOVER 2 6 UVTIME 2 6 V 2 5 5 7 5 8 VBUS 4 6 4 9 VCMD 2 5 5 8 VE 2 5 Velocity Loop 2 2 5 5 analog input 5 2 Configurable I O 2 2 features See AppNote ASU008H feed forward acceleration 2 3 5 6 filtering 2 2 5 6 homing See Appnote ASU008H OPMODE 0 5 2 OPMODE 1 5 2 specifications 2 9 tuning See AppNote ASU006H VER 2 6 5 4 VEXT 2 2 VLIM 2 2 2 10 2 11 VMAX 2 3 2 8 2 9 VOSPD 2 2 2 6 6 5 VSCALE 2 4 5 3 5 8 Warranty 1 2 Wiring 3 4 XENCDIR 2 2 XENCRES 2 2 ZERO 2 3 SERVOSTAR CD Product Family
17. 2 6 DISTIME 2 3 2 6 DRIVEOK 2 6 4 10 4 11 Dual Gain Input See Analog Input Dualloop operation 2 2 DUALFB 5 6 DUMP 24 4 9 ECHO 2 4 EN 2 6 4 10 Enable Input See Configurable I O Enabling System 4 10 5 3 ENCINIT 2 4 ENCINITST 2 4 Enclosure 3 4 Encoder Equivalent Output 2 4 2 14 Encoder System channel phasing 2 15 Resolver System channel phasing 2 15 index pulse 2 14 Encoders 2 4 2 11 SERVOSTAR CD Product Family 7 1 Index Kollmorgen accuracy 2 12 C2 connections 3 8 cable lenghts 2 12 initialization 2 5 resolution 2 12 specifications 2 12 types 2 4 2 11 ENCOUT 24 2 14 ENCSTART 2 4 5 1 ERR 2 6 6 1 Fault Output Relay See Configurable I O Feedback Devices Dualloop 2 2 encoders See Encoders resolvers See Resolvers sine encoders See Sine Encoders Filtering analog input 2 4 limits 2 5 low pass 2 2 5 2 notch 2 2 Filters See CE Mark FILTMODE 2 2 FLTCLR 2 6 FLTHIST 2 6 6 1 FOLD 2 1 2 6 5 9 6 5 FoldBack 5 9 drive 2 6 5 9 motor 2 3 5 9 FOLDMODE 2 1 2 6 GEAR 2 2 GEARI 2 2 GEARMODE 2 2 5 2 GEARO 2 2 GET 2 4 GETMODE 2 4 GP 2 3 GPAFR 2 3 GPAFR2 2 3 GPD 2 3 GPI 2 3 GPISATIN 2 3 GPISATOUT 2 3 GPVFR 2 3 Grounding 3 4 bonding 3 5 clamping 3 5 IC 2 5 5 9 ICMD 2 5 ICONT 2 5 5 7 5 8 5 9 IFRIC 2 3 IGRA 2 3 ILIM 2 1 5 7 5 8 ILIM2 2 1 ILSBMODE 2 3 IMAX 2 1 2 5 5 7 5 8 5 9 IN 2 5 INI 5 3 6 5 IN2 5 3 6 5 IN3 5 3 6 5 Indexing See Position Loop INDEX
18. 6 sets the Serial SERCOS baud rate to either 9600 2M switch off or 19200 4M switch on e Position Hold Activating switch 7 causes the drive to enter a position hold mode The condition is enunciated to the user by a flashing status display The display maintains its current OPMODE code If the drive is running during a HOLD command detection the motor will ramp to a stop at the DECSTOP rate e Enable Switch 8 is an input to the drive enable circuitry and can be used to force the drive to a disabled state e SERCOS Power Level Functions only on SERCOS interface products If switch 9 is set to 0 the SERCOS transmitter uses a low power setting so the receiver is not overdriven when using short cables Long cables require more power e Factory Reserved Must be set to 0 es O 5 lt Figure 3 1 Top View MSU032D Note Setting the switch to 1 means Closed or On Configuration Switch Switch Function MultiDrop Addressing Serial SERCOS Baud Rate 1 0 Hold Mode Inactive HOLD Mode Switch 1 Hold Mode Active Drive Enable Disable Enable 7 SERCOS Transmit Power 1 10 Settings it 0 of MultiDrop Address LSB it 1 of MultiDrop Address it 2 of MultiDrop Address it 3 of MultiDrop Address it 4 of MultiDrop Address MSB 19200 4M Drive Disable High Power Factory Reserved Must Be set to 0 SERVOSTAR CD Product Family Kollmorgen
19. Another option is to use cable bonding clamps offered by Phoenix Contact and others When using the Phoenix Contact parts make sure that a low impedance high frequency ground is connected from the ground bus bar to the back panel This can be done with a flat braid or a copper bus bar The SK parts from Phoenix SK8 SK14 amp SK20 slide onto the bus bar The cable with exposed shield is inserted through the SK piece and the thumbscrew on top of the SK piece is used to tighten the connection between the cable shield and the bus bar Phoenix Contact Part Cable Diameter Range 3025163 Shielded terminal block for SK8 Type SK8 placing the shield on bus bars up to 8mm or 0 315 inches 3025176 Shielded terminal block for SK14 5 14 placing the shield on bus bars 8mm to 14mm or 0 551 inches Type SK20 placing the shield on bus bars 14mm to 20mm or 0 787 inches Type AB SS mount ground bus Type NLS CU 3 10 copper at varying lengths Figure 3 6 and 3 7 represent a side and top view of the SK device that clamps down on the shield of the cable The use of the Phoenix SK device is an excellent method for providing a low impedance path between cable shield and the back panel Thumb screw to tighten down shield to bus bar cable shield compressed on copper bus bar copper bus bar 5 8 14 20 Shielded terminal block Figure 3 1 Phoenix Contact Side View MSU017D 3 6 SERVOSTAR CD Product Family Kollmo
20. Kollmorgen with closed loop control of torque speed and or position The rated voltage of the motors must be at least as high as the DC link voltage of the servo amplifier e servo amplifiers may only be operated in a closed switch gear cabinet taking into account the ambient conditions defined in the environmental specifications described in Section 2 1 3 Cx Electrical Specifications on page 2 8 e Weonly guarantee the conformance of the servo amplifiers with the standards for industrial areas stated in the front of this manual if Kollmorgen delivers the components motors cables amplifiers etc 1 2 SERVOSTAR CD Product Family Kollmorgen General Information 1 4 CUSTOMER SUPPORT Kollmorgen is committed to quality customer service Our goal is to provide the customer with information and resources as soon as they are needed In order to serve in the most effective way Kollmorgen offers a one stop service center to answer all your product needs This one number provides order status and delivery information product information and literature and application and field technical assistance NOTE Kollmorgen Seidel GmbH amp CO KG Wacholderstraf e 40 42 40489 D sseldorf Germany Phone 49 0 203 9979 0 Fax 49 0 203 9979 155 Email sales eu kollmorgen com Http www kollmorgen seidel de If you are unaware of your local sales representative please contact us at the number above Visit our web site
21. MPITCH 2 3 RS 232 A See Serial Communications MPOLES 2 3 RS 485 See Serial Communications MRESPOLES 2 3 RSTVAR 4 10 6 6 MSG 2 4 S 2 3 2 6 MSININT 2 4 Safety Instructions iv MSPEED 2 3 safety alert symbols iv MTANGLC 2 3 2 6 SAVE 4 8 4 9 4 10 MTANGLP 2 3 2 6 S curve acceleration 2 3 MultiDrop See Serial Communications SERCOS MVANGLF 2 3 Contact Factory See Customer Support MVANGLH 2 3 Serial Communications 4 2 NOTCHBW 2 2 Addressing Ol 2 5 5 3 MultiDrop DIP settings 3 9 4 3 OIMODE 2 5 5 3 5 6 C1 connections 3 8 OIRST 2 5 5 3 data transmission 2 4 OITRIG 2 5 5 3 MultiDrop communicating 4 10 OPMODE 2 1 2 2 3 9 5 1 5 2 5 5 5 6 5 8 Port Features 2 4 PCMD 2 5 protocol 2 4 See AppNote ASU003H PCMDMODE 2 2 RS 232 A 4 2 PE 2 3 2 5 RS 485 4 2 PEINPOS 2 2 2 3 Serial Number PEMAX 2 3 2 6 ServoStar 2 7 PEXT 2 2 2 5 Serial Torque Mode See OPMODES PEXTOFF 2 2 Serial Velocity Mode See OPMODES PFB 2 3 2 5 SERIALNO 2 6 PFBOFF 2 3 Sine Encoders 2 12 PLIM 2 3 2 6 accuracy 2 14 PMAX 2 3 2 6 C2 connections 3 8 PMIN 2 3 2 6 cable lengths 2 13 Position Loop 2 3 5 4 5 6 resolution 2 14 analog input 2 2 specifications 2 13 Dual loop 2 2 types 2 12 dual loop feedback 5 6 STAT 2 5 2 6 Electronic Gearing 2 2 STATUS 2 5 2 6 4 11 5 1 6 1 features See AppNote ASU007H Status Display 5 1 homing 2 2 5 6 decimal point 5 1 input 2 2 STATUS2 2 5 indexing 2 2 5 6 STEP 2 2 5 2 serial input 2 2 STOP 2 3 2 6 specifications 2 9 STOPMODE
22. Resolver The SERVOSTAR can use single two poles or multi speed multiple poles resolver feedback to monitor the motor shaft position A resolver can be thought of as a transformer whose output is unique for any given shaft position an absolute position feedback The transformer is driven with a sinewave reference signal Two AC signals are returned from the resolver into the Sine and Cosine inputs All three of these sinewave signals are low level and susceptible to noise 2 2 1 1 Specifications Resolver Requirements Modulation Frequency Table 2 1 Resolver Specifications 2 2 1 2 Cable Lengths It is important to use properly shielded cable and to keep it away from other noise radiating devices and cables It is not recommended to run the feedback and motor cables in the same conduit Kollmorgen has tested cable lengths up to 750ft 229m without degradation of commutation performance However performance may vary depending on motor and resolver type Tests were performed with standard Kollmorgen cable and its low impedance Kollmorgen GOLDLINE motor resolver Please consult factory for cable and resolver impedance specifications when long cable runs above 250ft 76m are desired Kollmorgen recommends twisted shielded pair for feedback cables 2 2 1 3 Resolution and Accuracy The SERVOSTAR calculates motor velocity as the derivative of position change in position over time With its patented technique all readings are ext
23. The current sample is used by the current loops to regulate the current in each of the three motor phases Two phases A and C of the current signal are sampled by the microprocessor at a 16kHz rate The momentary A phase current and C phase current can be monitored by examining the IA and IC variables respectively The microprocessor calculates the equivalent absolute current which can be monitored as I This value can be averaged for 2 4 8 16 32 or 64 samples 5 6 FOLDBACK The SERVOSTAR offers two types of FoldBack protection for both the motor and the drive The drive s microprocessor monitors the current feedback signal and develops an RMS value of this signal for the purpose of providing the user a value that represents the current in the motor The system is similar to an I squared T accumulator 5 6 1 Drive FoldBack This FoldBack algorithm monitors current feedback and if the feedback exceeds the continuous current rating of the drive motor combination ICONT will decrease the system s current to the ICONT level For example under a step command input condition the FoldBack algorithm will allow maximum peak current IMAX output from the drive for 0 5 seconds After this period the drive enters FoldBack mode FOLD 1 and begins an exponentially FoldBack to the system s continuous current It will take approximately six seconds for the exponential decay to drop from the system s peak current to its continuous level For dr
24. actually three current loops one for each motor phase Each current loop receives its own command input from the commutation loop The SERVOSTAR uses a fully digital pole placement current loop with high bandwidth and a current loop sampling rate of 16 kHz 62 5 uS All coefficients of the current loop are digitally calculated inside the drive for a given set of motor and drive characteristics The current loop also includes adaptive gain terms to compensate for some non linear effects The current loop incorporates electrical isolation for protection from the high voltage BUS These current loops also convert the output voltage to a Pulse Width Modulated PWM signal providing the highest efficiency possible The PWM center frequency can be 8 or 16 kHz according to the drive size See Section 2 1 3 Cx Electrical Specifications on page 2 8 for specific details 5 4 2 2 Commutation Loop This loop converts a single phase current command signal into a three phase position modulated sine wave input to the current loops The has a patented sinusoidal wave form generator which uses a technique called Torque Angle Advance to get top performance out of its motors The waveform generator Is part of the microprocessor and is updated at a 16 kHz rate This provides hi fidelity sinewave commutation at both low and high velocities The sinewave output must be aligned to the back EMF characteristics of the motor This
25. adjustment and scales it through the either the position loop input scaling GEARI GEARO velocity loop input scaling VSCALE or torque loop input scaling ISCALE before passing the data to the selected control loop The analog input ANIN variable indicates the analog reading after the offset ANOFF and the deadband ANDB adjustments but before the loop scaling The ANIN variable range is 22500 counts or mV The SERVOSTAR also offers an automatic analog input zeroing function Invoking ANZERO command while the drive is enabled or disabled will sample motor velocity over a 32mSec period and update ANOFF accordingly to cancel out analog input offset This command also incorporates an internal offset mechanism that has finer resolution than ANOFF is capable of providing 5 3 2 Remote Enable Input REMOTE The opto isolated Remote Enable input REMOTE provides a hardware drive enable switch This 12 24 VDC input will disable or enable the power stage output to the motor The signal must be customer supplied in order to get the drive to enable in combination with other parameters ACTIVE and operate Tapping the signal off the logic supply C5 is not recommended The toggling of this switch will also initiate an attempt to recover from a fault condition It can also be used to trigger various position homing features HOMETYPE 5 3 3 Configurable Inputs IN1 IN2 IN3 These 12 24 VDC inputs are defined by the INXMODE variab
26. and relationships 5 6 SERVOSTAR CD Product Family Kollmorgen System Operation 5 5 1 Serial Torque The SERVOSTAR can be operated as a serial torque controlled amplifier OPMODE 2 It receives a serial command T via a host to a command generator which in turn creates a current command ICMD The current or torque command is checked against peak IMAX ILIM and continuous FoldBack features ICONT current clamp limits Sinusoidal commutation modulation is added to the command and then fed to the three phase current loop regulator which calculates a current error This error is then fed through a digital pole placement compensation algorithm The output of the compensator is converted to a PWM signal and fed to the power transistor bridge The power bridge uses the high voltage DC BUS Module typical 325 VDC bus to supply the required current to the motor windings The actual motor current is updated and the process begins again The following is a graphical representation of the serial torque loop operation refer to the VarCom Reference Guide located on the CD ROM for detailed explanation on all variables and commands Control Limits IMAX DIPEAK MIPEAK CMD Command ICONT DICONT MICONT Compensator based on Serial Command 3d ILIM ILIM2 gt gt Motor parameters Generator j FOLD FOLDTIME FOLDMODE MFOLD MFOLDDIS MFOLDD MFOLDT MFOLDR
27. attention to general precautions which if not followed could result in personal injury and or equipment damage Note highlights information critical to the users understanding or use of these products iv SERVOSTAR CD Product Family Kollmorgen Agency Directives and Standards The SERVOSTAR CD product series have been successfully tested and evaluated to meet UL cUL 508C for both the U S and Canadian markets This standard describes the fulfillment by design of minimum requirements for electrically operated power conversion equipment such as frequency converters and servo amplifiers which is intended to eliminate the risk of fire electric shock or injury to persons being caused by such equipment CE Mark Conformance Servo drives are components which are intended to be incorporated into electrical plant and machines for industrial use When the servo drives are built into machines or plant the intended operation of the drive is forbidden until it has been established that the machine or plant fulfills the requirements of the EC Directive on Machines 89 392 EEC and the EC Directive on EMC 89 336 EEC EN 60204 and EN 292 must also be observed In connection with the Low Voltage Directive 73 23 EEC the harmonized standards of the EN 50178 series are applied to the amplifiers together with EN 60439 1 EN 60146 and EN 60204 The manufacturer of the machine or plant is responsible for ensuring that they meet the limits whi
28. each other to create a difference which is then used to command the rest of the system This type of input has a high degree of noise immunity and in many cases will allow for ground isolation between systems This analog input also has a low pass filter ANLPFHZ to prevent high frequency noise from entering the system The input voltage from the differential receiver is applied to a precise 14 bit Analog to Digital A D conversion system The A D conversion system is read by the microprocessor every 5005 for the position loop modes every 25005 for the velocity loop mode and every 62 545 for the torque current loop mode of operation Encoder based 5 2 SERVOSTAR CD Product Family Kollmorgen System Operation units come with the additional benefit of a Dual Gain ANDG input When enabled the system uses two 14 bit A D inputs to read the user supplied analog signal One input is a direct reading of the 10V signal while the other incorporates a 2x gain term When the input voltage is less than 4V the 2x channel is used to determine the user s input voltage thus extending the resolution to a 15 bit equivalent Above 4V the system uses the straight 14 bit conversion Special software algorithms are used to minimize cross over distortion and add 25V of hysterisis Analog systems often require scaling and offset bias The SERVOSTAR adds an analog offset ANOFF variable to this reading performs an analog deadband ANDB
29. ferrite or iron powder core toroid See Figure 3 1 will place common mode impedance in the line between the motor and the drive The use of a common mode choke on the motor leads may increase signal integrity of encoder outputs and associated I O signals The following is a list of toroidal and ferrite cores that can be used to make common mode chokes 3 14 SERVOSTAR CD Product Family Kollmorgen Hardware Installation Manufacturer s Part T400 26D OD 4in 102mm ID 2 25in 57 2mm 1 3in 33mm OD 1 025 in 26mm ID 6 in 15 2mm HT 475 in 12 1mm OD 1 52 in 38 6mm ID 835 in 21 2mm 825 in 21mm OD 2 01 in 51 1mm ID 1 24 in 31 5mm HT 1 025 in 26mm OD 1 09 in 27 7mm ID 555in 14 1mm HT 472in 11 99mm OD 2 4in 61mm ID 1 4in 35 55mm HT 5 12 7mm Table 3 1 Toroidal Core Recommendations Manufacturer s Part Kollmorgen Part Schaffner RD7137 36 0m5 96843 005 3 phase common mode choke 36 amps continuous Schaffner RD8137 64 0m5 96843 010 S00HEL3 phase con mon ode choke 64 amps continuous Table 3 2 Pre wound Common Mode Chokes 3 5 3 I O Filtering filtering while not a necessity for CE compliance may be desired depending on system installation application and integration with other equipment It may be necessary to place ferrite cores on I O lines to avoid unwanted signals entering and disturbing the drive system or other associated equipment The following ch
30. for MotionLink software upgrades application notes technical publications and the most resent version of our product manuals 1 4 LIST OF FIGURES Figure3 1 Cx Outline Dimension MSU001D 3 3 Figure 3 2 Cx Drive Clamp MSU033D Terminal Clamp MSU016D 3 5 Figure 3 3 Phoenix Contact Side View MSU017D 3 6 Figure 3 4 Phoenix Contact Top View MSUO018D 3 7 Figure 3 5 Front View MSU031D 3 8 Figure 3 6 Top View MSU032D 3 9 Figure 3 7 System Diagram MSU011D 3 11 Figure 3 8 Feedback Diagram MSU010D 3 12 Figure 3 9 Ferrite Core Wrapping MSU019D 3 14 Figure 3 10 I O Filtering Techniques MSU020D 3 16 Figure 3 11 Filter Bonding System Diagram MSU033D 3 17 Figure 4 1 Memory Flow Diagram MSU029D 4 4 Figure 4 2 Startup Screen MSU012D 4 6 Figure 4 3 Main MotionLink Screen MSU013D 4 8 Figure 5 1 Control Loop Structure MSU028D 5 5 Figure 5 2 Serial Torque Mode w MotionLink MSU024D 5 7 Figure 5 3 Analog Torque Mode w MotionLink MSU025D 5 8 CD Product Family 1 3 General Information Kollmorgen 1 ABBREVIATIONS A D or ADC Analog to Digital Converter AppNote Application Note CCW Counter Clockwise CMR Common Mode Rejection CW Clockwise CR LF ASCII Carriage Return Line Feed D A or DAC Digital to Analog Converter EMF Electro Motive Force EMC Electromagnetic Compatibility EMI Electromagnetic Interference ESD Electrostatic Discharge Hz Hertz I Current In
31. give the customer a fully compatible drive to meet most motion control applications The following illuminates all the user features Bulleted words that begin in capital letters indicate formal feature names Words that are all capitals in parenthesis indicate the software variables and commands associated with the feature This section 1s NOTE designed to draw the user to the VarCom reference manual for details on these features Current Torque Control e See section 5 5 Torque Loop Operation on page 5 6 for a comprehensive discussion on the feature e digital current loop control Torque Mode OPMODE 2 or 3 receiving serial T or analog command e PWM sine wave commutation PWMFRQ providing smooth and precise low speed control and high speed performance e current loop adaptive gain MLGAINC MLGAINP MLGAINZ e system current limiting capability ILIM ILIM2 IMAX MICONT MIPEAK e exponential current vs time limiter FOLD FOLDMODE e back EMF compensator MBEMFCOMP SERVOSTAR CD Product Family 2 1 System Description Kollmorgen Velocity Control See AppNotes ASU006H and ASU008H on the PSP CD ROM for a comprehensive discussion on the features listed below digital velocity loop control Velocity Mode OPMODE 0 or 1 receiving serial J analog ANIN or triggered commands MISPEEDx INx INXMODE where is 1 2 3 velocity stepping and jogging capability STEP J serial control through stored commands
32. includes the trailing CONFIG command This variable file format is an ASCII file consisting of a series of variable assignment statements The resulting transmission of data from the drive can then be saved with an SSV extension Restoring Factory Variable Parameters If the user has not saved any changes stored in RAM to EEPROM then type LOAD at the prompt and the original parameters will be loaded from the EEPROM into RAM SERVOSTAR CD Product Family 4 9 System Startup Kollmorgen If changes have already been previously saved contact the factory to obtain a set of motor variable parameters for the motor specified in the model number At the prompt re enter all the motor variable parameters Type the CONFIG command followed by the RSTVAR command e Restoring Custom Variable Parameters At the prompt type RSTVAR Transmit to the drive the custom variable SSV file The contents of this file should have the CONFIG command as its last statement The drive will execute this command and configure itself to the parameters that were just transmitted Follow this by a SAVE command to store the contents into EEPROM 4 2 2 MultiDrop Communication When the user runs MotionLink the opening communication screen displays a Scan For Drives button Selecting this forces the software to scan for any active drives and the address location on the chain Any addresses detected will then be listed in the Device Select drop down menu at th
33. indexing with I O triggering capability MAPOS MASPEED MIDISTx and MISPEEDx where x is 0 1 2 3 through either the serial port or the hardware configurable inputs INx INXMODE where x is 1 2 3 position homing with I O triggering capability MH HOMESPD HOMESTATE HOMETYPE through either the serial port or the configurable inputs INx where x is 1 2 3 Electronic Gearing Position Mode OPMODE 4 featuring pulse following or master encoder capability with resolution up to 3MHz through C8 connector 2 5K Hz through opto isolators in C3 GEAR GEARMODE GEARI GEARO PEXT VEXT XENCRES XENCDIR Homing capability 1s provided dual loop mode DUALFB capable of positioning from a load feedback C8 input PEXTOFF PEXT VEXT XENDIR device while controlling velocity and torque from the motor feedback C2 input SERVOSTAR CD Product Family Kollmorgen System Description e PID position loop tuning GP GPI with feed forward acceleration gain input to both the velocity and current loops GPAFR GPAFR2 and feed forward velocity gain input to the velocity loop GPVFR e software position limits PLIM PMAX PMIN PEMAX e configurable integrator dynamics through travel range GPISATOUT GPISATIN e cumulative revolution and error position counters HWPOS PRD PE e position indicators INPOS PEINPOS PE PEMAX PFBOFF Profile Ramping Control e Electronic Braking
34. is serially communicated to the drive upon power up The data is received synchronously by a clock signal provided by the drive Absolute position is known immediately therefore an index signal is not needed 2 2 3 1 Specifications Sine Encoder Requirements Required Signals Types A B with or without Index A B Index with discrete Hall Channels A B Index with C D once per revolution A B Endat Signal Level Signal Index Data Clock Halls Maximum Frequency 125 kHz from encoder Maximum Cable Length System Dependent 50ft 15m Recommended Motor Electrical Cycle 10 000 000 Line counts after interpolation SERVOSTAR for encoders Protection Separate Voltage Regulator Broken wire detector for A B Index and Hall channels Illegal Hall Code Detection signals out of range burst pulse overflow Maximum Interpolation input x256 after quad Table 2 1 Sine Requirements 2 2 3 2 Cable Lengths The recommended cable length when using the to source the encoder is no longer than 50ft 15m Long encoder cables tend to have high DC resistance that may create significant loading affects in the supply lines to the encoder Please consider this carefully when designing the system An option that SERVOSTAR CD Product Family 2 13 System Description Kollmorgen would allow the use of longer lengths would be to put a separ
35. is why resolver or encoder alignment to the motor 15 critical 5 4 2 3 Velocity Loop The purpose of the velocity loop 1s to regulate motor speed Like the current and the commutation loops the velocity loop 15 fully digital and uses the resolver or the encoder feedback signals to calculate actual motor velocity see AppNote ASU008H on the PSP CD ROM for a comprehensive feature discussion The command for the velocity loop can come from a direct user input OPMODE S 0 1 or can be the output of the position loop The velocity loop is a digital sampling system operating at 4 kHz SERVOSTAR CD Product Family 5 5 System Operation Kollmorgen The difference between actual and desired velocity is filtered through a compensator algorithm and fed to the commutation loop The SERVOSTAR offers four velocity compensators methods of regulating velocity and are selectable through the COMPMODE variable The four are as follows Proportional Integral PI Pseudo Derivative Feedback with Feed Forward PDFF Standard Pole Placement and Extended Standard Pole Placement see AppNote ASU006H on the PSP CD ROM 5 4 2 4 Position Loop The final control configuration is the position loop The purpose of this loop is to maintain motor shaft position Like the previous loops the position loop is fully digital and uses resolver encoder and sine encoder feedback signals to determine actual motor position The drive can also accept a position signa
36. operate in one of three settings Encoder Follower Pulse Direction Up Down Counter The setting used is determined by the GEARMODE variable 6 Position Controller OPMODE 8 the SERVOSTAR is configured as a serial an analog positioning controller depending on the value of PCMDMODE that can receive simple absolute incremental indexing homing and analog commands 7 SERCOS Controller OPMODE 5 the SERVOSTAR must be ordered from the factory as a SERCOS unit to establish communications in this OPMODE The drive 15 shipped with Connector C4 as the Transmit Receive port no longer the Encoder Equivalent Output SERCOS operation is only compatable with the MC controller Contact the Kollmorgen Customer Support Network for more information 5 3 SYSTEM I O This section discussions the I O features of the C3 connector except for the Thermostat input on C2 For detailed explanation on the electrical specifications of these features see section 2 1 5 Product Family Control Specifications on page 2 9 For further explanation on how to use these features refer to the VarCom Reference Guide located on the PSP CD ROM 5 3 1 Analog Input ANIN The position velocity or torque loop can receive its command from an analog voltage source and 1 selectable through the OPMODE variable The analog input to the SERVOSTAR is differential meaning that the signals received at the two inputs are subtracted from
37. refer to the description of the variable in section 1 to determine why 44 45 46 47 es E 5 a e e E lt 48 49 50 51 2410 e lt e E EX 52 53 54 ___ Command Into Limit 55__ Drive is in Zero Mode 56 57 Argument must be a multiple of 20 to be accepted 58 Encoder Initialization Process A command cannot be executed because it has been requested while the encoder initialization process is active Qc rive is in Hold mode Motion was requested with the drive in Hold mode e lt elo G 817 19 2 p gi zm 9 6 lt N SERVOSTAR CD Product Family 6 3 SERVOSTAR Helps Kollmorgen 60 Tune failed no rotation Tune cmd failed because motor could not rotate 62 66 Tune failed current sat Tune cmd failed because the current loop saturated 70 74 63 67 Tune failed no vel design Tune failed because the vel loop could not be designed 71 75 76 une cmd failed because drive was disabled while tuning 77 une cmd failed because drive entered Hold mode while tuning 78 une cmd failed because VLIM is too low 79 une cmd requires a lower bandwidth in order to execute Drive in Dual Feedback mode _ Command cannot be accepted because dual feedback is active 81 Drive is in Gear mode ommand cannot be accepted because drive is in gear mode 82 Selected INXMODE function is already assig
38. shielded cables be bonded to the back panel Power input wiring does not require shielding screening if the power is fed to the cabinet enclosure via metallized conduit If the metallized conduit is used with proper high frequency grounds bonding technology and recommended wire routing then power input wire shielding will have no affect In the event that metallized conduit is not implemented into the system shielded cable will be required on the power input wires and proper bonding technologies should be implemented The motor and feedback cables should have the shield exposed as close to the drive as possible This exposed shield can be bonded to the back panel using one of the two suggested methods below 3 3 4 1 Non insulated Cable Clamp The following figures shows how cable bonding can be implemented using non insulated metallic cable clamps The first figure demonstrates clamping to the back panel in the vicinity of the drive The second shows a technique for bonding a terminal strip for best results it is recommended not to break the shielding of the cable From the drive Bonded to Back Motor Figure 3 1 Cx Drive Clamp MSU033D Terminal Clamp MSU016D SERVOSTAR CD Product Family 3 5 Hardware Installation Kollmorgen 3 3 4 2 Alternative Bonding Methods
39. to a PWM signal and fed to the power transistor bridge The power bridge uses the high voltage DC BUS Module typical 325 VDC bus to supply the required current to the motor windings The actual motor current is updated and the process begins again r analog input gt ANZERO Control Limits IMAX DIPEAK MIPEAK CMD N ICONT DICONT MICONT gt Compensator based on __ ANLPFHZ ANIN 9 ISCALE gt ILIM ILIM2 gt gt gt Motor parameters FOLD FOLDTIME FOLDMODE L MFOLD MFOLDDIS MFOLDD MFOLDT MFOLDR IA IC C 44 gt ANOUT 7 ISCALE os i ServoStar MotionLink Off Line File Edit Configure Tune Options ju lan j e wur NEN SE03 160 volts Operation m Analog mus Input Command 243 Generator 4 eating t nput Amu Encoder Om fan System Motor oee 10 pr B 202 4 axis 0 Set C Disable Enable Figure 5 1 Analog Torque Mode w MotionLink MSU025D 5 8 SERVOSTAR CD Product Family Kollmorgen System Operation 5 5 3 Current Sampling The current loop receives corrective feedback from the current sampling circuitry The current sensors use closed loop hall sampling techniques in all units
40. triggered through the Configurable I O INx INXMODE where x is 1 2 3 automatic control loop tuning through the AutoTune feature TUNE configurable application and system speed limits VLIM VOSPD VMAX advanced control algorithms COMPMODE 1 Proportional Integral GV 2 Pseudo Derivative w Feed Forward KV KVI KVFR 3 Standard Pole Placement BW MJ LMJR TF 4 Extended Standard Pole Placement BW MJ LMJR TF first and second order low pass filtering capability FILTMODE LPFHZ1 LPFHZ2 COMPFILT notch filtering capability FILTMODE NOTCHHZ NOTCHBW bandwidths up to 400Hz on the fly homing capability HOMETYPE in analog velocity mode OPMODE 1 through either the Configurable Inputs or terminal on the fly switching between velocity and current torque control INx INXMODE where x is 1 2 3 Position Control See AppNotes ASU007H Position Control and ASU002H Pulse Control on the PSP CD ROM for a comprehensive discussion on the features listed below serial positioning loop control Position Mode OPMODE 8 amp PCMDMODE receiving serial or 1 controlled command INx INxMODE where x is 1 2 3 analog positioning loop control Position Mode OPMODE 8 amp PCMDMODE over a 10V range with scaling capability PSCALE GEAR GEARI GEARO and I O triggering incremental and absolute positioning with an in position indicator MI MA INPOS PEINPOS simple absolute and incremental
41. uses are authorized without written permission of Kollmorgen Information in this document is subject to change without notice and does not represent a commitment on the part the Kollmorgen Corporation Therefore information contained in this manual may be updated from time to time due to product improvements etc and may not conform in every respect to former issues Kollmorgen Table of Contents Table of Contents SECTION 1 GENERAL INFORMATION sscccscscssssssssrcccsesssssccccecscssssnsccesccssssssncceceseesssssacscsessssssssscscsesees 1 1 TeIJHOW TOUSE THIS PACKAGE iter peace 1 1 1 1 1 Installation and Setup Manual esi rosi 1 1 Dui 2 GD ROM GOHIORIS 1 1 1 2 WARRANTY INFORMATION eene e ne ebe cO aia y 1 2 eles ane ct tret 1 2 1 4 CUSTOMER SUPPORT m 1 3 esie od ec 1 3 185 ABBREVIATIONS acc rain lesu 1 4 SECTION 2 SYSTEM DESCRTIP LIO 2 1 2 1 1 EEE ac Current Torque Velocity Position Control Profile Ramping Control Motor ek k ke keke F
42. 0 msec at 230 10 3 7 8 7 15 4 14 Line Fuses amps FRN or equivalent 24Vdc Ext Logic Voltage volts 10 20 24Vdc Ext Logic Current amps sink Max Surge Current amps Max Charge Time sec Fault Contact Rating 1 A UCB Fault Contact Closing Period mSec Close 3mS Open 2mS UCB OverTemperature trip C Continuous Power Capability KVA 4 230 1 3 Line Input 45 Ambient 80 C Continuous Current Arms Peak Continuous ratio for 5 00mSec Peak Current Arms for 500mSec Peak Continuous ratio for 2Sec Peak Current Arms for 2Sec PWM Frequency kHz PWM Motor Current Ripple kHz Form Factor rms avg UnderVoltage Trip nominal 90 Vde OverVoltage Trip 430 Vdc OverTemperature Trip 80 C Internal heat dissipation watts Operation temperature C 84 5 to 45 C Storage temperature C 0 to 70 Ambient humidity 10 to 90 Atmosphere w o no corrosive gasses or dust Altitude Derate 5 per 300m above 1000m Vibration 0 5 g Table 2 1 SERVOSTAR Cx Electrical Specifications 2 1 4 Cx Regen Information Product Model Cx03 External Shunt Regulator Application Information External Regen Kits Peak current amps Minimum resistance ohms Watts Capacitance Farads 0 00082 0 00164 BUS Voltage nominal Vdc
43. 2 2 1 3 Resolution and Accuracy on page 2 10 It provides a configurable ENCOUT resolution of up to 16384 lines 65536 quad counts per revolution of the motor shaft The placement of the index pulse INDEXPOS can be varied on resolver systems within 360 electrical degrees of the feedback signal For single speed resolvers this means the user can vary the position of this signal over one mechanical revolution For multi speed resolvers the mechanical position variation is determined by the pole pair count of the resolver e g three speed resolver gives mechanical variation of the pulse within 1 3 of a revolution 2 3 2 Encoder Systems The output signal is the actual encoder feedback signal that is pre configured MENCRES in the drive s motor parameters It can be scaled down by multiples of two ENCOUTO 1 2 4 8 16 and has a maximum frequency limit of 3MHz 2 3 3 Sine encoder Systems This output signal is developed for a resolution that is determined by a divisor SININTOUT 128 64 32 16 8 4 2 1 of the actual sine encoder line resolution MENCRES It is then encoded to a quaduature signal before being exported out of the drive The maximum frequency limit is 1 2MHz A frequency limiter MSINFRQ is provided with burst frequency fault protection 2 14 SERVOSTAR CD Product Family Kollmorgen System Description 2 3 4 EEO Phasing The EEO signals are not phased the same for resolver and encoder systems The followi
44. ING SYSTEM SERVOSTAR s microprocessor is constantly monitoring the status of many different components In general the philosophy of the SERVOSTAR is to latch all fault conditions so the user can readily determine the source of the problem When a fault is detected it is logged in the internal error log indicated in the Status Display enunciated over the serial port and in most conditions causes a drive disable Many faults can be reset by toggling the hardware remote enable REMOTE input The following provides a list of some of the more frequent faults the drive may detect in the unit hardware and operating system e Motor OverTemperature The Motor s External Thermostat input is monitored for an open circuit condition The user can define using THERMODE what happens under this fault condition The worst case event is a power stage disable when an appears in the status display and the fault relay contacts RELAY are open e Hardware Position Limit Inputs The IN1 IN2 IN3 Inputs are constantly monitored If the variables INxMODE set these inputs for CW CCW hardware position limits then they are monitored for an open circuit condition Although not necessarily an error condition motor operation can be affected by these inputs The SERVOSTAR can ignore the hardware position limits if the user sets LIMDIS 1 The worst case event is that further motion in the given direction is not allowed with an L illuminated
45. NOILVWYOANI 9NIQVOT 303 SNOILVOIJIO3dS 7991819378 HVISOAH3S 335 NI 5 H3MOd Ave 931189915 YISN AV I38 LAdLNO Ln va Alddns NOWWOO bium Jndarig Moi AOL LNANI soww usi 391430 gt ovadaa4 YOLOW OL NOILOANNOO TOIdAL 51 368 WVHOVIGO ZI 310N JJS WVISOAM3S OL VIVO YVLSOAYSS WO V1VG Hardware Installation 11101830 8 urojs s XO wom STSGOW 509445 f9 8840 NI 1X31 33 NOWWOO LNdLNO LNIANO 189 SLOWSY o EL 3LON 33S 39 VHH3 INI 318v330913NO9 0 3LON ILON 33S 9 31ON 33S 0900000000000 ON o o o o o o o o o o o NOWWOO oxi Lt 3LON 35 OLXO 9 90x9 54 8 2 ENTERS 1VIH3S 265 54 Es Lo he s NOWWOS 4 gt e sex gt lt gt lt gt L x peus a 0 1 ANIT TVINS 987 54 660 SNOILVOINNWWOO xig El NOWNOO 91607 ieuondo la mi i lt H30OON3 SLOWSY EL 33S 0 3LON TANNOSYAd OL SNLLOOHS3 1800H L ANY NOLLVTIVISNI 333533 NOILRVO ASN OQA 009 OVA 062 SV
46. ONNECT t R eeiite ke kv sveteegee ge Teka spec roe beste repe ene veles Peers tops SAD FONG ONNCCIONS atte a BAD RE 3 5 CE BILTERING TECHNIQUES 3 54 Input Power Filleying 3 3 2 Motor Line al ung Re rrr 3 2 3 ME 3 5 4 Filter and Bonding System 3 5 5 Recommended Manufacturers List eese SECTION 4 SYSTEM STARTUP tee eec do 4 1 ANS YSTEM COMMUNICATION rettet eode e er Or RR 4 1 4 1 1 Computer Requirements 4 1 42 Drive Communications en MER Rb Ri m ERE a beet ROSE GERANA EE 4 2 4 1 2 1 5 2325 2 re eoe err RP 4 2 41 2 2 RS AES ConfiectiOfi 4 2 4 1 2 3 Setting Drive Address 4 3 4 1 3 Sending Retrieving System 4 4 4 1 4 MotionEink Installation dee certet tentent eene etre entree eye oce dere ec eee 4 4 4 14 1 Installing on PC wri Re Hp RE P e BOR p Ei de diae dei o pde eats 4 4 4 1 4 2 Running the Program 4 4 4 251 yn EELEE ea t YE 4 5 qo US baee sse eu e oce ME ME A E durs 4 5 4 2 1 1 SERVOSTAR Startup 4 5 4 2
47. POS 2 14 ININVx 5 3 INPOS 2 2 2 3 2 5 INx 5 6 INxMODE 5 6 ISCALE 2 4 5 3 ISTOP 2 3 2 6 IZERO 2 3 J 2 2 5 2 2 3 2 6 2 9 4 1 2 2 2 2 2 2 LIMDIS 2 3 2 6 5 1 5 3 6 5 LIST 2 4 LMJR 2 2 LOAD 4 9 LPFHZ1 2 2 LPFHZ2 2 2 MA 2 2 2 8 3 19 MAPOS 2 2 5 6 MASPEED 2 2 5 6 2 3 2 1 2 3 2 4 5 2 4 2 14 2 4 MFBDIR 2 3 MFOLD 2 3 2 6 5 9 MFOLDD 2 3 2 6 5 9 MFOLDDIS 2 3 2 6 5 9 MFOLDR 2 3 2 6 5 9 MFOLDT 2 3 2 6 5 9 enclosure 3 4 MH 2 2 wiring 3 4 MHINVA 2 4 GV 2 2 MHINVB 2 4 GVI 2 2 MHINVC 2 4 HALLS 2 5 MI 2 2 HOLD 2 3 3 9 5 3 5 6 6 5 MICONT 2 1 2 3 HOMESPD 2 2 MIPEAK 2 1 2 3 HOMESTATE 2 2 MLGAINC 2 1 HOMETYPE 2 2 5 3 MLGAINP 2 1 Homing See Position Loop MLGAINZ 2 1 Host Terminal See MotionLink MLIST 2 4 HWPOS 2 3 2 5 Model Number I 2 5 5 7 5 8 5 9 SERVOSTAR 2 7 See Configurable I O MotionLink 2 5 5 9 auto setup screen 4 5 7 2 SERVOSTAR CD Product Family Kollmorgen Index installation 4 4 RELAY 2 6 5 4 6 5 main screen 4 8 RELAYMODE 2 6 5 4 running program 4 4 REMOTE 2 6 4 5 4 10 4 11 5 3 6 5 savings variables to EEPROM 4 8 Remote Enable Input See Configurable I O setting variable parameters 4 6 Resolvers 2 3 2 10 terminal mode 4 9 C2 connections 3 8 MOTOR 2 6 cable lenghts 2 10 MOTORTYPE 2 3 specifications 2 10 MPHASE 2 3 zero offsetting 2 3
48. R and therefore the drive s encoder equivalent output is fixed because it is a hardware characteristic of the encoder device The encoder interface includes three groups of wires 1 A B and complements lines These lines make up the encoder quadrature signals The signals are received differentially through line receivers before being passed through wire break detection circuit 2 Index pulse This narrow pulse normally appears once per revolution and indicates a known physical position of the shaft This pulse is received differentially through a line receiver before being passed through wire break detection circuit This signal is hardware capturable 3 Hall signals These signals provide information representing the approximate absolute location of the motor shaft From this information the motor can sinusoidally commutate forward until the index signal is detected at which time true position is known These signals are isolated by an opto coupler and can be differential or open collector type signals SERVOSTAR CD Product Family 2 11 System Description Kollmorgen 2 2 2 1 Specifications Encoder Requirements Required Signals Types A B with or without Index pulse A B Index with or without Hall Channels Halls may be integral or discrete Signal Type A quad B and Marker Differential do not connect single ended Halls Differential or Open Collector System Voltage Vdc MHz Maximum Cable Length System Dep
49. R CD Product Family Hardware Installation Kollmorgen 3 20 SERVOSTAR CD Product Family Kollmorgen System Startup Section 4 System Startup 4 1 SYSTEM COMMUNICATION The user can communicate with the SERVOSTAR through either the serial port or on a SERCOS fiber optic ring for use with MC controllers only The serial port can transmit data at baud rates of 9600 or 19200 DIP switch 6 in either RS232 or RS485 configurations Multiple drives can be addressed simultaneously when daisy chained as described later in this section The SERVOSTAR comes with its own software interface called MotionLink MotionLink is a Windows 95 based program designed to effectively assist the user in setting up and controlling the drive s operation It is highly intuitive in nature and contains an extensive context sensitive on line Help F1 tool The on line Help describes how to use the program in detail and serves as a valuable reference for the drive s variable and command set setup process and troubleshooting techniques This software package can be downloaded from the PSP CD ROM accompanying this manual Also provided on this CD ROM is the VarCom Reference Guide detailing the complete variable and command set This guide is a great added resource to MotionLink when using the package in the Terminal mode of operation Since the software is designed to guide the customer through the operation process of the drive the Mot
50. SERVOSTAR CD Installation Manual SERVOSTAR CD Product Series Installation and Setup Manual M SU 004 H Issue 1 Mat No 89748 Firmware Version 3 4 and earlier Record of Revisions ISSUE NO DATE BRIEF DESCRIPTION OF REVISION FIRMWARE 9 30 99 ServoStar CD document for European market VGA and PC AT is a registered trademark of International Business Machines Corporation Windows is a register trademark of Microsoft Corporation EnDat is a registered trademark of Dr Johannes Heidenhain GmbH 5 is a registered trademark of the Kollmorgen Corporation MOTIONLINK is a registered trademark of the Kollmorgen Corporation Copyright Information Copyright 1999 Kollmorgen All rights reserved Printed in the Federal Republic of Germany NOTICE Not for use or disclosure outside of Kollmorgen except under written agreement rights are reserved No part of this book shall be reproduced stored in retrieval form or transmitted by any means electronic mechanical photocopying recording or otherwise without the written permission from the publisher While every precaution has been taken in the preparation of the book the publisher assumes no responsibility for errors or omissions Neither 15 any liability assumed for damages resulting from the use of the information contained herein This document is proprietary information of Kollmorgen that is furnished for customer use ONLY No other
51. adiation from the drive This radiation may be in the form of high frequency energy resulting from internal processor clocks The second thing this bonding effort does is provide immunity for the drive Since the feedback device is located internal to the motor it is going to pick up some noise currents and transmit them along the feedback cable The bonding will direct the currents from the shield of the feedback cable to back panel ground This will reduce the amount of noise entering the drive 7 power lines that must be routed past other lines such as motor cables or I O lines should cross at a 90 degree angle This will minimize the coupling effect Additionally the power lines should be routed as close to the back panel as possible Any noise currents on the lines may then be capacitively coupled to the ground plane and not to other lines 8 Control I O signals should be kept separate from all power and motor cables 1f possible Keep control wiring as short as possible and use screened wire Bonding is also recommended but not required for CE compliance Separation distance of 20cm 8 in should be sufficient in most cases Where control cables must cross power cables they should cross with an angle of 90 degrees 9 Motor cables and feedback cables exiting the cabinet going to the motor should be separated as much as possible Ideally the use of separate conduits will provide good isolation which can limit coupling of noise from moto
52. ample LIMDIS 1 Table 5 2 Status Display Decimal Point SERVOSTAR CD Product Family 5 1 System Operation Kollmorgen 5 2 OPERATIONAL MODES The SERVOSTAR has the ability to assume different modes of operation It is factory configured in OPMODE 1 Analog Velocity Controller but may be reconfigured by the user Not all commands and variables are active or meaningful in every OPMODE 1 Serial Velocity Controller OPMODE 0 the SERVOSTAR is configured as a velocity loop controller and is controlled by issuing a velocity command J jog command or STEP step command to the drive via the serial port 2 Analog Velocity Controller OPMODE 1 the SERVOSTAR is configured as a velocity loop controller and is controlled through either a 10V analog input signal or jog J commands stored in the Configurable The commanded velocity is proportional to the input voltage 3 Serial Torque Current Controller OPMODE 2 the SERVOSTAR is configured as a torque loop controller and 15 controlled by issuing a current command using the T command to the drive via the serial port 4 Analog Torque Current Controller OPMODE 3 SERVOSTAR is configured as a torque loop controller and is controlled via a 10V analog input signal The commanded current is proportional to the input voltage 5 Gearing Position Controller OPMODE 4 the is configured as a positioning controller that can
53. ardware Installation 3 5 CE FILTERING TECHNIQUES SERVOSTAR CD system meets the CE Mark standards stated in the front of this manual It is imperative for the user to apply proper bonding and grounding techniques described earlier in this section when incorporating EMC noise filtering components for the purpose of meeting this standard Noise currents often occur in two types The first is conducted emissions that are passed through ground loops The quality of the system grounding scheme will inversely determine the noise amplitudes in the lines These conducted emissions are of a common mode nature from line to neutral or ground The second is radiated high frequency emissions that are usually capacitively coupled from line to line therefore they are differential in nature To properly mount the filters the enclosure should have an unpainted metallic surface This will allow for more surface area to be in contact with the filter housing and provide a lower impedance path between this housing and the back plane The back panel should in turn have a high frequency ground strap connection to the enclosure frame and or earth ground 3 5 1 Input Power Filtering The Kollmorgen SERVOSTAR C series drive system requires EMI filtering of the input power leads to meet the conducted emission requirements for the industrial environment This filtering will block conducted type emissions from exiting onto the power lines and or provide a ba
54. art lists some ferrite parts that may be used for I O filtering and noise attenuation These parts are ideal for providing an in line common mode impedance for I O lines Fair Rite Products Corporation also has a varied selection which can suit most any application Manufacturer s Part Kollmorgen Part Ferrishield SS33B2032 A 96770 003 Ferrishield SS33B2036 A 96769 005 Ferrishield FA28B2480 A 96771 003 Clamp on core flat cable clamp Ferrishield SA28B4340 A 96772 009 Clamp on core flat cable clamp 2643167251 Table 3 1 I O Filter Recommendations The following figure illustrates the use of multiple turns through a clamp on core The more turns created the more impedance is added to the line Avoid putting the shield in a clamp on core It is undesirable to place an impedance in line with the shield The use of ribbon cable may be common in many cabinets Some ferrite clamps are designed just for ribbon cable use as shown below SERVOSTAR CD Product Family 3 15 Hardware Installation Kollmorgen wo Flat cable clamp used with ribbon cable Figure 3 1 Filtering Techniques MSU020D 3 16 SERVOSTAR CD Product Family Kollmorgen Hardware Installation 3 5 4 Filter and Bonding System Diagram Cabinet Enclosure Contactor Fuses Xfmr etc lu 230 120 VAC XFMR Back Plane CNC PLC Controller
55. ate supply at the motor to source the encoder Except for noise susceptibility signals returned to the drive are differentially connected which normally do not constitute a problem with longer cable lengths 2 2 3 3 Resolution and Accuracy Internal resolution of the system can be derived through the following calculation Encoder line resolution x 256 x 4 quadrature System accuracy is largely dependent upon the accuracy of the encoder itself To get an approximate total value the customer need only look to the specifications listed for the encoder being used 2 3 ENCODER EQUIVALENT The provides a motor position output to the user in the form of quadrature encoder signals eliminating the need for an additional position feedback device The outputs are differential line drivers There is an associated dc common output C4 pin 3 which can connect to the user s port to keep common mode noise and voltage spikes minimized for device protection Because there are normally differences of potential between the user s controller and the drive connection is recommended if ground loops occur disconnect and retest The source of the Encoder Equivalent Output EEO signals depends on the type of motor feedback device 2 3 1 Resolver Systems The output signal is developed through the R D hardware circuitry for minimal phase lag and has a maximum frequency determined by the motor speed and R D limits see section
56. ates of 9600 or 19200 4 configurable protocol ECHO PROMPT ACKMODE GETMODE MSG 5 interface through Kollmorgen s MotionLink or a dumb terminal 6 See AppNote 5 on Serial Communications Protocol the PSP CD ROM differential analog input command ANIN 1 10v 14 bit resolution 2 510 15 bit resolution below 4V of input for slow speed operation using the Dual Gain feature ANDG SE units only 2 input signal filtering ANLPFHZ 3 flexible analog input scaling VSCALE ISCALE ANOFF ANZERO ANDB SERCOS communications port for use with SERVOSTAR MC controllers only 1 2msec update rate 2 complete set of manufacturer s IDNs 3 MotionLink communication through the serial port Encoder Equivalent Output signal C4 connector eliminates the need for an additional position feedback device The maximum frequency of this output is 3MHz for standard encoders and 1 2MHz for sine encoders 1 resolver based systems developed through R D hardware circuitry for minimal phase lag it provides a before quad resolution of up to 16384 lines 65536 quad counts per revolution of the motor shaft dependant on motor speed This signal resolution is configurable ENCOUT Index pulse can be varied as much as one complete revolution INDEXPOS 2 encoder based systems actual encoder signals are exported through this output MENCRES and can be scaled down by multiples of two ENCOUTO 3 sine encoder systems developed thro
57. calling Kollmorgen for technical support be sure to have the firmware version number readily available The most recent version of firmware is available for purchase and is easily field upgradable through a PC It can be obtained by contacting a Kollmorgen sales representative or by contacting the Kollmorgen Customer Support Network see Customer Support on page 6 7 5 4 2 Servo Loop Description The SERVOSTAR provides high performance motor control by controlling up to four distinct closed loop systems within the DSP the current commutation velocity and position loops Figure 5 1 depicts the control loops graphically 5 4 SERVOSTAR CD Product Family Kollmorgen System Operation zz VELOCITY LOOP tet de r COMMUTATION LOOP ioi pee CURRENT LOOP 330VDC 1 POWER TRAns _ 6 ISTORS DCN zo 4d roo Figure 5 1 Control Loop Structure MSU028D 5 4 2 1 Current Loop Since current and torque are proportional in a Permanent Magnet PM motor the current loop is often referred to as the torque loop see Section 5 5 Torque Loop Operation on page 5 6 The function of the current loop is to regulate motor current as directed by a current command signal The current command signal from the microprocessor can either come from a direct user input OPMODE s 2 3 or from the output of the velocity loop There are
58. ce this equipment Properly qualified personnel are persons who are familiar with the transport assembly installation commissioning and operation of motors and who have the appropriate qualifications for their jobs The qualified personnel must know and observe the following standards and regulations IEC 364 resp CENELEC HD 384 or DIN VDE 0100 IEC report 664 or DIN VDE 0110 National regulations for safety and accident prevention or VBG 4 e Read all available documentation before assembly and commissioning Incorrect handling of products in this manual can result in injury and damage to persons and machinery Strictly adhere to the technical information on the installation requirements e tis vital to ensure that all system components are connected to earth ground Electrical safety is impossible without a low resistance earth connection e SERVOSTAR product contains electrostatically sensitive components that can be damaged by incorrect handling Discharge yourself before touching the product Avoid contact with high insulating materials artificial fabrics plastic film etc Place the product on a conductive surface e During operation keep all covers and cabinet doors shut Otherwise there are deadly hazards that could possibility cause severe damage to health or the product e In operation depending on the degree of enclosure protection the product can have bare components that are live or have hot surfaces Control and po
59. ch are required by the EMC regulations Advice on the correct installation for EMC such as shielding grounding arrangement of filters treatment of connectors and the laying out of cabling can be found in this documentation Conformance with the EC Directive on EMC 89 336 EEC and the Low Voltage Directive 73 23 EEC is mandatory for the supply of servo drives within the European Community The servo drives have been tested by an authorized testing laboratory in a defined configuration with the system components which are described in this documentation Any divergence from the configuration and installation described in this documentation means that you will be responsible for the performance of new measurements to ensure that the regulatory requirements are met Kollmorgen s SERVOSTAR C Series of drives and systems have been successfully tested and evaluated to the limits and requirements of the EC Directive on EMC 89 336 EEC and the EC Directive on Low Voltage 72 23 EEC The product lines have been evaluated to EN50178 and EN60204 as a component of a machine and other relevant standards The EMC of a system can be identified in two parts emissions and immunity Emissions refer to the generation of EMI electromagnetic interference and immunity refers to the susceptibility levels of the equipment Limits were derived from generic standards 55081 2 and EN55082 2 for heavy industrial environment The SERVOSTAR C series of drives hav
60. cs computers mechanics and proper safety practices However you do not have to be an expert in motion control to install and operate the drive system It is recommended that you read the entire manual completely before installation and operation is attempted The layout of material in this manual is designed to guide you through the following process e Product description and features Section 2 e System hardware installation Section 3 e System startup through a host communicator Section 4 e Basic theory including the system s various modes of operation Section 5 e System troubleshooting and customer support Section 6 1 1 2 CD ROM Contents The CD ROM contains the software interface package Product feature content is also provided for the user desiring to obtain a more comprehensive understanding of the SERVOSTAR drive Adobe s Acrobat Reader is necessary to read and print these documents The reader is provided for easy installation If you have a version earlier than 3 01 it is recommended that you reinstall this reader for graphic clarity The material on the CD ROM provides the following information about this product e Application notes providing comprehensive feature and application explanation MotionLink software package e Software Reference VarCom Reference Guide Variable Command Set SERVOSTAR CD Product Family 1 1 General Information Kollmorgen 1 2 WARRANTY INFORMATION All products c
61. de of the cable as possible for effective grounding If bonding is installed the shield on the cable end need not be connected to the star point configuration Only connect the shield on one end of the cable preferably on the drive side See section 3 3 Installation Practices on page 3 4 for detailed information Note 11 Units must be installed in an enclosure that meet the environmental IP rating of the end product ventilation or cooling may be necessary to prevent enclosure ambient from exceeding 45 C Note 12 Do not connect unused pins on C1 connector Some manufacturers cables connecting all pins may give unpredictable operation Note 13 See 3 2 1 SERVOSTAR Cx Hardware Specifications on page 3 2 for wire gauge and ferrule sizes Note 14 See 3 5 CE Filtering Techniques on page 3 13 for further information Note 16 See 3 2 1 SERVOSTAR Cx Hardware Specifications on page 3 2 for spade and ring terminal sizes SERVOSTAR CD Product Family 3 11 Kollmorgen NOWWOO AS 8 15 5 gu vu TIVH 3019537109 N3dO STIVH 9NILO3NNOO YVLSOAYIS LNIWITANO9 o1 gu TIVH SSHJAIHO STIVH 9NILO3NNOO AMLInONIO ost 8 u TIVH YVLSOAYIS 091 vU TIVH OILVIN3HOS 1 TIVH TWOIdAL 02 5 21 33 AVIN HOLIMS 1V LSOWHSH L dasn 38 LSNW 1 1VNH31X3
62. e been tested for radiated emissions conducted emissions EFT ESD surge conducted immunity and radiated immunity These tests have been done in accordance with EN55011 EN61000 4 2 ENV50140 IEC 1000 4 4 EN61000 4 5 and ENV50141 The installation of the equipment is critical in designing for system and machine electromagnetic compatibility EMC The user must apply the installation recommendations in See Section 3 3 Installation Practices on page 3 4 and 3 5 CE Filtering Techniques on page 3 13 this manual when mounting and installing the drive system for CE conformance SERVOSTAR CD Product Family Kollmorgen vi SERVOSTAR CD Product Family Kollmorgen General Information Section 1 General Information 1 1 HOW TO USE THIS PACKAGE This Product Support Package PSP is designed to provide the user with a complete set of support tools for easy installation and setup feature understanding and application implementation of a SERVOSTAR CD drive system It is divided into two parts Installation and Setup manual and a CD ROM that includes the drive s software package software reference guides application notes and sales publications in a pdf format 1 1 1 Installation and Setup Manual This manual is designed to lead you through the proper installation and setup of a SERVOSTAR CD servo system It was developed with the assumption that there is a fundamental understanding of basic electroni
63. e bottom of the Main MotionLink screen The user need only highlight the desired drive to begin communications To communicate with individual drives in a daisy chain from a terminal the user must type at the prompt Xx where 0 9 A V V corresponding to the DIP address setting of that desired drive For example to communicate to drive 8 DIP setting 01000 the user would have to type at the prompt 8 lt cr gt To globally address all drives on the chain the user must type at the prompt ec k When globally addressing the drives no character echo to the terminal occurs 4 2 3 Power Up Sequence Upon powering up the SERVOSTAR performs a series of self tests If the Status Display illuminates a solid number then no errors were found and the EEPROM has loaded its variable parameters or loaded with default values in case of invalid EEPROM data into RAM The Remote Enable switch on the I O connector C3 may now be energized thus enabling the servo loops 4 2 4 Enabling the System The drive enable logic is based on the following variable switches and flags ACTIVE This is the overall readiness flag indicating the enable disable state of the drive If high 1 the drive is enabled and power is being applied to motor The following equation must hold true for ACTIVE to go high ACTIVE READY AND REMOTE AND DIPEN where READY DRIVEOK AND SWEN READY flag that indicates the dri
64. e reset by toggling the Remote Enable but only by power cycling This condition is indicated by a flashing in the status display e Feedback Loss Hardware is used to detect a wire break condition in encoder based systems or the presence of the Sine and Cosine resolver feedback signals in resolver based systems Either of these signals not being present will cause the SERVOSTAR to disable and display an r in the status display e Low voltage power supply faults Out of tolerance values on the 12 VDC analog supplies will cause an A to be displayed and cause the drive disable SERVOSTAR CD Product Family 6 5 SERVOSTAR Helps Kollmorgen e OverSpeed fault Software continuously monitors the actual feedback speed If the motor speed exceeds the VOSPD limit a J will be displayed and the drive will be disabled This normally occurs when there is an improperly tuned system and the load overshoots its commanded speed e Nocompensator In case the SERVOSTAR cannot design a compensator such as after a RSTVAR command CLREEPROM or any change in the motor or drive parameters a flashing minus sign will be displayed and will cause the drive to disable This display normally indicates that the drive does not have a compensation file loaded e Memory reliability During the initialization process upon power the run time variables memory RAM Random Access Memory and the program memory EPROM Elect
65. eedback Devices rero rro HE ER EO ED E es Ue E Ie Evi System Communications MotionLink Software Environment Monitoring and Troubleshooting Tools reee eke keke ke kek ek trennen teen nente KAYA 2 5 Fault and Safety Detection iS zi icr HEEL 231 2 Part Nimber Description x dae ot 2 7 21 3 Cx Electrical Specifications 2 8 214 Cx RegemInformation d ka 2 8 2 1 5 Product Family Control Specifications eee eene eene nennen nnne 2 9 2 2 EEEDBACK 2 2 15 i oot etek acest oti eis 2 2 1 1 Specifications 2 2 1 2 Cable Lengths 2 2 1 3 Resolution and Accuracy 2 2 22 ENCODER o VOA NA DD AEEA eene atti 2 2 2 155 5 Reo e tdem te aided de dee ied t aee 22 22 Cable Lengths 2 2 2 3 Resolution and CR 2 2 3 1 Specifications eie Fe de eek da eie eee oie ask eae 22 32 Cable Eeregths 2 2 3 3 Resolution and 2 3 ENCODER EQUIVALENT OUTPUT ende SER EN EK 2 14 2 3 Resolver Systems aio RENE eee I ile 2 14 2 3 2 Encoder System ia d
66. ended to a resolution of 16 bit For velocity feedback calculations the drive converts the resolver input to 18 bits of resolution giving smooth motor velocity control The digital resolution RDRES of the Resolver to Digital Converter system is determined automatically according to the application velocity limit VLIM The following is a summary of the SERVOSTAR s resolution capabilities assuming single speed resolver 2 10 SERVOSTAR CD Product Family Kollmorgen System Description VLIM RPM RDRES Counts Rev Encoder Output C4 gt 6100 12 4096 4096 quad counts 1500 to 6100 14 16384 16384 quad counts lt 1500 16 65536 65536 quad counts Table 2 1 R D Converter Specifications System accuracy using resolver feedback is affected by several components The following table gives the user information on the inaccuracy that each of these components contribute to the total accuracy of a standard SERVOSTAR system Components ArcMinutes R D Converter 4 Resolver mechanics rotational 8 Resolver mounting on motor shaft 2 Inter LSB digital dither over the least significant bit 5 Total Worse case 19 Table 2 2 Resolver Accuracy Specifications 2 2 2 Encoder The SERVOSTAR can use encoder feedback to monitor the motor shaft position As opposed to a resolver which 15 an absolute position feedback device the encoder is an incremental device that indicates changes in position The encoder resolution of the SERVOSTA
67. endent 50ft 15m Recommended Maximum Line Count 10 000 000 Lines per Motor Electrical Cycle Maximum Supply Current from 250mA SERVOSTAR Protection Separate Voltage Regulator Broken wire detector for A B Index and Hall channels Illegal Hall Code Detection Table 2 1 Encoder Specifications gt Maximum Input Frequency 2 2 2 2 Cable Lengths The recommended cable length when using SERVOSTAR to source the encoder is no longer than 50ft 15m Long encoder cables tend to have high DC resistance that may create significant loading effects in the supply lines to the encoder Please consider this carefully when designing the system An option that would allow the use of longer lengths implements a separate supply located at the motor to source the encoder Quadrature signals returned to the drive are differentially connected which normally do not constitute a problem with longer cable lengths 2 2 2 3 Resolution and Accuracy SERVOSTAR encoder based system typically exhibits minimal inaccuracies outside of the encoder itself To get an approximate total value the customer need only look to the specifications listed for the encoder being used 2 2 3 Sine Encoder The can receive an analog or sine encoder feedback device to monitor the motor shaft position As opposed to a digital encoder which generates incremental square wave signals a sine encoder outputs analog differential sinusoidal si
68. eration ACKMODE 2 4 ACONFIG 2 3 ACONFIGST 2 3 ACTIVE 2 6 4 10 4 11 5 3 ADDR 2 4 Addressing See Serial Communications Agency Standards CE Mark v cUL v UL v Analog Input description 5 2 dual gain 2 4 filtering 2 4 specifications 2 9 Analog Torque Mode See OPMODES Analog Velocity Mode See OPMODES ANDB 24 5 3 5 8 ANIN 24 5 2 5 3 5 8 ANLPFHZ 2 4 5 2 ANOFF 24 5 3 5 8 ANOUT 2 5 5 3 ANZERO 24 5 3 AutoConfig routine 2 3 AutoTune 5 Velocity Loop Bonding 3 5 BW 2 2 CCWLIM 2 3 2 6 CE Mark v 3 13 Filtering v 3 11 3 13 I O 3 15 manufacturers 3 19 motor 3 14 Communications Analog See Analog Input Inputs Outputs See Configurable I O SERCOS See SERCOS Serial See Serial Communications COMPFILT 2 2 COMPMODE 2 2 5 6 CONFIG 4 9 4 10 Configurable I O C3 inputs 5 3 inverting 5 3 C3 outputs 5 3 use in positioning 5 6 Connectors C3 See Configurable I O Copyright Information 2 cUL v Current Loop 2 1 5 5 adaptive gain 2 1 analog input 5 2 analog torque 5 8 Commutation 5 5 features 2 1 feed forward acceleration 2 3 loop operation 5 6 sampling 5 9 serial torque 5 7 specifications 2 9 Customer Support KCSN 1 3 6 7 CWLIM 2 3 2 6 DEC 2 3 Deceleration 2 3 5 3 electronic braking 2 3 linear 2 3 s curve 2 3 DECSTOP 2 3 2 6 3 9 DICONT 2 5 DIP 2 4 2 5 3 9 4 1 4 2 4 3 4 6 4 10 4 11 DIP Switch See Serial Communications DIPEAK 2 5 DIPEN 2 5 2 6 4 10 4 11 2 2 2 3 DIS 2 3 2 6 4 10 DISSPEED 2 3
69. erstanding of the SERVOSTAR drive MotionLink and its variable and command set by using the context sensitive Help F1 provided in MotionLink 4 2 1 1 SERVOSTAR Startup Screen This screen appears the first time and any time after should the user choice not to deselect it MotionLink 15 run on a PC It is designed to guide the user through a step by step approach to configure a drive Click the START button on the first user screen and walk through the complete sequence of buttons provided to set the drive motor and application Opmode Tune Backup Go variable parameters Should the user de activate this screen it can be reactivated by going to the MotionLink screen pulling down the Configuration menu and selecting the NOTE New Drive 123 option SERVOSTAR CD Product Family 4 5 System Startup Kollmorgen ServoStar MotionLink New Amplifier Startup Off Line 123 You have finished setting up this ServoStar axis You can go back to any setup screen 1 5 by clicking the appropriate button or Click Exit or Go to go to the Main MotionLink screen Don t Show Next Time Help Figure 4 1 Startup Screen MSUO12D e Setting Drive Variable Parameters Click the Drive button This screen allows the user to select a BUS value that corresponds to the incoming line voltage This selection actually determines the setting of the variable VBUS Also i
70. f radiated interference e Where control cables must cross power or motor cables they should be done with an angle of 90 degrees if possible This will reduce the field coupling effect 3 3 3 Grounding System grounding is essential for proper performance of the drive system A ground bus bar may be used as a single point ground for the system Safety grounding should be provided to all pieces of the system from a star point In addition to the safety grounding a high frequency ground must be provided that connects the back panel to the enclosure and ultimately to earth ground The objective is to provide an extremely low impedance path between the filters drives power supplies and earth ground This high frequency ground can be accomplished with the use of a flat braid or copper bus bar It is important not to rely on a standard wire for the high frequency ground In general a wire has an inductance of 8nH in regardless of diameter At higher frequencies this unwanted inductance between grounds equates to limited filter performance When connecting high frequency grounds use the shortest braid possible 3 4 SERVOSTAR CD Product Family Kollmorgen Hardware Installation 3 3 4 Bonding The proper bonding of shielded cables is imperative for minimizing noise emissions and increasing immunity levels of the drive system Its effect is to reduce the impedance between the cable shield and the back panel Kollmorgen recommends that all
71. f range failed due to MBEMF 37 06 ofrange CONFIG failed due to MJ CONFIG failed due to ACC 37 08 DEC out of range CONFIG failed due to DEC 37 09 DECSTOP outofrange CONFIG failed due to DECSTOP 37 10 VLM out of range CONFIG failed due to VLIM CONFIG failed due to VOSPD 37 12 outofrange CONFIG failed due to VSCALE 37 13 OITRIGoutofrange CONFIG failed due to OITRIG CONFIG failed due to OTRST 37 15 DISSPEED out of range CONFIG failed due to DISSPEED CONFIG failed due to MENCTYPE 40 EXT velocity param warning D H R parameters for COMP MODE 3 do not have the proper relationship to each other 41 Vel loop design failed The velocity loop can t be con figured with given parameters 42 Invalid EEPROM The EEPROM test failed 43 Recording active The requested command cannot be executed because it conflicts with a recording in progress Rec data not available data are available for the GET command EEPROM is empty Data cannot be loaded because the EEPROM 15 empty Argument must be binary Variable argument must be a power of 2 The requested function cannot be executed during Burnin a factory function urnin is not active urnin factory function cannot be stopped if it is not active onflicts with ENCOUT The requested value for VLIM conflicts with ENCOUT onflicts with VLIM The requested value for ENCOUT conflicts with VLIM The requested variable value is not available
72. factory already configured for a particular motor The user can verify this by applying logic power and monitoring the Status Display A factory configured drive will go through a power up sequence flashing all segments of the display before settling out to a number indicating the mode of operation If the drive is not configured with a particular motor the display will flash a minus sign indicating that the user must enter drive motor and application variable parameters The remainder of this section will describe the process of setting up a non configured drive Caution must be taken when applying power to the drive It is factory configured to enable upon application of power Verify that the hardware Remote Enable REMOTE enable switch is disabled 4 2 1 Using MotionLink MotionLink gives the user three methods to configure the drive The first uses the SERVOSTAR Startup screen and is the easiest and most highly recommended approach Its main purpose is for initial startups The second approach allows the user to more indirectly perform the same configuration as the first using the Main MotionLink screen This method is most convenient when corrections to an existing configuration is needed The third method uses the Terminal Mode screen to directly set or monitor values for the same variables and commands that the other two methods configure through a more friendly user interface The user can gain a more thorough und
73. ge 3 8 for switch description and Section 4 1 2 3 Setting Drive Address on page 4 3 for drive addressing Switch 6 of the DIP determines the serial communication baud rate for either 9600 BPS or 19200 BPS The SERVOSTAR cannot be configured for RS 232 A and RS 485 at the same time warne Damage could occur to the drive 4 1 2 1 RS 232 A Connection The drive can be configured for a RS 232 A single ended connection through the C1 connector by wiring the 9 pin mating connector See Section 3 4 1 Front Connectors on page 3 8 or the System Wiring diagram on page 3 11 for pinout connections To configure for multiple units the drives must be daisy chained across the C7 connectors of each drive in that chain When communicating to single line unit the drive s DIP switch must be set for a binary 0 address When communicating to multiple units the DIP switch can be set for any binary equivalent number from 1 to 31 see table below as desired by the user The user can also communicate with any or all called Global Addressing drives within the daisy chain configuration from any one RS 232 A port on that chain 4 1 2 2 RS 485 Connection The drive can also be configured for RS 485 differential connection through the same C1 connector The user need only wire the 9 pin mating connector for RS 485 See Section 3 4 1 Front Connectors on page 3 8 or the System Wiring diagram on page 3 11 for pinout connections No software or hardware changes are neces
74. gen s engineering and technical resource staff The PSP CD ROM contains technical content stored in an electronic PDF format The user must have Adobe s Acrobat Reader also available on the ROM installed on their computer to view and print these documents This package is available on the CD ROM The most recent versions of all the material contained in this PSP manual and CD ROM can be downloaded from Kollmorgen s Web site see Customer Support on page 6 7 6 2 TROUBLESHOOTING TOOLS The SERVOSTAR s MotionLink package comes with a comprehensive monitoring and troubleshooting help set For troubleshooting the drive it provides a Status screen click on Status button in the upper right hand corner of Main MotionLink screen allowing the user to check the drive enable switches the Status Display LED fault status with complete error history and mode settings for several of the drive s protection features If using the terminal mode the user can simply check the contents stored in the STATUS FLTHIST and ERR variables An additional help provided by MotionLink is the I O screen click on I O button on the side of the Main MotionLink screen which gives the user the ability to check the status of the hardware position limit switches the motor thermostat and the encoder equivalent output It also allows the user to set up the I O on the C3 connector for a variety of troubleshooting and monitoring approaches For monitoring
75. gnals the SERVOSTAR S CD product line only supports Heidenhain sine encoders These sine signals are quadrature decoded and passed to an interpolation circuit that breaks each 360 cycle into 256 parts before passing it to the drive s control board Thus the resolution seen by the drive is 256 times the fundamental sinusoidal track on the motor s encoder The advantage of this approach is the ability to obtain much high encoder resolution while maintaining a relatively low input frequency through the cable and into the SERVOSTAR See ASU009H Sine Encoders on the PSP CD ROM for detailed information The encoder interface includes three groups of wires 1 A B and complements lines These lines make up the encoder quadrature signals The signals are received differentially at Vp p amplitudes before being processed by the interpolation circuitry 2 Index pulse This narrow pulse normally appears once per mechanical revolution and indicates a known physical position of the shaft This pulse is received differentially through an op amp before being squared up and sent to the control board 3 Commutation signals Upon power up these signals are used to communicate coarse position information The first three signal types give approximate position information so the drive can commutate the motor forward until 2 12 SERVOSTAR CD Product Family Kollmorgen System Description the Index pulse is found There are situations where the i
76. in the status display If both CW and CCW position limit inputs have detected an open circuit condition the SERVOSTAR enters into Hold position state HOLD 1 e Drive OverTemperature The internal heatsink temperature is monitored for an unsafe condition This condition causes a t to be displayed and disables the drive The drive will eventually cool enough to allow reset of this condition e RMS OverCurrent FoldBack the FoldBack detection system can clamp the available output current This is not a true fault condition but may cause undesired performance due to the command current being limited below what is required to achieve the desired performance This condition is indicated with a flashing F in the status display and can be detected by monitoring the FOLD switch variable e Bus OverVoltage an over voltage condition shuts down the drive and displays a lower case in the status display This fault will occur mostly during regen operation where the BUS is raised to higher values than that produced by the power supply e Bus UnderVoltage an under voltage condition shuts down the drive and displays u in the status display This fault normally occurs when the incoming line voltage drops out or a fault occurs in the power supply e PowerStage Fault OverCurrent Hardware circuitry monitors load short circuit transistor failure and instantaneous OverCurrent In general a power stage fault cannot b
77. ing instructions listed in this section In addition to these practices some localities and industries may require applicable electrical and safety codes laws and standards 3 3 1 Enclosure The Kollmorgen SERVOSTAR series of electronic system components are designed for panel assemble This panel assemble should then be mounted in a metallic enclosure Enclosures are supplied by the manufacturers of the final product and must meet the environmental IP rating of the end product ensure proper grounding and to optimize EMC the enclosure should have continuous ground continuity maintained between all metal panels This ground continuity is intended to be both a safety ground and a high frequency ground The units should be mounted on a back plane which is installed into the enclosure Ideally the back plane should be an unpainted metallic surface to optimize electrical bonding of the frame and provide the lowest possible impedance path to earth ground These enclosures also provide added safety 3 3 2 Wiring Practices Particular care should be used when layout of an enclosure 15 designed Efforts to separate power wires from small signal wires should be taken The following guidelines highlight some important wiring practices to implement e Control and signal cables must be separated from power and motor cables Distance of 20cm 8in will be sufficient in most cases e Control and signal cables must be shielded to reduce the effects o
78. ionLink discussion in this section will cover only general steps of use A dumb terminal can also be used to communicate to the drive The user will find this method of communication very awkward until a certain level of familiarity with the drive s operation is achieved MotionLink also provides a terminal emulation feature that contains many useful editing tools for this type of communication 4 1 1 Computer Requirements MotionLink requires an IBM PC or compatible computer with the following features XT AT 386 486 PS 2 or compatible computer e 512 RAM e Windows 95 CD ROM player e Standard Video Adapter CGA MDA EGA MCGA and VGA Serial Port for communication link with SERVOSTAR The serial communications port may be COMI 2 or 4 COMI 15 the normal configuration COMI Address 3F8h Interrupt Request 4 2 Address 2F8h Interrupt Request 3 COM3 Address 3E8h Interrupt Request 4 Address 2E8h Interrupt Request 3 SERVOSTAR CD Product Family 4 1 System Startup Kollmorgen 4 1 2 Drive Communication The SERVOSTAR has the flexibility to be addressed and controlled from a single line or daisy chain MultiDrop configuration in RS 232 A and RS485 The first five switches of the 10 position DIP located on the top of the drive sets the binary address number for that particular drive See Section 3 4 2 Top Connectors of the drive on pa
79. ite Rei te ke ed eee nt IRE 2 14 2 3 3 S ne encoder Systems oe o emite meten Re e EE 2 14 2 34 Phasing i iei dc Reip ens 2 15 2 3 4 E Resolver Systems 2 eene Med tte a dde G ates e ans 2 15 2 3 4 2 Encoder and Sine encoder SystemS E eee ekere ek keke ek eke k enne KK KAK KA KAK 2 15 SECTION 3 HARDWARE INSTALLATION yers eno eee bace HK HN HKH HKH HE KH HK KH HK KARE 3 1 UNPACKING AND INSPECTION KERE KE E RAA E 3 1 3 2 MOUNTING 3 2 3 2 1 SERVOSTAR Cx Hardware Specifications etit quite 3 2 DUEB OIM MTM 3 3 SERVOSTAR CD Product Family i Table of Contents Kollmorgen 3 3 INSTALLATION PRACTICES yan e n n kre e ties S BS RUD To 01712 20 e K ME OE Ma a 3 3 2 Wiring 410161 D FIG oo on ee ia a oue cad latins ete 3 34 Bonding Ls 3 3 4 1 Non insulated Cable Clamp 3 3 42 Alternative Bonding 3 4 SYSTEM INTERC
80. ive currents that exceed ICONT but are below IMAX the system period before FoldBack occurs is extended beyond two seconds Two seconds is the shortest time period that will elapse before the drive enters FoldBack and only occurs when maximum peak current IMAX is drawn NOTE This FoldBack feature is designed to protect the drive electronics not the motor The Configurable Output O1 pin 12 can be configured to indicate a drive FoldBack WARNING POR condition 5 6 2 Motor FoldBack This FoldBack algorithm is designed to provide motor protection in cases where the drive s continuous current rating 15 above the motor s continuous rating This combination is often desired in applications where maximum peak motor torques are required However the possibility exist that the drive could source current on a continuous basis indefinitely to the motor and would force it beyond its thermal capability Unlike the drive FoldBack the user has complete configurability over this feature MFOLD MFOLDD MFOLDDIS MFOLDR MFOLDT SERVOSTAR CD Product Family 5 9 System Operation Kollmorgen 5 10 SERVOSTAR CD Product Family Kollmorgen SERVOSTAR Helps Section 6 SERVOSTAR Helps 6 1 TECHNICAL INFORMATION Technical papers and publications about the SERVOSTAR and its associated applications complete the information package necessary for the user to become well versed with the product These notes have been prepared by Kollmor
81. l from an external feedback device e g load encoder It samples at a rate of 2 kHz and can be configured for three different modes of operation OPMODE 4 This mode of operation sets the SERVOSTAR up to run as a pulse or master encoder follower by using the Electronic Gearing feature The pulse input can either be applied through the Configurable Inputs on the C3 connector up to 2 5KHz max opto isolated or through the Remote Encoder Input on the C8 connector up to 3MHz on top of the drive see 4ppNote ASU002H on the PSP CD ROM for a comprehensive discussion on this feature OPMODE 8 This mode of operation configures the SERVOSTAR as a simple positioning controller See AppNote ASU007H on the PSP CD ROM for a comprehensive discussion on this feature Once in this mode position commands can be given through the serial port through the Configurable I O or through the analog input determined by the PCMDMODE variable The position loop has been enhanced to a full PID controller with acceleration and velocity feed forward gains Two integral gain variables have been added to limit the action of the integral term during selected parts of the profile This helps to minimize overshoot and settling problems Using a serial command PCMDMODE O SERVOSTAR can execute simple absolute incremental or indexing and homing motion profiles either by direct commands through the serial port MI MA MH or by pre configuring a profile in me
82. le Placing the appropriate value in INXMODE See VarCom Reference Guide on the PSP CD ROM for detailed explanation will set up the inputs to be used for such features as CC CCW hardware position limits Electronic Gearing serial and analog position triggering for incremental moves and homing fault output relay configuration MotionLink scope triggering and more When set for the CC CCW hardware position limits the inputs prevent any further motor travel in their respective direction but do not disable the drive or prevent motion in the opposite direction Note that if acceleration control is in place PROFMODE 1 the motor will ramp to a stop after the opening of the End Travel Limit These inputs are opto isolated and considered active enable meaning current must flow through these signals to allow the system to operate This provides a dead man safety feature Energizing both the CW and CCW hardware position limits causes the SERVOSTAR to enter the HOLD mode These inputs can also be inverted ININVx where x 1 2 3 The default settings of these inputs are for the hardware position limits The Status Display may flash L upon power up indicating that a travel limit has been tripped If wort these position limits are not in use set LIMDIS 1 5 3 4 Configurable Outputs ANOUT O1 The 10V 12 bit analog output ANOUT is to be used as a monitoring tool only The setting of this variable will allow the user to meter variou
83. le to incoming cabinet power e Filter should be mounted as close as possible to drive If separation exceeds 30 cm 1 ft flat cable braid may be used for the high frequency connection between filter and BUS Module e When mounting the filter to the panel remove any paint or material covering Use an unpainted metallic back panel if possible low impedance between all system components e Filters are provided with an earth connection All ground connections should be tied to ground e Filters can produce high leakage currents Filters must be earthed before connecting the supply e Filters should not be touched for a period of 10 seconds after removal of the supply potential capacitive charges SERVOSTAR CD Product Family 3 13 Hardware Installation Kollmorgen Recommended EMI Line Filter Kollmorgen Part CD03 three phase Schaffner FN258 30 07 A 96776 003 Table 3 1 Recommended Line Filters 3 5 2 Motor Line Filtering Motor filtering may not be necessary for CE compliance of SERVOSTAR systems however this additional filtering may increase the reliability of the system Poor non metallic enclosure surfaces and lengthy unbonded or unshielded motor cables that couple noise line to line differential and line to ground common mode are just some of the factors that may lead to the necessity of motor lead filtering Motor lead noise may be either common mode or differential The common mode conducted currents occur bet
84. lection 1s incorrect or the drive is set up for MultiDrop communications then a DOS screen will pop up indicating an error has occurred Simply close the window and select another baud rate and or communications port To obtain the latest firmware version or receive additional help contact the Kollmorgen Customer Support Network 6 6 SERVOSTAR CD Product Family Kollmorgen SERVOSTAR Helps 6 6 CUSTOMER SUPPORT Kollmorgen is committed to quality customer service Our goal is to provide the customer with information and resources as soon as they are needed In order to serve in the most effective way Kollmorgen offers a one stop service center to answer all our customer s product needs This one number provides order status and delivery information product information and literature and application and field technical assistance Kollmorgen Seidel GmbH amp CO KG WacholderstraBe 40 42 40489 D sseldorf Germany Phone 49 0 203 9979 0 Fax 49 0 203 9979 155 Email sales eu kollmorgen com Http www kollmorgen seidel de If you are unaware of your local sales representative please contact us at the number above Visit our web site for MotionLink software upgrades technical articles and the NOTE most resent version of our product manuals SERVOSTAR CD Product Family 6 7 SERVOSTAR Helps Kollmorgen 6 8 SERVOSTAR CD Product Family Kollmorgen Index Section 7 n d ex ACC 2 3 Acceleration See Decel
85. lectrical null point ZERO IZERO Resolvers e variety of motor resolver pole combinations MPOLES MRESPOLES e resolver zero offsetting MPHASE e system accuracy s better than 20 arc minutes reduced when resolver pole count is increased e inter LSB interpolation between least significant bits ILSBMODE allows 18 bit velocity control and 16 bit positioning capability automatic resolution configuring based on application speed requirements RDRES VMAX SERVOSTAR CD Product Family 2 3 System Description Kollmorgen Encoders maximum frequencies to 3 MHz before quad up to 10 million counts per motor electrical cycle MENCRES configures automatically ENCINIT ENCINITST ENCSTART IENCSTART index pulse offsetting capability MENCOFF variety of encoder types MENCTYPE 1 encoder with or without index 2 encoder hall effects with or without index MHINVA MHINVB MHINVC HALLS Sine Encoders See AppNote ASUO09H Sine Encoder Feedback on the PSP CD ROM for a comprehensive discussion on this feature 256x internal interpolation up to 128x Encoder Equivalent Output SININTOUT most standard encoder features mentioned above System Communications serial communications port address setting through DIP switch on top of drive 1 RS232 single and up to 31 axis MultiDrop addressing ADDR 2 RS485 single and up to 31 axis MultiDrop addressing ADDR 3 Data transmission DUMP GET LIST MLIST GETMODE baud r
86. les request the information from the drive Receive button into the editor and save button the contents in a SSV format to a specified disk location Restoring Factory Variable Parameters To restore the original factory variable parameters pull down the Configure menu select Motor and select the motor family and motor model Click the To Drive button to send the variable parameters to RAM and the RAM E SAVE button to save to EEPROM Restoring Custom Variable Parameters This process assumes that the user saved the custom variable parameters to a SSV file as described above To restore the custom parameters pull down the Edit menu select Backup Variables and click on Open Highlight the custom SSV file to import variable parameters into editor Click Xmit to send variable parameters to drive 4 2 1 3 Terminal Mode Use the MotionLink Terminal Mode or any other dumb host to directly monitor or modify the variable set and command the drive This approach should only be taken when a PC with a Windows 95 operating system is not available and or the user is well versed with the SERVOSTAR variable command set The VarCom Reference Guide contains the complete variable and command set Each variable command must be referenced for its syntax and parameter definition The variables commands are grouped by function for use by terminal users Clear EEPROM If a does not appear and the user wishes
87. mory to be used in conjunction with the Configurable I O MASPEED MISPEEDO 3 MAPOS O1 1 INx INXMODE Using an analog command PCMDMODE 1 SERVOSTAR can scale the analog input GEARI GEARO to establish a wide range of relationships between an analog input adjustment and a corresponding shaft movement Homing types HOMETYPE are available that home to a particular analog input level and position count triggering either through the Configurable Inputs or the Remote Enable In this mode of operation the drive can also accept an external load feedback signal through the C8 connector DUALFB 1 This helps eliminate the positional inaccuracies due to gear backlash and poor coupling by positioning according to the load s position not the motor shaft s position The SERVOSTAR also operates in the position mode when the drive is in the hold position state HOLD 1 5 5 TORQUE LOOP OPERATION Most applications use the SERVOSTAR in the torque mode configuration For this reason the torque loop operation is explained in this hardcopy manual of this SERVOSTAR s PSP The design of the control loops was discussed in the previous section Now the operation as a system is presented The SERVOSTAR has many internal variables that can be used to examine and dictate system operation Many of these variables and their locations in MotionLink are presented graphically in the following discussions to help disclose meanings
88. ncluded is a real time monitoring of the DIP switch on top of the drive so the user can verify the proper setting for the drive address baud rate and various other parameters Click Exit to return to the SERVOSTAR Startup screen e Setting Motor Variable Parameters Click the Motor button This screen allows the user to access the MotionLink motor database Select a motor family and then a model within that family Information will appear in the blank parameter fields on the right Click on the To Drive button beneath the fields to send the variable parameters to the drive Click Exit to return to the SERVOSTAR Startup screen For the user that has a configured drive a From Drive button is provided NOTE to retrieve the motor data already in the drive Retrieving this data will not erase it from the drive If the motor cannot be found in the database click on the User Define tab Contact the Kollmorgen Customer Support Network for detailed instructions NOTE See Customer Support page 6 7 e Customizing to Application Click the Opmode button in the SERVOSTAR Startup screen to select the mode of loop control desired position velocity or torque See Section 5 2 Operational Modes on page 5 2 for detailed explanation Click Exit to return to the SERVOSTAR Startup screen 4 6 SERVOSTAR CD Product Family Kollmorgen System Startup e Click on the Tune button in the SERVOSTAR Startup screen to set the sys
89. ndex signal is not available Course position information is used to commutate the motor indefinitely The fourth gives absolute information bypassing the need for the Index signal They are as follows No Hall signals If no power up commutation signals are is available The SERVOSTAR can excite two phases and lock the shaft in place It then approximates position of the locked shaft and uses only the incremental signals to commutate forward until the index is found Hall signals These signals provide information representing the approximate location of the motor shaft 6 transitions per electrical cycle of the motor From this information the motor can six step commutate forward until the index signal is detected at which time true position is known and sinusoidal commutation begins These signals are isolated by an opto coupler and can be differential or open collector type signals C D lines an alternative to Hall signals are C D lines These lines provide a SIN COS sinusoidal signal where one electrical cycle equals one mechanical revolution identical to single speed resolver feedback Interpolation is performed on these signals thus absolute position is known within 256 parts of a mechanical revolution The motor can commutate forward until the Index signal is detected Endat Sine encoders with Endat capability add another approach to communicating commutation position Here absolute position information is stored in the encoder and
90. ned to another INxMODE 3 Selected GEARMODE requires A B inputs to be routed using INxMODE 5 and 6 4 Warning Limit sw not routed Limit switches must be routed using INXMODE 1 and 2 85 Move is pending The last ordered move command has not been completed yet 90 Incorrect password password entered by the user was incorrect 91 protected The command or variable requested by the user is password protected and intended for factory use only Capture during homing A position capture occurred during homing 93 Homing during capture homing request was made during position capture being complete being active 96 Capture process not enabled Position capture cannot be executed 97 ENCSTARTwhile ACONFIG 999 SERCOS test failure 6 3 3 MESSAGE FAULTS Fault Description Fatal Non Fatal Flashing Status Steady Status Displa Displa Watchdog HPC ERE E No Compensation AutoConfig failure e ll 2 wc rj Hardware CW limit switch open Tb 1 2 Hardware CCW limit switch open Hardware CW and CCW limit switchesopen X 00 Software CW limit switch is tripped L4 amp PLIM 2 5 Positive and negative analog supply fail X RAM failure during init Software CCW limit switch is tripped X L PFB lt PMIN amp PLIM 2 6 4 SERVOSTAR CD Product Family Kollmorgen SERVOSTAR Helps 6 4 FAULT MONITOR
91. ng demonstrates these phasing relationships 2 3 4 1 Resolver Systems A Leads B convention for clockwise rotation Channel A E Channel VER HM Index AB high 2 3 4 2 Encoder and Sine encoder Systems B Leads A convention for clockwise rotation Channel A Channel B Index determined by encoder SERVOSTAR CD Product Family 2 15 System Description Kollmorgen 2 16 SERVOSTAR CD Product Family Kollmorgen Hardware Installation Section 3 Hardware Installation 3 1 UNPACKING AND INSPECTION Electronic components in this amplifier are design hardened to reduce static sensitivity However proper procedures should be used when handling CAUTION Upon receipt of the equipment inspect components to ensure that no damage has occurred in shipment If damage is detected notify the carrier immediately Check all shipping NOTE material for connector kits manuals diskettes and other small pieces of equipment Remove all packing material and equipment from the shipping container Be aware that some connector its and other equipment pieces may be quite small and can be accidentally cow discarded if care is not observed when unpacking the equipment Do not dispose of shipping materials until the packing list has been checked SERVOSTAR CD Product Family 3 1 Hardware Installation Kollmorgen 3 2 MOUNTING For proper ve
92. ntilation the CD units should be mounted vertically and spaced approximately 0 5in 12 7mm apart These products are designed for mounting in an electrical enclosure to protect them from physical and environmental damage 3 2 1 SERVOSTAR Cx Hardware Specifications Amplifier Model Cx03 Unit Weight Ibs Kgs 3 56 1 61 4 9 2 22 Mounting Hardware English Metric 10 32 M4 Applied Torque 201 2 26Nm Connection Hardware Line Screw Size Torque BUS Screw Size Torque Motor Screw Size Torque Ground Screw Size Torque M3 5 121 1 35Nm Wire Size AWG Control Logic AWG mm 28 16 0 5 1 5 Motor Line AWG mm 14 2 5 Main Input AWG mm 14 2 5 12 4 Configurable I O wire gauge 22 18 AWG 0 5 1mm Ferrules recommended 18 AWG Type H1 0 14 Weidmuller 4630 0 or equivalent 20 AWG 75 14 Weidmuller 4629 0 or equivalent Spade Terminals 16 14 AWG 1 5mm Hollingsworth XSS0954S OR SS20947SF or equivalent 12 10 AWG 4 6mm Hollingsworth XSS20836 OR SS20832F or equivalent Ring Terminals 8 AWG 10mm Hollingsworth R3027BF or equivalent 6 AWG 16mm Hollingsworth R4001BF or equivalent 4 AWG 25mm Hollingsworth R5100BF or equivalent 2 AWG 35mm Hollingsworth R7998BFN or equivalent Clearance Distance Side to Side Sin 12 7mm Top Bottom 2 5in 63 5mm
93. overed in this manual are warranted to be free of defects in material and workmanship and to conform to the specifications stated either in this document or a product catalog description All Kollmorgen brushless motors and electronics are warranty for a period of 24 months from the time of installation or 30 months from time of shipment which ever comes first There are no other warranties expressed or implied including the warranty of merchantability and fitness for a particular purpose which extends beyond this warranty Kollmorgen warrants that the products covered in the manual are free from patent infringement when used for normal purposes 1 3 USE AS DIRECTED The following guidelines describe the restrictions for proper use of the SERVOSTAR CD system e These amplifiers are components which are built into electrical equipment or machines and can only be commissioned as integral components of such equipment e servo amplifiers are to be used only on earthed three phase industrial mains supply networks TN system TT system with earthed neutral point e servo amplifiers must not be operated on power supply networks without an earth with an asymmetrical earth e Ifthe servo amplifiers are used in residential areas or in business or commercial premises then additional filter measures must be implemented by the user e servo amplifiers are only intended to drive specific brushless synchronous servomotors from
94. put Output kHz KiloHertz KCSN Kollmorgen Customer Support Network KW KiloWatts LED Light Emitting Diode NEC National Electrical Code PC Personal Computer PSP Product Support Package P N Part Number PWM Pulse Width Modulation R D Resolver to Digital Regen Regeneration RMS Root Mean Square Rx SERCOS Receiver Port SERCOS SErial Real time COmmunication Standard Tx SERCOS Transmit Port UL Underwriters Laboratories VarCom Variable and Command Set Reference Guide 1 4 SERVOSTAR CD Product Family Kollmorgen System Description Section 2 System Description 2 1 SERVOSTAR The SERVOSTAR is a digital servo motor amplifier that meets the needs of many servo applications such as machine tooling packaging electronic assembly and document handling It has been designed to be a multifaceted amplifier capable of driving Kollmorgen s vast product basket of motors and their assorted feedback devices The C series Compact Drive that includes an integrated power supply is available in 3 and 6 amp sizes All are packaged in a small frame size perfect for minimizing cabinet space This product can be commanded through analog serial and SERCOS for use with SERVOSTAR MC controllers only user interfaces and has its own tailored software environment in Kollmorgen s MotionLink for Windows 2 1 1 Product Features The SERVOSTAR includes vast array of features Its various control techniques interfaces and user tools
95. r to feedback cables 3 18 SERVOSTAR CD Product Family Kollmorgen Hardware Installation 3 5 5 Recommended Manufacturers List Schaffner Electronik AG Nordstrasse 11 CH 4708 Luterbach Switzerland Phone 065 802 626 Fax 065 802 641 Corcom World Headquarters 844 E Rockland Road Livertyville 60048 North America Schaffner EMC Inc 9 B Fadem Road Springfield 07081 Phone 201 379 7778 Fax 201 379 1151 East Coast Sales Office 17 Sarah s Way Fairhaven MA 02719 West Coast Sales Office 6700 Fallbrook Ave Suite 160 West Hills CA 91307 Phone 708 680 7400 Phone 508 992 4495 Phone Fax 708 680 8169 Fax 508 992 3798 Fax Filter Concepts Inc 2624 South Rouselle Street Santa Ana CA 92707 USA Phone 714 545 7003 Fax 714 545 4607 FerriShield Interference Control Components Empire State Building 350 Fifth Ave Suite 7505 New York NY 10118 7591 Phone 212 268 4020 Fax 212 268 4023 Fair Rite Products Corp P O Box J One Commercial Row Wallkill NY 12589 Phone 914 895 2055 Fax 914 8985 2629 E Mail ferrites fair rite com Micrometals Iron Powder Cores 5615 E La Palma Anaheim CA 92807 Phone 800 356 5977 Fax 714 970 0400 Worldwide 714 970 9400 Magnetics P O Box 391 Butler PA 16003 0391 Phone 412 282 8282 800 245 3984 Fax 412 282 6955 Phoenix Contact Inc P O Box 4100 Harrisburg 17111 0100 Phone 800 888 7388 Fax 717 948 3475 SERVOSTA
96. rgen Hardware Installation SKX for connecting shield to bus bar Support for bus bar Q O D Copper Bus Bar high frequency ground connection to back panel from bus bar Figure 3 2 Phoenix Contact Top View MSU018D SERVOSTAR CD Product Family 3 7 Hardware Installation Kollmorgen 3 4 SYSTEM INTERCONNECT 3 4 1 Front Connectors _Pin l pin Resolver Encoder Sine Encoder 1 4 B B L6 pp qs Shed 7 EsVRewm LS gps Fa TT 85V 9 Das 00 Clock Eu HB Ta r rna i ESV Supiy ESV Supply 6 Fault Output Relay Contact 85 Supply ESV Supply for return pins 8 9 10 11 HIM ESV Supply ESV Supply 23222 21 Shield Shield Shield E Remote Enable een eee 3 TA Configurable Input See INI variable 10 Configurable input See INZ variable DD DD TE E 11 Configurable Input See INS variable 12 Configurable Output See O1 variable 13 Configurable Output See ANOUT variable Reference to Pin 4 DC Common 600000000006 C geyan o o o o o o o o o o o o o Goood 2 ED Figure 3 1 Front View MSU001D SERCOS Po
97. rically Programmable Read Only Memory are tested Ifa RAM fault is detected an I will be displayed and cause the drive to halt If an EPROM fault is detected a c will be displayed and cause the drive to halt The user configuration non volatile memory EEPROM Electrically Erasable Programmable Read Only Memory is also checked for integrity upon power up Any discrepancy in this data is noted with an e in the status display After power up is successfully completed any subsequent fault in the operation of the EEPROM is noted with an E in the status display e WatchDogs In addition the SERVOSTAR incorporates a watchdog system to maintain software operation integrity Failure of the watchdog mechanism will display three bars on the status display and cause the drive to halt This normally indicates serious problems Please contact the factory for support 6 5 FIRMWARE UPGRADES From time to time Kollmorgen adds features to its products that expand their overall capabilities Features added to the SERVOSTAR can be easily implemented at the customer s site This is accomplished by downloading new firmware via the drive s serial port directly from a host computer The customer ordering a firmware upgrade receives a file labeled UPGRADE EXE Click on this file and a Windows program will prompt the user to choose an unzipping method baud rate and communications port If the baud rate and communications port se
98. rrier for EMI that might be present on the power lines Care must be taken to adequately size the system The type of filter must be based on the voltage and current rating of the system and whether the incoming line is single or three phase One input line filter may be used for multi axis control applications These filters should be mounted as close to the incoming power as possible so noise is not capacitively coupled into other signal leads and cables Similarly care should be taken when routing wires from the load side of the filter to the drive input These lines may be noisy and should be separated from other sensitive cabling to avoid unwanted coupling of noise When these lines must pass other lines whether I O or power they should cross perpendicularly Also route the ac input lines physically close to the back panel This will create a capactive coupled path for noise to route back to the ground plane as opposed to being radiated from the cabinet Several manufacturers of these filters are listed below They should be able to recommend the best filter design for most typical motor control applications Kollmorgen has also provided specific filters recommendations that will adequately attenuate the conducted noise to levels below the CE limits The implementation of the EMI filter should be done in accordance with the following guidelines e Filter should be mounted on the same panel as the drive e Filter should be mounted as close as possib
99. rts Function Replaces C4 6 Shield 8 Index Output Low 9 For use with SERVOSTAR MC controllers only 3 8 SERVOSTAR CD Product Family Kollmorgen Hardware Installation 3 4 2 Top Connectors C7 MultiDrop Communications Type 10 Pin 0 1 x 0 1 Female Ribbon Cable Connector and cable are included in the optional CK100 kit 1 000000000000000000000000 This connector functions only when using the RS232 interface It will NOT function using RS485 M Pin Function 6 Shield Connection Index o s dde section 5 4 2 4 Position page 5 6 for features using this input 1 Notes DIP switch The 10 position DIP switch is provided for drive configuration The first 6 switches control communications parameters and are read only at power up Any changes in these settings will require cycling the power The other two switch functions 7 8 control the motor operation and are monitored in real time This switch provides the following functions e MultiDrop Address Select Switches 1 through 5 set the drive s address A drive having address 0 powers up in the addressed state If these five switches are set to anything but 0 the drive will assume an address code indicated by the switch settings See Address Switch Settings on page 4 3 for additional information e Baud Rate Switch
100. s feedback quantities such as velocity current horse power position feedback and following error and more This pin must be referenced to DC Common pin 4 The digital output 01 OTLMODE can be toggled in an On Off state to indicate various drive motor and variable conditions These include absolute speed and current levels FoldBack conditions motor braking motion complete and zero speed conditions position overshoot flagging programmable limit switch detection and an enable ACTIVE flag Condition reset and triggering levels are established through O1 MODE OIRST SERVOSTAR CD Product Family 5 3 System Operation Kollmorgen 5 3 5 Fault Output Relay RELAY RELAYMODE The SERVOSTAR provides a drive ready drive up output in the form of a relay RELAY output The relay RELAY output is controlled by SERVOSTAR s microprocessor There is a software switch RELA YMODE that configures the relay RELAY output to act as a Drive Ready or Drive Up indicator 1 If RELAYMODE 0 the relay is closed when the drive is error free and ready to run This is a Drive Ready configuration 2 If RELAYMODE 1 the relay will be closed only when the drive is enabled This is a Drive Up configuration 3 If RELAYMODE 2 the relay will open during a fault when the drive is disabled The user can program this fault output to open on any system fault by triggering the Configurable Inpu
101. sabled at the occurrence of a fault Executing a drive disable command DIS or K followed by the EN command or toggling the Remote Enable line REMOTE will reset the ame fault latch and if the fault condition is no longer present will re enable the system 6 3 1 FATAL FAULT ERROR CODES Err Status Fault Message Possible Cause Displa 2 OverVoltage excessive decel rates 3 P OveCurn power stage surge current break in encoder index line 5 Motor over temperature motor overload caused overheating OverSped vetocity gt V088D_________L__L_ U OverSpeed Velocity 1 8xVLIM 9 E __ EEPROM failure FaultyEEPROM 00000000 10 e EEPROM checksum fail _ EEPROM checksum invalid on power up 142 ds Negative over travel exceeded PMIN with PLIM 1_____________ These faults can only be cleared by cycling power 6 3 2 NON FATAL ERROR CODES Possible Cause 0 jNoEmor _____________ho error was reeorded 20 Unknown Command Undefined command 21 Unknown Variable undefined variable name 22 Checksumeror on comm message checksum ACKMODE 2 6 2 SERVOSTAR CD Product Family Kollmorgen SERVOSTAR Helps 24 25 26 27 28 33 34 Bad Bandwidth AutoTuning BW is out of range 35 37 01 23 DriveActive drive needs to be inactive for the requested command or variable CON 37 02 37 03 37 04 37 05 out o
102. sary Setting the drive s DIP address is identical to that described for the RS 232 When addressing multiple units the drives must be daisy chained across C1 The user cannot daisy chain across the C7 connector in RS 485 configuration Termination hardware is provided internal to the drive for those applications where noise becomes a problem and or the host connection is single ended Contact the factory for instructions on how to set the drive s hardware for proper termination 4 2 SERVOSTAR CD Product Family Kollmorgen System Startup 4 1 2 3 Setting Drive Address The following table shows the MultiDrop DIP switch address settings Note OFF 0 Drive Address Switch 5 Switch 4 Switch3 Switch 2 Switch 1 9 1 0 0 0 0 1 Table 4 1 Address Switch Settings When the switch setting is set for binary 0 the drive assumes a single line serial configuration CAUTION SERVOSTAR CD Product Family 4 3 System Startup Kollmorgen 4 1 3 Sending Retrieving System Data The following chart describes the flow of data between the PC and the SERVOSTAR When logic power is applied to the drive it loads the variable parameters stored in EEPROM into the dynamic RAM for fast and easy access The user can read and write these variable parameters to and from the PC by one of several methods described in the INITIAL STARTUP section below USER SETTING VARIABLE FILE SSV MOTDN LNK PC OR TERM NAL DUMP
103. system performance MotionLink comes with a variety of monitoring tools The customer can monitor a variety of variables from the Monitor screen click Monitor button at the top of the Main MotionLink screen and compare up to three variables against themselves all at one time The Tune and Record screen allows the user to evaluate the system s actual performance against a predefined command profile Also from this screen the performance can be varied by adjusting the gains until optimum following is achieved 6 3 ERROR CODES In most cases the SERVOSTAR communicates error codes with a text message via the serial port to the host Some error codes are also transmitted to the Status Display The same message is saved in the EEPROM under an error history log FLTHIST ERR so that nothing is lost when power is removed Not all errors reflect a message back to the host In these cases the no message errors communicate to the Status Display only SERVOSTAR CD Product Family 6 1 SERVOSTAR Helps Kollmorgen The response of the SERVOSTAR to an error depends on the error s severity There are three levels of severity 1 warnings simply called errors are not considered faults and do not disable operation 2 non fatal errors or simply faults that disable the drive and indicate a fault status and 3 fatal errors or fatal faults that disable almost all drive functions including communications The drive will automatically di
104. t ERR FLTHIST FLTCLR Also includes a run time counter TRUN that records the time the error occurred configurable motor thermal protection that accepts various thermostat types THERM THERMODE THERMTYPE THERMTIME configurable drive thermal protection through the FoldBack feature FOLD FOLDMODE It sets the maximum time limit the drive can provide peak current 2 1 Sx 3 1 Cx to the motor configurable motor thermal protection through the motor FoldBack feature MFOLD MFOLDD MFOLDDIS MFOLDR MFOLDT It sets the maximum time limit the drive can provide continuous current to the motor hardware position limit switch detection CCWLIM CWLIM LIMDIS INx INXMODE where x is 1 2 3 configurable software position limits PLIM PMAX PMIN PEMAX configurable fault relay output RELAY RELAYMODE DISTIME INxMODE active disable feature ACKFAULT that allows the user to determine how the system should react at the occurrence of a fault The system can immediately disable where the motor will coast to a stop or it can be programmed to a controlled decelerated stop DECSTOP DISSPEED DISTIME STOPMODE ISTOP active enable indicator through the Status Display decimal ACTIVE DRIVEOK SWEN READY REMOTE DIPEN many enabling and disabling features K S STOP REMOTE EN DIS flash firmware memory for easy field upgrade installation Kollmorgen s patented Torque Angle Control for buried magnet motor designs MTANGLC
105. tem bandwidth the type of loop control and the filtering necessary for the application see section 5 5 Torque Loop Operation on page 5 6 AppNote 50006 and AppNote 50008 for further explanation Caution should be used when executing the AutoTune feature Some applications are not capable of handling the vibration caused as the shaft senses its load If this is in question manually tune the drive Also when the load inertia is very large and the selected bandwidth is high this feature may fail to perform WARNING e Setup Completion Click EXIT to go to the MotionLink screen Saving Variables Parameters to EEPROM Saving Variables Parameters to SSV file For explanation on these functions Restoring Factory Variable Parameters refer to the Main MotionLink Restoring Custom Variable Parameters Er Screen below SERVOSTAR CD Product Family 4 7 System Startup Kollmorgen 4 2 1 2 Main MotionLink Screen This screen appears the when the user exits out of the SERVOSTAR Startup screen All the screens mentioned in the method above can be accessed from this screen and should be used to make corrections in the current system configuration ServoStar MotionLink Off Line OF File Edit View Configure Tune Options Help Velocity 2 277 Gearing t nput d Generator AIUTU Encoder a L Dutput System 120 m Device Select Axis
106. to enter a new set of variable parameters type CLREEPROM at the terminal prompt to clear the EEPROM memory Setting Drive Variable Parameters At the prompt enter a value for VBUS Other drive parameters are determined automatically Setting Motor Variable Parameters Locate the motor parameter group of variables in the VarCom Reference Guide At the prompt enter values for the variable parameters listed in this group by typing the name of the variable space and the numerical value Customizing to Application Locate the following variable groups in the VarCom Reference Guide Analog Input Related Current Parameters Velocity Parameters Position Parameters Loop Compensation and Gains Parameters Motion Control Parameters At the prompt enter values for the variable parameters listed in these groups by typing the name of the variable space and the numerical value The user is strongly encouraged to develop a full understanding of these variables before finalizing the configuration Saving Variable Parameters to EEPROM At the prompt type SAVE This will save the variable parameters stored in the RAM to the EEPROM of the variables listed in the VarCom Reference Guide indicate whether its contents can be saved to EEPROM Saving Variable Parameters to SSV file At the prompt type DUMP The DUMP command causes the drive to output variables and their contents to the serial port in the format of a variable file this
107. ts INxMODE INx 5 3 6 Motor Thermostat Input THERM THERMODE The SERVOSTAR provides a motor thermostat input on the C2 connector that can be configured for different types of thermal protections as well as manipulation of how the drive responses to a motor thermal condition THERM THERMODE THERMTIME Kollmorgen GOLDLINE motors and cables connect the thermostat through the feedback cable The input to the SERVOSTAR should be electrically closed through the thermostat for proper operation The drive will normally flash an in the Status Display when this input 15 electrically opened If a motor thermal device is not used then THERMODE must be set to 3 to disable the feature thus turning the H status display indicator off CAUTION 5 4 CONTROL LOOPS This section describes the servo control loops their characteristics and how to configure them for additional information and a more detailed discussion of the control loops see AppNote ASUO006H 5 4 1 Core Processors 40 MHz embedded Controller and a 40 MHz DSP controller are the heart of the SERVOSTAR They use its internal operating system to monitor inputs adjust outputs communicate serially maintain servo control and monitor faults The flash memory firmware that controls the core processor and gives the SERVOSTAR its operating characteristics is saved in EPROM The version number of the firmware can be read using the VER command When
108. ugh the interpolator circuit SININTOUT and encoded to a quaduature signal A frequency limiter MSINFRQ is provided with fault protection SERVOSTAR CD Product Family Kollmorgen System Description MotionLink Software Environment easy setup commanding and monitoring techniques contains an extensive database for many of Kollmorgen s motor series a Backup Screen that provides automatic loading of system parameters real time metering of many system parameters PC Scope feature for profile recording and real time motion performance measuring optional Terminal Mode feature for keystroke commanding and monitoring Status Screen indicating system operation and fault error checking extensive On line Help file F1 designed to assist the user in MotionLink s intuitive nature a set of Limits folders allowing the user to manipulate the position velocity current and filtering limits from one screen an I O Screen for easy manipulation of the drive s I O thermostat options encoder output and hardware position limits capabilities a Feedback Device Screen that provides real time pictorial positioning information It also includes a Resolver Zeroing routine and an encoder initialization folder a Tuning Screen designed to allow the user to adjust control loop gains quickly while visibly watching the affects on performance a Control Loops Screen that provides direct manipulation of velocity and position loop gain parameters
109. ve is free of faults and ready to hardware enable DRIVEOK switch indicates the status of the drive faults SWEN switch indicates the status of the software enable EN or DIS REMOTE switch indicates the status of the hardware Remote Enable line on the C3 connector DIPEN switch indicates the state of the DIP enable disable switch 8 4 10 SERVOSTAR CD Product Family Kollmorgen System Startup Ready Flag DRIVEOK SWEN READY fault status software enable drive ready 0 fault exists 0 disable e ij 0 fault exists 1 enable r o0 1 no faults 0 disable 1 0205 OE 1 faults 1 enable Active Flag READY REMOTE DIPEN ACTIVE drive ready hardware enable DIP switch enable power to the motor oe LX o A X qe LS NG If the drive will not enable the user can check the state of the switches and flags by clicking the Status button in the upper right hand corner of the Main MotionLink screen If using a terminal the user can query the drive for the value stored in the STATUS variable refer to Varcom Reference Guide on the PSP CD ROM for explanation on STATUS parameters The Status Display will indicate an enabled drive when the decimal point is illuminated solid SERVOSTAR CD Product Family 4 11 System Startup Kollmorgen 4 12 SERVOSTAR CD Product Family Kollmorgen System Operation Section 5 System Operation 5 1 STATUS DISPLAY The SERVOSTAR
110. ween each motor lead and ground line to neutral Differential radiated currents will exist from one motor lead to another line to line The filtering of the lines feeding the motor will provide additional attenuation of noise currents that may enter surrounding cables and equipment I O ports that are in close proximity Differential mode currents commonly occur with lengthy motor cables As the cable length increases so does its capacitance and its ability to couple noise from line to line While every final system is different and every application of the product may cause a slightly different emission profile it may become necessary to use differential mode chokes to provide additional noise attenuation to minimize the radiated emissions The use of a ferrite core placed at the drive end on each motor lead as shown in the diagram below can attenuate differential mode noise and lower frequency 30 60 MHz broadband emissions to within specifications Kollmorgen recommends a Fair Rite P N 263665702 or equivalent ferrite core The user should wrap each motor lead through the core several times as shown in the figure below Never wrap a ground lead through a core CAUTION Differential Mode Filtering Common Mode Filtering To motor To Motor 7 From Drive From Drive Output Figure 3 1 Ferrite Core Wrapping MSU019D Common mode currents commonly occur from noise spikes created by the PWM switching frequency of the drive The use of a
111. wer cables can carry a high voltage even when the motor is not rotating e Never pull out or plug in the product while the system is live There is a danger of electric arcing and danger to persons and contacts e After powering down the product wait at least 10 minutes before touching live sections of the equipment or undoing connections e g contacts screwed connections Capacitors can store dangerous voltages for long periods of time after power has been switched off To be safe measure the contact points with a meter before touching e safety alert symbols are illustrated as follows WARNING CAUTION NOTE When these symbols are seen in this manual be alert to the potential for personal injury Follow the recommended precautions and safe operating practices included with the alert symbols Safety notices in this manual provide important information Read and be familiar with these instructions before attempting installation operation or maintenance The purpose of this section 1 to alert users to possible safety hazards associated with this equipment and the precautions that need to be taken to reduce the risk of personal injury and damage to the equipment Failure to observe these precautions could result in serious bodily injury damage to the equipment or operational difficulty Warning alerts users to potential danger or harm Failure to follow warning notices could result in personal injury or death Caution directs

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