Kollmorgen SERVOSTAR 300 Instruction Manual
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Kollmorgen SERVOSTAR 300 Instruction Manual

Digital servo amplifier
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SERVOSTAR 300
Digital Servo Amplifier S300
Instruction Manual
Edition 02/2017
Translation of the original instructions.
Valid for Hardware Revision 04.20
Keep all manuals as a product component
during the life span of the product.
Pass all manuals to future users / owners
of the product.
File sr300_e.***

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Summary of Contents for Kollmorgen SERVOSTAR 300

  • Page 1 SERVOSTAR 300 Digital Servo Amplifier S300 Instruction Manual Edition 02/2017 Translation of the original instructions. Valid for Hardware Revision 04.20 Keep all manuals as a product component during the life span of the product. Pass all manuals to future users / owners of the product.
  • Page 2 Technical changes which improve the performance of the device may be made without prior notice! All rights reserved. No part of this work may be reproduced in any form (by photocopying, microfilm or any other method) or stored, processed, copied or distributed by electronic means without the written permission of Kollmorgen Europe GmbH.

  • Page 3: Table Of Contents

    Kollmorgen Contents 02/2017 P a g e General About this manual ..............7 Notes for the online edition (PDF format).
  • Page 4 Contents Kollmorgen 02/2017 P a g e Safety function STO .............37 6.9.1...
  • Page 5 Kollmorgen Contents 02/2017 P a g e 8.13 Electronic Gearing, Master-slave operation ......... . .87 8.13.1...
  • Page 6 Contents Kollmorgen 02/2017 P a g e Expansions Cards 10.1 Guide to installation of expansion cards..........115 10.2 Expansion card -I/O-14/08- .

  • Page 7: General

    02/2017 General About this manual This manual describes the S300 series of digital servo amplifiers SERVOSTAR 300 (S300 standard version, 1.5A ...10A rated current). A more detailed description of the expansion cards that are currently available and the digital connection to automation systems can be found, together with our applications notes, in Acrobat-Reader format on the accompanying CD-ROM (system requirements: WINDOWS, Internet Browser, Acrobat Reader) in different languages.

  • Page 8: Symboles Used

    General Kollmorgen 02/2017 Symboles used Symbol Indication Indicates a hazardous situation which, if not avoided, will result in death DANGER or serious injury. Indicates a hazardous situation which, if not avoided, could result in WARNING death or serious injury. Indicates a hazardous situation which, if not avoided, could result in CAUTION minor or moderate injury.

  • Page 9: Abbreviations Used

    Kollmorgen General 02/2017 Abbreviations used Abbrev. Meaning AGND Analog ground BTB/RTO Ready to operate Fieldbus (CANopen) Communité Europeenne Clock signal Serial interface for a PC-AT DGND Digital ground (for 24V and digital I/O) German Institute for Industrial Standards Disk Magnetic storage (diskette, hard disk)

  • Page 10: Safety

    Check the Hardware Revision Number of the product (see product label). This revision number must match the Hardware Revision Number on the cover page of the manual. If the numbers do not match up, visit the Tech-WIKI (http://www.wiki-kollmorgen.eu). The 'Download" section contains the various manual versions based on the hardware version number.
  • Page 11 (according to IEC61800-5-1) against system com- ponents with power voltage, according to the required application test voltage. All Kollmorgen components meet these requirements. Never modify the servo amplifiers! It is not allowed to modify the servo amplifiers without permission by the manufacturer.

  • Page 12: Use As Directed

    Safety Kollmorgen 02/2017 Use as directed Servo amplifiers are safety components that are built into electrical plant or machines, and can only be operated as integral components of such plant or machines. The manufacturer of the machine must generate a risk assessment for the machine, and take appropriate measures to ensure that unforeseen movements cannot cause injury or damage to any person or property.

  • Page 13: Prohibited Use

    Kollmorgen Safety 02/2017 Prohibited use Other use than described in chapter 2.2 is not intended and can lead to damage of per- sons, equipment or things. The use of the servo amplifier in the following environments is prohibited: potentially explosive areas...

  • Page 14: Handling

    Handling Kollmorgen 02/2017 Handling Transport Transport by qualified personnel in the manufacturer’s original recyclable packaging Avoid shocks while transporting Transport temperature: -25 to +70°C, max. rate of change 20K / hour, class 2K3 acc. to EN61800-2, EN 60721-3-1 Transport humidity: max.

  • Page 15: Decommissioning

    Kollmorgen Handling 02/2017 Decommissioning Only professional staff who are qualified in electrical engineering are allowed to decom- mission parts of the drive system. DANGER : Lethal voltages! There is a danger of serious personal injury or death by electrical shock or electrical arcing.

  • Page 16: Repair

    1. Decommission the device (see chapter 3.4). 2. Demount the device (see chapter 3.6). 3. Contact Kollmorgen and clarify the logistics. Send the device to the address given by Kollmorgen. 4. Install a new device as described in this manual.

  • Page 17: Approvals

    Kollmorgen Approvals 02/2017 Approvals Certificates can be found in our Product Wiki on page Approvals. Conformance with UL and cUL This servo amplifier is listed under UL file number E217428. UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S.

  • Page 18: Ec Conformance

    Any divergence from the configuration and installation described in this documentation means that you will be responsible for carrying out new measurements to ensure confor- mance with regulatory requirements. Kollmorgen declares the conformity of the product SERVOSTAR 300 (S300) with the fol- lowing directives: EC Machinery Directive...

  • Page 19: Safety Conformance (Sto) According To Machine Directive

    Eurasian Customs Union (Russia, Belarus, Kazakhstan) similar to the European CE mark. Kollmorgen declares, that the S300 has passed all required conformity procedures in a member state of the Eurasian Customs Union, and that the S300 meets all technical requirements requested in the member states of the Eurasian Customs Union:...
  • Page 20 Approvals Kollmorgen 02/2017 This page has been deliberately left blank. S300 Instructions Manual...

  • Page 21: Package

    The nameplate is attached to the side of the servo amplifier. The information described below is printed in the individual fields. Picture similar to the original nameplate. Servo amplifier type Serial number Comments Enclosure Rating Kollmorgen Europe GmbH Customer Support E217428 Pempelfurtstraße 1 Europe Tel. +49 (0) 2102 / 93940 ®...

  • Page 22: Part Number Scheme

    Package Kollmorgen 02/2017 Part number scheme S 3 0 6 0 1 - S E - zzz Family Customer specific S300 specials Current rating Device Options 1.5A rms Base device (208 to 480V only) controlled FAN 3A rms EtherCAT 6A rms...

  • Page 23: Technical Description

    Kollmorgen Technical description 02/2017 Technical description The S300 family of digital servo amplifiers Standard version Two voltage classes with large nominal voltage range +10% 1 x 110V ... 3 x 230V (SERVOSTAR 303-310, S3xx6) -10% + 10% 3 x 208V ...
  • Page 24 Technical description Kollmorgen 02/2017 Auxiliary supply voltage 24V DC Electrically isolated, internal fusing, from an external 24V DC power supply unit with, for instance, isolating transformer or uninterruptible power supply. Operation and parameter setting With our user-friendly setup software, for setup via the serial interface of a PC.

  • Page 25: Technical Data

    Kollmorgen Technical description 02/2017 Technical data 6.2.1 Technical data for 110/230 V (types S3_ _6_) SERVOSTAR Electrical data Order Code — S30361 S30661 S31061 +10% 1 x 110V … 1 x 230V -10% Rated supply voltage (L1,L2,L3) +10% 3 x 110V …...

  • Page 26: Technical Data For 400/480 V (Types S3

    Technical description Kollmorgen 02/2017 6.2.2 Technical data for 400/480 V (types S3_ _0_) SERVOSTAR Electrical data Order Code — S30101 S30301 S30601 +10% Rated supply voltage (L1,L2,L3) 3 x 208V … 480V , 50/60 -10% (grounded supply, phase to phase)

  • Page 27: Inputs / Outputs, Auxiliary Voltage

    Kollmorgen Technical description 02/2017 6.2.3 Inputs / outputs, Auxiliary voltage Interface electr. data ±10V Analog inputs 1, 2 (resolution 14/12 bit) ±10V Max. common-mode voltage Digital control inputs as per IEC 61131-2 Type 1, max. 30VDC Digital control outputs, active high open Emitter, max.

  • Page 28: Ambient Conditions, Ventilation, Mounting Position

    For multi-axis systems, observe the specific operating conditions for your system. To reach the max. permitted cable length, observe cable requirements ð p. 53. * Kollmorgen North America supplies cables up to 39 meters Kollmorgen Europe supplies cables up to max. length...

  • Page 29: Motor Holding Brake

    Kollmorgen Technical description 02/2017 Motor holding brake A 24V / max.1.5A holding brake in the motor can be controlled directly by the amplifier. CAUTION No functional safety! Danger by falling load (in case of suspended load, vertical axes). An additional mechanical brake is required for funktional safety, which must be safely operated.

  • Page 30: Led Display

    A simple method is described in the "Product Wiki" which is acces- sible at www.wiki-kollmorgen.eu. A description of the interface can be found on page 61. Functional description: 1.- Individual amplifiers, not coupled through the DC bus link circuit (DC+, DC-)
  • Page 31 Kollmorgen Technical description 02/2017 Technical Data: Brake circuit Supply voltage / V Type Rated data Switch-on (upper) threshold of brake circuit Overvoltage F02 Internal brake resistor (RBint) Continuous power for internal resistor (RBint) — Max. brake power (average for 1s)

  • Page 32: Switch-On And Switch-Off Behavior

    Technical description Kollmorgen 02/2017 Switch-on and switch-off behavior This chapter describes the switch-on and switch-off behavior of the S300 and the steps required to achieve operational stopping or emergency stop behavior that complies with standards. The servo amplifier’s 24 V supply must remain constant. The ASCII commands...

  • Page 33: Behavior In Standard Operation

    Kollmorgen Technical description 02/2017 6.7.1 Behavior in standard operation The behavior of the servo amplifier always depends on the current setting of a number of different parameters (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see online help). The diagram below illustrates the correct functional sequence for switching the servo amplifier on and off.

  • Page 34: Behavior In The Event Of An Error (With Standard Setting)

    Technical description Kollmorgen 02/2017 6.7.2 Behavior in the event of an error (with standard setting) The behavior of the servo amplifier always depends on the current setting of a number of different parameters (ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see online help).

  • Page 35: Stop-, Emergency Stop-, Emergency Off Function To Iec 60204

    Kollmorgen Technical description 02/2017 Stop-, Emergency Stop-, Emergency Off Function to IEC 60204 With the functional safe, certified safety function STO (see page 37 onwards) the drive can be secured on standstill (torque-free) using its internal electronics so that even when power is being supplied, the drive shaft is protected against unintentional restart.

  • Page 36: Emergency Stop

    Technical description Kollmorgen 02/2017 6.8.2 Emergency Stop The Emergency Stop function is used for the fastest possible shutdown of the machine in a dangerous situation. The Emergency Stop function is defined by IEC 60204. Princi- ples of emergency stop devices and functional aspects are defined in ISO 13850.

  • Page 37: Safety Function Sto

    Kollmorgen Technical description 02/2017 Safety function STO A frequently required application task is the protection of personnel against the restarting of drives. The S300 servo amplifier offers, even in the basic version, a single channel STO function (Safe Torque Off) that can be used as a functional safe restart lock.

  • Page 38: Safety Notes

    Technical description Kollmorgen 02/2017 6.9.2 Safety notes WARNING High electrical voltage! Risk of electric shock! The function STO does not provide an electrical separation from the power output. If access to the motor power terminals is necessary, disconnect the S300 from mains supply, consider the discharging time of the intermediate circuit.

  • Page 39: Use As Directed

    Kollmorgen Technical description 02/2017 6.9.3 Use as directed The safety function STO is exclusively intended to provide functional safety, by prevent- ing the restart of a system. To achieve this functional safety, the wiring of the safety cir- cuits must meet the safety requirements of IEC 60204, ISO 12100, IEC 62061 SIL CL2 respectively ISO 13849-1 PLd.

  • Page 40: Functional Description

    Technical description Kollmorgen 02/2017 6.9.8 Functional description In case of use of the STO function the input STO-Enable must be connected to the exit of a security control or a safety relay, which meets at least to therequirements of the SIL CL2 according to IEC 62061 and PL d according to ISO 13849-1 (see the connection dia- gram on page 42).
  • Page 41 Kollmorgen Technical description 02/2017 6.9.8.1 Safe operation sequence If a controlled braking before the use of STO is necessary, the drive must be braked and the input STO-ENABLE has to be separated from +24 VDC time-delayed. 1. Brake the drive in a controlled manner (speed setpoint = 0V) 2.

  • Page 42: Control Circuit

    Technical description Kollmorgen 02/2017 6.9.8.2 Control circuit The example shows a circuit diagram with two separated work areas connected to one emergency stop circuit. For each work area individually "safe stop" of the drives is switched by a protective screen.
  • Page 43 Kollmorgen Technical description 02/2017 6.9.8.3 Functional test With initial starting and after each interference into the wiring of the drive or after exchange of one or several components of the drive the STO function must be tested. 1. Method: 1. Stop drive, with setpoint 0V, keep servo amplifier enabled.

  • Page 44: Shock-Hazard Protection

    Technical description Kollmorgen 02/2017 6.10 Shock-hazard protection 6.10.1 Leakage current Leakage current via the PE conductor results from the combination of equipment and cable leakage currents. The leakage current frequency pattern comprises a number of frequencies, whereby the residual-current circuit breakers definitively evaluate the 50Hz current.

  • Page 45: Mechanical Installation

    Kollmorgen Mechanical Installation 02/2017 Mechanical Installation Important notes CAUTION High leakage current! There is a danger of electrical shock by high EMC level which could result in injury, if the servo amplifier (or the motor) is not properly EMC-grounded. Do not use painted (i.e. non-conductive) mounting plates.

  • Page 46: Assembly

    Mechanical Installation Kollmorgen 02/2017 Assembly Material: 3 x M5 hexagon socket screws to ISO 4762 Tool required : 4 mm Allen key Cable duct >1.6" >1.6" >3" >3" 2" 2" 2" Cable duct >0.1" mounting panel conductive (zinc-coated) Cabinet door...

  • Page 47: Dimensions

    Kollmorgen Mechanical Installation 02/2017 Dimensions S300 Instructions Manual...
  • Page 48 Mechanical Installation Kollmorgen 02/2017 This page has been deliberately left blank. S300 Instructions Manual...

  • Page 49: Electrical Installation

    Kollmorgen Electrical installation 02/2017 Electrical installation Important notes WARNING High voltage up to 900V! There is a danger of serious personal injury or death by electrical shock or electrical arcing. Capacitors can still have dangerous voltages present up to five minutes after switching off the supply power. Control and power connections can still be live, even if the motor is not rotating.

  • Page 50: Guide To Electrical Installation

    Electrical installation Kollmorgen 02/2017 Guide to electrical installation Correct wiring is the basis for reliable functioning of the servo system. Route power and control cables separately. We recommend a distance of at least 200mm. This improves the interference immunity. If a motor power cable is used that includes cores for brake control, the brake control cores must be separately shielded.

  • Page 51: Wiring

    Kollmorgen Electrical installation 02/2017 Wiring The installation procedure is described as an example. A different procedure may be appropriate or necessary, depending on the application of the equipments. We provide further know-how through training courses (on request). DANGER High voltage up to 900V! There is a danger of electrical arcing with damage to contacts and serious personal injury.

  • Page 52: Shielding Connection To The Front Panel

    Electrical installation Kollmorgen 02/2017 8.3.1 Shielding connection to the front panel Remove the outside shroud of the cable and the shielding braid on the desired core length. Secure the cores with a cable tie. Remove the outside shroud of the line on a length from for instance 30mm without da- maging the shielding braid.

  • Page 53: Technical Data For Connecting Cables

    Kollmorgen Electrical installation 02/2017 8.3.2 Technical data for connecting cables Further information on the chemical, mechanical and electrical characteristics of the cables can be obtained from our customer service. Observe the rules in the section "Conductor cross-sections" on page 28. To reach the max.

  • Page 54: Components Of A Servo System

    Electrical installation Kollmorgen 02/2017 Components of a servo system Controls / PLC S300 24V PSU Fuses Brake resistor (optional) Drive cut-out Motor choke (optional) Terminals Motor Cables drawn bold are shielded. Electrical ground is drawn with dash-dotted lines. Optional devices are connected with dashed lines to the servo amplifier. The required accessories are described in our accessories manual.

  • Page 55: Block Diagram

    Kollmorgen Electrical installation 02/2017 Block diagram The block diagram below just provides an overview. RS232 ROD/SSI DIGITAL-IN1 DIGITAL-IN2 Inrush circuit DIGITAL-IN3 VBUS DIGITAL-IN4 Intermediate circuit ENABLE DIGITAL-OUT1 DIGITAL-OUT2 Bext Bint Controller Power stage STO-ENABLE DGND U2 V2 Analog-In 1- Analog-In 1+...

  • Page 56: Connector Assignments

    Electrical installation Kollmorgen 02/2017 Connector assignments X2 RESOLVER COMCODER X6 PC/CAN X5 ROD/SSI pulse-direction master-slave BiSS X3 I/O BTB/RTO BTB/RTO Analog-In 1+ Analog-In 1- Analog-In 2+ Analog-In 2- AGND DIGITAL-IN1 DIGITAL-IN2 View: looking at DIGITAL-IN3 the face of the DIGITAL-IN4...

  • Page 57: Connection Diagram (Overview)

    Kollmorgen Electrical installation 02/2017 Connection diagram (Overview) Refer to the Safety Instructions (ðp.10) and Use as Directed (ð p.12) ! Control +/-10V speed setpoint1 thermal control ð p.70ff referred to included CNC-GND digital Encoder ð p.92 Feedback +/-10V speed setpoint2...

  • Page 58: Electrical Supply

    Electrical installation Kollmorgen 02/2017 Electrical supply 8.8.1 Connection to various mains supply networks An isolating transformer is required for 400V to 480V networks that are asymmetrically grounded or not grounded as shown below. 400V / 480V : SERVOSTAR 341-346* 110V : SERVOSTAR 303-310* 400...480V...

  • Page 59: Auxiliary Supply (X4)

    Kollmorgen Electrical installation 02/2017 8.8.2 24V auxiliary supply (X4) — External 24V DC power supply, electrically isolated, e.g. via an isolating transformer — Required current rating ð p.25 — Integrated EMC filter for the 24V auxiliary supply S300 +24V +24V...

  • Page 60: Mains Supply Connection (X0), Single Phase With Neutral

    Electrical installation Kollmorgen 02/2017 8.8.5 Mains supply connection (X0), single phase with neutral S300 with 230V version (SERVOSTAR 303-310) can be operated with a single phase mains supply. In single phase operation the electrical power of the amplifier is limited.

  • Page 61: Dc Bus Link (X8)

    Kollmorgen Electrical installation 02/2017 DC bus link (X8) Terminals X8/1 (-DC) and X8/3 (+RBext). Can be connected in parallel, whereby the brake power is divided between all the amplifiers that are connected to the same DC bus link circuit. S300...

  • Page 62: Capacitor Modules Kcm (X8)

    02/2017 8.9.2 Capacitor Modules KCM (X8) KCM modules (KOLLMORGEN Capacitor Modules) absorb energy gen- erated by the motor when it is operating in generator mode. Normally, this energy is dissipated as waste via brake resistors. KCM modules, however, feed the energy they have stored back into the DC Bus link as and when it is required.
  • Page 63 Kollmorgen Electrical installation 02/2017 Wiring example KCM Modules Maximum cable length between servo amplifier and S300 module: 500 mm. Twist the cables +DC/-DC. Longer cable lengths require shielding. Ensure that the polar- ity is correct; swapping round DC+/DC- will destroy the KCM modules.

  • Page 64: Motor Connection With Brake (X9)

    Electrical installation Kollmorgen 02/2017 8.10 Motor connection with brake (X9) Together with the motor supply cable and motor winding, the power output of the servo amplifier forms an oscillating circuit. Characteristics such as cable capacity, cable length, motor inductance, frequency and voltage rise speed (see Technical Data, p. 25) deter- mine the maximum voltage in the system.

  • Page 65: Feedback Systems

    Kollmorgen Electrical installation 02/2017 8.11 Feedback systems Every closed servo system will normally require at least one feedback device for sending actual values from the motor to the servo drive. Depending on the type of feedback device used, information will be fed back to the servo amplifier using digital or analog means.

  • Page 66: Primary And Secondary Feedback Types

    Electrical installation Kollmorgen 02/2017 8.12 Primary and secondary feedback types This chapter provides an overview of the supported feedback types, their corresponding parameters and a reference to the relevant connection diagram in each case. Single Cable connection (Power and Feedback in one cable)

  • Page 67: Sfd3 (X1), Single Cable Connection

    Kollmorgen hybrid cable (see table on p.66 or Accessories Manual). Maximum cable length 25 m. FBTYPE: 36 Motor Drive COM+ SFD3 COM- max. 250mA Power Brake Brake+ Brake- The pin assignment shown on the encoder side relates to the Kollmorgen motors (connector code D). S300 Instructions Manual...

  • Page 68: Hiperface Dsl (X1), Single Cable Connection

    Maximum cable length 25 m. FBTYPE: 35 Motor Drive Feedback COM+ DSL+ HIPERFACE DSL COM- DSL- max. 250mA Power Brake Brake+ Brake- The pin assignment shown on the encoder side relates to the Kollmorgen motors (connector code D). S300 Instructions Manual...

  • Page 69: Resolver (X2)

    If cable lengths of more than 100m are planned, please consult our customer service. FBTYPE: 0 S300 SubD 9 round 12-pin Resolver Motor thermal control min.5VDC/5mA The pin assignment shown on the encoder side relates to the Kollmorgen motors. S300 Instructions Manual...

  • Page 70: Sine Encoder With Biss Analog (X1)

    12V analog (BiSS B) 7,5...11V SubD 15 round, 17-pin S300 Encoder cosine sine CLOCK CLOCK Sense Sense max. 250mA voltage supply Motor thermal control min. 5VDC/5mA The pin assignment shown on the encoder side relates to the Kollmorgen motors. S300 Instructions Manual...

  • Page 71: Sine Encoder With Biss Digital (X1)

    5V digital (BiSS C, Renishaw) 5V +/-5% SubD 15 round, 17-pin Encoder S300 CLOCK CLOCK Sense Sense max. 250mA voltage supply Motor thermal control min. 5VDC/5mA The pin assignment shown on the encoder side relates to the Kollmorgen motors. S300 Instructions Manual...

  • Page 72: Sine Encoder With Endat 2.1 (X1)

    SubD 15 Encoder round, 17-pin S300 EnDat DATA DATA CLOCK CLOCK sense sense 5V +/-5 voltage supply max. 250mA Motor thermal control min. 5VDC/5mA The pin assignment shown on the encoder side relates to the Kollmorgen motors. S300 Instructions Manual...

  • Page 73: Sine Encoder With Endat 2.2 (X1)

    12V ENDAT 2.2 7,5...11V SubD15 round, 17-pin Encoder S300 EnDat 2.2 DATA DATA CLOCK CLOCK sense sense voltage supply max. 250mA Motor thermal control min. 5VDC/5mA The pin assignment shown on the encoder side relates to the Kollmorgen motors. S300 Instructions Manual...

  • Page 74: Sine Encoder With Hiperface (X1)

    SubD 15 round, 17-pin Encoder S300 + SIN REFSIN + COS REFCOS RS485 7.5V ...11V voltage supply max. 250mA Motor thermal control min. 5VDC/5mA The pin assignment shown on the encoder side relates to the Kollmorgen motors. S300 Instructions Manual...

  • Page 75: Sine Encoder With Ssi (X5, X1)

    Kollmorgen Electrical installation 02/2017 8.12.9 Sine Encoder with SSI (X5, X1) Wiring of sine-cosine encoder with SSI interface as a linear feedback system (primary, ð p.66) to X5. The thermal control in the motor is connected via the encoder cable to X1 and evaluated there.

  • Page 76: Sine Encoder Without Data Channel (X1)

    Electrical installation Kollmorgen 02/2017 8.12.10 Sine Encoder without data channel (X1) Wiring of a sine-cosine encoder without data channel as a feedback (primary and sec- ondary, ð p.66). Every time the 24V auxiliary voltage is switched on, the amplifier needs start-up information for the position controller (parameter value MPHASE).

  • Page 77: Sine Encoder With Hall (X1)

    Kollmorgen Electrical installation 02/2017 8.12.11 Sine Encoder with Hall (X1) Feedback devices (incremental or sine-cosine), which don't deliver an absolute informa- tion for commutation, can be used as complete feedback system combined with an addi- tional Hall encoder (primary, ð p.66).

  • Page 78: Rod (Aquadb) 5V, 1.5 Mhz (X1)

    Electrical installation Kollmorgen 02/2017 8.12.12 ROD (AquadB) 5V, 1.5 MHz (X1) Wiring of a 5V incremental encoder (ROD, AquadB) as a feedback (primary or second- ary, ð p.66). Every time the 24V auxiliary voltage is switched on, the amplifier need start-up information for the position controller (parameter value MPHASE).

  • Page 79: Rod (Aquadb) 5V, 350 Khz (X1)

    FBTYPE EXTPOS GEARMODE Remarks AquadB 5V MPHASE EEPROM AquadB 5V MPHASE Wake&Shake Incremental Encoder S300 sense 5V +/-5 voltage supply max. 250mA Motor thermal control min. 5VDC/5mA The pin assignment shown on the encoder side relates to the Kollmorgen motors. S300 Instructions Manual...

  • Page 80: Rod (Aquadb) 5V With Hall (X1)

    17 pin SubD15 Comcoder S300 100pF 100pF 100pF 100pF Hall-U Hall-V Hall-W sense 5V +/-5 voltage supply max. 250mA Motor thermal control min. 5VDC/5mA The pin assignment shown on the encoder side relates to the Kollmorgen motors. S300 Instructions Manual...

  • Page 81: Rod (Aquadb) 5V (X5)

    Kollmorgen Electrical installation 02/2017 8.12.15 ROD (AquadB) 5V (X5) A 5V incremental encoder (AquadB) can be used as standard motor feedback (primary and secondary, ð p.66). Every time the 24V auxiliary voltage is switched on, the amplifier need start-up information for the position controller (parameter value MPHASE). Depend- ing on the feedback type either Wake&Shake is executed or the value for MPHASE is...

  • Page 82: Rod (Aquadb) 5V With Hall (X5, X1)

    Electrical installation Kollmorgen 02/2017 8.12.16 ROD (AquadB) 5V with Hall (X5, X1) Wiring of a 5V incremental encoder (ROD, AquadB) with Hall sensors as a feedback unit (primary, ð p.66). For the commutation hall sensors are used and for the resolution an incremental encoder.

  • Page 83: Rod (Aquadb) 24V (X3)

    Kollmorgen Electrical installation 02/2017 8.12.17 ROD (AquadB) 24V (X3) Wiring of a 24V incremental encoder (ROD AquadB) as a feedback system (primary or secondary, ð p.66) using the digital inputs DIGITAL-IN 1 and 2 on connector X3. Every time the 24V auxiliary voltage is switched on, the S300 need start-up information for the position controller (parameter MPHASE).

  • Page 84: Rod (Aquadb) 24V With Hall (X3, X1)

    Electrical installation Kollmorgen 02/2017 8.12.18 ROD (AquadB) 24V with Hall (X3, X1) Wiring of a 24V incremental encoder (ROD, AquadB) and Hall sensors as a feedback unit (primary, ð p.66). For the commutation hall sensors are used and for the resolution an incremental encoder.

  • Page 85: Ssi Encoder (X5, X1)

    Kollmorgen Electrical installation 02/2017 8.12.19 SSI Encoder (X5, X1) Wiring of a synchronous serial absolute encoder as a feedback system (primary or sec- ondary, ð p.66). The signal sequence can be read in Gray code or in Binary (standard) code.

  • Page 86: Hall Sensors (X1)

    Electrical installation Kollmorgen 02/2017 8.12.20 Hall sensors (X1) Wiring of Hall sensors as a feedback unit (primary, ð p.66). The thermal control in the motor is connected to X1 and evaluated there. If cable lengths of more than 25m are planned, please consult our customer service.

  • Page 87: Electronic Gearing, Master-Slave Operation

    Kollmorgen Electrical installation 02/2017 8.13 Electronic Gearing, Master-slave operation In the case of the “electronic gearing” functionality (see setup software and description of GEARMODE parameter), the servo amplifier is controlled by a secondary feedback device as a slave. It is possible to set up master/slave systems, use an external encoder as a setpoint encoder or connect the amplifier to a stepper motor control.

  • Page 88: Connection To Stepper Motor Controllers (Step And Direction)

    Electrical installation Kollmorgen 02/2017 8.13.2 Connection to stepper motor controllers (step and direction) You can connect the servo amplifier to a third-party stepper-motor controller. Parameter setting for the slave amplifier is carried out with the aid of the setup software (electronic gearing).

  • Page 89: Master-Slave Connection

    Kollmorgen Electrical installation 02/2017 8.13.2.3 Step/Direction 5V, 1.5 MHz (X5) Wiring of the servo amplifier (SubD connector X5) to a stepper-motor controller with a 5 V signal level. Frequency limit: 1.5 MHz Type GEARMODE Step/Direction 5V S300 Master Pulse+ Pulse 150 * Ù...

  • Page 90: Encoder Emulation

    Electrical installation Kollmorgen 02/2017 8.14 Encoder emulation 8.14.1 Incremental encoder output - A quad B (X5) The incremental-encoder interface is part of the standard package. Select encoder func- tion ROD (A Quad B) Encoder (“Encoder Emulation” screen page). The servo amplifier calculates the motor shaft position from the cyclic- absolute signals of the resolver or encoder, generating incremental-encoder compatible pulses from this information.

  • Page 91: Ssi Encoder Output (X5)

    Kollmorgen Electrical installation 02/2017 8.14.2 SSI encoder output (X5) The SSI interface (synchronous serial absolute-encoder emulation) is part of the standard package. Select encoder function SSI (“Encoder Emulation” screen page, ENCMODE 2). The servo amplifier calculates the motor shaft position from the cyclic-absolute signals of the resolver or encoder.

  • Page 92: Digital And Analog Inputs And Outputs

    Electrical installation Kollmorgen 02/2017 8.15 Digital and analog inputs and outputs 8.15.1 Analog inputs (X3) The servo amplifier is fitted with two programmable differential inputs for analog setpoints. AGND (X3/7) must always be joined to the GND of the controls as a ground reference.

  • Page 93: Digital Inputs (X3/X4)

    Kollmorgen Electrical installation 02/2017 8.15.2 Digital inputs (X3/X4) All digital inputs are electrically isolated via optocouplers. Technical characteristics — Ground reference is Digital-GND (DGND, terminals X4/3 and X4/4) — The inputs at X3 are PLC-compatible (IEC 61131-2 Type 1) High: 11...30 V / 2...11 mA , Low: -3...5 V / <1 mA —...

  • Page 94: Digital Outputs (X3)

    Electrical installation Kollmorgen 02/2017 8.15.3 Digital outputs (X3) Technical characteristics — Ground reference is Digital-GND (DGND, terminals X4/3 and X4/4) — All digital outputs are floating — DIGITAL-OUT1 and 2 : Open Emitter, max. 30 V DC, 10 mA BTB/RTO : Relay output, max.

  • Page 95: Rs232 Interface, Pc Connection (X6)

    Kollmorgen Electrical installation 02/2017 8.16 RS232 interface, PC connection (X6) Operating, position control, and motion-block parameters can be set up by using the setup software on an ordinary commercial PC. Connect the PC interface (X6) of the servo amplifier to a serial interface on the PC via a null-modem cable, while the supply to the equipment is switched off.

  • Page 96: Canopen Interface (X6)

    Electrical installation Kollmorgen 02/2017 8.17 CANopen interface (X6) The interface for connection to the CAN-bus (default : 500 kBaud). The integrated profile is based on the CANopen DS301 communication profile and the DS402 drive profile. The following functions are available in connection with the position controller: Jogging with variable speed, homing run (zeroing to reference), start motion task, start direct task, digital setpoint provision, data transmission functions and many others.

  • Page 97: Setup

    Kollmorgen Setup 02/2017 Setup The procedure for setup is described as an example. Depending on the application, a dif- ferent procedure may be appropriate or necessary. In multi-axis systems, set up each servo amplifier individually. Before setting up, the manufacturer of the machine must generate a risk assessment for the machine, and take appropriate measures to ensure that unforeseen movements can- not cause injury or damage to any person or property.

  • Page 98: Setup Software

    Setup Kollmorgen 02/2017 Setup software This chapter describes the installation of the setup software DRIVEGUI.EXE for the S300 digital servo amplifiers. We offer training and familiarization courses on request. 9.2.1 Use as directed The setup software is intended to be used for altering and saving the operating parameters for the S300 series of servo amplifiers.

  • Page 99: Hardware Requirements

    Kollmorgen Setup 02/2017 9.2.3 Hardware requirements The PC interface (X6, RS232) of the servo amplifier is connected to the serial interface of the PC by a null-modem cable (not a null-modem link cable!) (ð p.95). Connect / disconnect the interface cable only when the electrical supply is switched off for both the PC and the servo amplifier.

  • Page 100: Quickstart

    Setup Kollmorgen 02/2017 Quickstart 9.3.1 Preparation Unpacking, Mounting and Wiring the Servo Amplifier 1. Unpack servo amplifier and accessories 2. Observe safety instructions in the manuals 3. Mount the servo amplifier as described in chapter 7 4. Wire the servo amplifier as described in chapter 8 or apply the minimum wiring for drive testing as described in chapter 9.3.1...
  • Page 101 Kollmorgen Setup 02/2017 Minimum Wiring for Drive Test This wiring does not fulfill any requirements to safety or functionality of your application, it just shows the required wiring for drive testing without load. Motor-Feedback Power ON Enable 24V ON 24V DC...

  • Page 102: Connect

    Setup Kollmorgen 02/2017 9.3.2 Connect Connect the interface cable to a serial interface on your PC and to the serial interface X6 of the servo amplifier. USB to serial converter can be used optionally. Switch on the 24 V power supply for the servo amplifier.

  • Page 103: Important Screen Elements

    Kollmorgen Setup 02/2017 If communication works, you see the start screen. Select "Setup Wizard" in the navigation frame. Make sure, that the amplifier is disabled (Input Enable connector X3 pin 12 must be 0 V or open)! 9.3.3 Important Screen Elements...

  • Page 104: Setup Wizard

    Setup Kollmorgen 02/2017 9.3.4 Setup Wizard The Setup Wizard leads you through the necessary steps for configuring your servo amplifier. Depending on the selected application, only the active screen pages are necessary. For a quick setup / drive test, select the setup type "Quick Motor/Drive...
  • Page 105 Kollmorgen Setup 02/2017 9.3.4.2 Units/Mechanical The user units for all in- put fields in the setup software can be prese- lected here. Position, Velocity, Acceleration Select usable units for your application referring to the moved load. Mechanical Conversion The relationship between motor shaft revolution (pole pait pitch with linear motors) and motion distance of the load is specified here.
  • Page 106 Setup Kollmorgen 02/2017 9.3.4.3 Motor (rotary) / Feedback Simplified setting of the motor related parameters. Feedback: Select the feedback system used in the motor. Resolver is fixed to 2 pole in the Quick Motor/Drive Setup! Change "pole n°" on feedback screen in Complete Setup later, if required.

  • Page 107: Motion Service (Jog Mode)

    Kollmorgen Setup 02/2017 9.3.4.5 Save Parameters and Restart You are going to finish the Setup Wizard and you have changed several basic parame- ters. Depending on the parameters you changed, two possible reactions will occure now: Configuration parameters changed A warning appears, that you have to restart the amplifier, this is called "coldstart".

  • Page 108: More Setup Screens

    Setup Kollmorgen 02/2017 9.3.6 More Setup Screens Observe the safety instructions in the manuals and in the online help before you change parameters in the additional setup screens. For all setup functions detailed information can be found in the online help system and the integrated command reference.

  • Page 109: Multi-Axis System

    Kollmorgen Setup 02/2017 Multi-axis system With a special cable you can connect up to 255 servo amplifiers to your PC: cable type -SR6Y- (for four aplifiers) or -SR6Y6- (for six amplifiers) see Accessories Manual. Addr.: Addr.: Addr.: Addr.: Cable -SR6Y-...

  • Page 110: Keypad Operation

    Setup Kollmorgen 02/2017 9.5.1 Keypad operation The two keys can be used to perform the following functions: Key symbol Functions press once : move up one menu item, increase number by one press twice in rapid succession : increase number by ten...

  • Page 111: Advanced Menu

    Kollmorgen Setup 02/2017 9.5.4 Advanced menu To operate the amplifier via the advanced menu, you must keep the right key pressed while switching on the 24 V supply. serial number : 9-digit number State divided in 3 blocks, decimal dot...

  • Page 112: Error Messages

    Setup Kollmorgen 02/2017 Error messages Any errors that occur are shown in coded form by an error number in the LED display the front panel. Additional information coded with "ixx" are shown for faults with an asterix "*" in the table below (ERRCODE2).

  • Page 113: Warning Messages

    Kollmorgen Setup 02/2017 Warning messages Faults which occur, but which do not cause a switch-off of the amplifier output stage (BTB/RTO contact remains closed), are indicated in the LED display on the front panel by a coded warning number. Some warning messages result in a controlled shut-down of the drive (braking by emer- gency stop ramp).

  • Page 114: Trouble Shooting

    Setup Kollmorgen 02/2017 Trouble Shooting There may be a wide variety of reasons for the fault, depending on the conditions in your installation. In multi-axis systems there may be further hidden causes of a fault. Eliminate errors and faults in compliance with work safety rules. Troubleshooting only by qualified and trained staff.

  • Page 115: Expansions Cards

    Kollmorgen Expansions Cards 02/2017 Expansions Cards You can find information about availability and order numbers on page 135. Expansions cards can only be built into amplifiers without option -FN or -EC! 10.1 Guide to installation of expansion cards Before you start working, safely disconnect the device from any voltage, that means nei- ther the electrical power supply nor the 24 V auxiliary voltage of the servo amplifier nor the supply voltages of any other connected equipment is switched on.

  • Page 116: Expansion Card -I/O-14/08

    Expansions Cards Kollmorgen 02/2017 10.2 Expansion card -I/O-14/08- This section describes the additional features that the expansion card -I/O-14/08- pro- vides for the S300. If you ordered the expansion card together with the servo amplifier, then it will be delivered already inserted into the expansion slot of the servo amplifier and screwed in place.

  • Page 117: Connector Assignments

    Kollmorgen Expansions Cards 02/2017 10.2.4 Connector assignments The functions are adjustable with the setup software. In the table below the default values are described. Connector X11A Default func- Pin Dir Description tion Motion block number, LSB Motion block number, 2...

  • Page 118: Connection Diagram (Default)

    Expansions Cards Kollmorgen 02/2017 10.2.5 Connection diagram (default) Control X11A S300 +24V ref. to I/O-GND -IO14/8- binary coded motion task No. Reference (Home) FError_clear I/O-GND Start_MT next Start_Jog v=x X11B MT_Restart Start_MT I/O InPos Next-InPos / PosReg0 FError PosReg1 PosReg2...

  • Page 119: Expansion Card -Profibus

    Kollmorgen Expansions Cards 02/2017 10.3 Expansion card -PROFIBUS- This section describes the PROFIBUS expansion card for the S300. Information on the range of functions and the software protocol can be found in our man- ual “Communication Profile PROFIBUS DP”. The PROFIBUS expansion card has two 9-pin SubD sockets wired in parallel.

  • Page 120: Expansion Card -Sercos

    Expansions Cards Kollmorgen 02/2017 10.4 Expansion card -SERCOS- ® This section describes the sercos II expansion card for S300. Information on the range of functions and the software protocol can be found in our manual “Communication Pro- ® file sercos ”.

  • Page 121: Connection Diagram

    Kollmorgen Expansions Cards 02/2017 10.4.3 Connection diagram ® Layout of the sercos bus system in ring topology, with optical fiber cables (schematic). Fiber optic cable 10.4.4 Modifying the station address The drive address can be set to a value between 0 and 63. With address 0, the drive is ®...

  • Page 122: Expansion Card -Devicenet

    Expansions Cards Kollmorgen 02/2017 10.5 Expansion card -DEVICENET- This section describes the DeviceNet expansion card for S300. Information on the range of functions and the software protocol can be found in our man- ual “DeviceNet Communication Profile”. 10.5.1 Connection technology Cable selection, cable routing, shielding, bus connector, bus termination and transmis- sion times are all described in the “DeviceNet Specification, Volume I, II, Edition 2.0”,...

  • Page 123: Combined Module/Network Status-Led

    Kollmorgen Expansions Cards 02/2017 10.5.3 Combined module/network status-LED Meaning The device is not online. The device has not yet finished the Dup_MAC_ID test. The device is possibly not yet switched on. The device is operating as normal, is online, and the connections have been green established.

  • Page 124: Bus Cable

    Expansions Cards Kollmorgen 02/2017 10.5.6 Bus cable To meet ISO 11898, a bus cable with a characteristic impedance of 120 W should be used. The maximum usable cable length for reliable communication decreases with increasing transmission speed. As a guide, you can use the following values which we have measured, but they are not to be taken as assured limits.

  • Page 125: Expansion Card -Synqnet

    Kollmorgen Expansions Cards 02/2017 10.6 Expansion card -SYNQNET- This section describes the SynqNet expansion card for S300. Information on the range of functions and the software protocol can be found in the SynqNet documentation. 10.6.1 NODE ID Switch LED2 LED1...

  • Page 126: Digital Inputs/Outputs, Connector X21A (Subd 15-Pin, Socket)

    Expansions Cards Kollmorgen 02/2017 10.6.4 Digital inputs/outputs, connector X21A (SubD 15-pin, socket) Inputs (In): 24V (20...28V), opto-isolated, one high-speed input (Pin 4) Outputs (Out): 24V, opto-isolated, Darlington driver Pinout connector X21A (SubD 15 pin) Pin Type Description Pin Type Description...

  • Page 127: Expansion Card - Fb-2To1

    Kollmorgen Expansions Cards 02/2017 10.7 Expansion card - FB-2to1 - This chapter describes the Feedback extension card FB-2to1 for the S300. The card enables simultaneous connection of a digital primary and of an analog secondary feed- back to the connector X1. The supply of 24V DC auxiliary voltage to X33 is converted on the extension card into a precise 5V DC encoder supply for the secondary feedback.

  • Page 128: Wiring Example With Biss Digital (Primary) And Sincos (Secondary)

    Expansions Cards Kollmorgen 02/2017 10.7.2 Wiring example with BiSS digital (primary) and SinCos (secondary) S300 Encoder X1 X1A FB-2to1 cosine sine 300mA voltage supply Sense Sense +24V Encoder BiSS digital CLOCK CLOCK Sense voltage supply Motor thermal control min. 5VDC/5mA...

  • Page 129: Expansion Module -2Can

    Kollmorgen Expansions Cards 02/2017 10.8 Expansion module -2CAN- Connector X6 of the S300 is assigned to the signals for the RS232 interface and the CAN interface. It is therefore not the standard pin assignment for these interfaces, and a spe- cial cable is required to be able to use both interfaces simultaneously.

  • Page 130: Connector Assignments

    Expansions Cards Kollmorgen 02/2017 10.8.3 Connector assignments RS232 CAN1=CAN2 X6A Pin Signal X6B=X6C Pin Signal CAN-Low CAN-GND CAN-High 10.8.4 Connection diagram Master 2-CAN RS232 CAN1 CAN2 2-CAN RS232 CAN1 CAN2 S300 Instructions Manual...

  • Page 131: Option "Ethercat

    Kollmorgen Expansions Cards 02/2017 10.9 Option "EtherCAT" Offers EtherCAT interface to the S300. This option uses the expansion slot. Information on the range of functions and the software protocol can be found in the EtherCAT documentation. This option enables the S300 to be connected to the EtherCAT network via RJ-45 connectors (IN and OUT ports).

  • Page 132: Option "Fan", Ventilator Control

    Expansions Cards Kollmorgen 02/2017 10.10 Option "FAN", ventilator control To reduce the average noise emission of servo amplifiers with fan, these amplifiers can be ordered with built-in fan option card (ventilator control). This option uses (invisible from the outside) the expansion slot.

  • Page 133: Glossary

    Kollmorgen Appendix 02/2017 Appendix 11.1 Glossary Brake circuit Converts superfluous energy fed back by the motor during braking (regenerated energy) into heat. Clock Clock signal Common-mode voltage The maximum amplitude of a disturbance (on both inputs) which a differential input can eliminate...
  • Page 134 Appendix Kollmorgen 02/2017 Machine The complete assembly of all connected parts or devices, of which at least one is movable Motion block Data packet with all the position control parameters which are required for a motion task Multi-axis system Machine with several independently driven axes...

  • Page 135: Order Codes

    Kollmorgen Appendix 02/2017 11.2 Order codes The order numbers of accessories such as cables, brake resistors, mains supplies, etc., can be found in the accessories manual. Servo amplifiers Article Rated voltage Order code* SERVOSTAR 303 110-230 V AC S30361-NA SERVOSTAR 303-EC...

  • Page 136: Index

    Appendix Kollmorgen 02/2017 11.3 Index External fusing ....27 24V aux. supply, interface ..59 Feedback systems ... . 65 Abbreviations .
  • Page 137 Kollmorgen Appendix 02/2017 SFD3 interface ....67 SSI, interface ....91 STO-ENABLE ....93 Safety Function STO.
  • Page 138 We are committed to quality customer service. In order to serve in the most effective way, please contact your local sales representative for assistance. If you are unaware of your local sales representative, please contact the Customer Support. Europe KOLLMORGEN Internet www.kollmorgen.com/en-gb E-Mail technik@kollmorgen.com Tel.: +49 (0)2102 - 9394 - 0...

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