Keba ServoOne Series Operation Manual
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Keba ServoOne Series Operation Manual

Keba ServoOne Series Operation Manual

Multi-axis system with sinusoidal regeneration
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ServoOne
Multi-Axis System
Operation Manual
Supply Unit
Multi-axis system
with sinusoidal regeneration

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Summary of Contents for Keba ServoOne Series

  • Page 1 ServoOne Multi-Axis System Operation Manual Supply Unit Multi-axis system with sinusoidal regeneration...
  • Page 2 Applicable as from firmware version: V220.13-01 Information and specifications may be subject to change at any time. For information on the latest version please visit www.keba-lti.com. The German version is the original of this operation manual.

  • Page 3: Table Of Contents

    Table of contents General ..................7 Mechanical installation..............15 Target group .......................7 Notes for mechanical installation................15 Prerequisites ........................7 3.1.1 Arrangement and mounting ..............15 Reference documents ....................7 Switch cabinet layout ....................16 Order code ........................8 Mounting supply unit, wall mounting housing variant ..........18 Data on manufacture ....................8 3.3.1 Dimensions, wall mounting housing variant ..........
  • Page 4 Table of contents Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Overview of the connections ..................32 Control connections (X4)...................50 4.3.1 Layout, BG5 (SO84.040.S and SO84.076.S) ..........32 4.9.1 Specification, control connections .............50 4.3.2 Layout, BG6a (SO84.115.S and SO84.170.S) ..........32 4.9.2 Standard terminal assignment ..............
  • Page 5 Glossary ....................87 5.2.10 Switching on mains supply voltage ............65 5.2.11 Switching on regulation ................65 Diagnostics .......................65 5.3.1 Malfunctions and warnings in DriveManager 5 ..........65 Integrated control unit ....................66 5.4.1 Function of buttons T1 and T2 ..............67 5.4.2 Display .......................67 5.4.3 Parameter menu (PA) .................68 5.4.4 Ethernet IP address menu (IP) ..............68...
  • Page 6 Table of contents Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020...

  • Page 7: General

    General Reference documents ID no. Document Contents The product DVD from KEBA Industrial Automation Germany GmbH contains the Format complete documentation for the related product series. The documentation for a product Safety, mechanical installation, electrical installation, commissioning, ServoOne junior - 1300.20B.x...

  • Page 8: Order Code

    General Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Order code Data on manufacture The supply unit (SOVE) has the article designation SO84.xxx.S0xx.xxxx.x. This provides On the rating plate for the SOVE you will find the serial number, from which you can information on the related variant of the SOVE supplied.

  • Page 9: Pictograms

    For safe operation. Service To achieve stated performance features and product characteristics. KEBA does not accept any liability for injuries, damage or financial losses that result from the failure to follow the documentation. Disposal Follow the applicable national regulations! If necessary, dispose of individual parts, depending on their characteristics and existing national regulations, e.g.
  • Page 10 Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020...

  • Page 11: Safety

    Safety Protection against magnetic and/or electromagnetic fields during installation and operation. Persons fitted with heart pacemakers, metallic implants and hearing aids etc. must not be allowed access to the following areas: • Areas in the immediate vicinity of electrical equipment! Overview • Areas in which electronics components and drive controllers are installed, repaired and operated!

  • Page 12: General Safety Instructions And Warnings

    Safety Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 General safety instructions and warnings DANGER! Risk of injury due to rotating parts on the motor! • Carelessness will result in serious injuries or death. Hazards may emanate from our devices. For this reason it is imperative you follow the Follow safety instructions and warnings in this document.

  • Page 13: The Servoone Multi-Axis System

    The warranty provided by “Safety of machinery”. The safety requirements on electrical machines defined there are KEBA will be rendered void. intended to protect personnel and machinery or systems. The emergency stop function (as per EN 60204) shuts down the supply of power to a Misuse machine, which results in the drives coasting down in an uncontrolled manner.

  • Page 14: Declaration Of Conformity

    ID no.: 1101.21B.6-00 Date: 04/2020 Declaration of conformity Relevant laws, standards and directives applied For information on the laws, standards and directives applied by KEBA, refer to the declaration of conformity. NOTE: Depending on the specific application for the devices, other laws, standards and directives with provisions on "Safety"...

  • Page 15: Mechanical Installation

    Mechanical installation 3.1.1 Arrangement and mounting The following guidelines apply in principle to the supply unit and DC axis controller: The backing plate must be well-earthed. The device is designed only for installation in a stationary switch cabinet. The switch cabinet must as a minimum provide IP4x protection.

  • Page 16: Switch Cabinet Layout

    Mechanical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Switch cabinet layout The positioning of the components in the switch cabinet has a significant effect on the trouble-free system and machine function. You should take into account the following points in your planning: LOCK Evaluate the assemblies used in relation to EMC.
  • Page 17 NOTe: Arrange the controller separated from the power area to prevent EMC coupling mechanisms. Control cables, signal cables and cable shields have been omitted for clarity. Use bare metal backing plates. The rear of the drive controller must have good contact to the switch cabinet ground.

  • Page 18: Mounting Supply Unit, Wall Mounting Housing Variant

    Mechanical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Mounting supply unit, wall mounting housing variant Arrange the devices starting from the supply unit to the right or left sorted in ServoOne descending order by power rating to minimise thermal interaction. Pay attention Supply unit BG5 to the notes on effective EMC installation prior to mounting the devices and components in the switch cabinet.

  • Page 19: Dimensions, Wall Mounting Housing Variant

    3.3.1 Dimensions, wall mounting housing variant Size BG6a SO84.040.Sxxx.0 SO84.115.Sxxx.0 Device SO84.076.Sxxx.0 SO84.170.Sxxx.0 Weight [kg] B (width) H (height) T (depth) 406.5 418.5 Figure 3.6 Dimensional drawing wall mounting housing variant BG5 + BG6a (symbolic depic- Fastening screws 4 x M5 4 x M8 tion) Direct butt mounting, max.

  • Page 20: Mounting Supply Unit, Liquid Cooling Housing Variant

    Mechanical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Mounting supply unit, liquid cooling housing variant ServoOne Arrange the devices starting from the supply unit to the right (up to ServoOne Supply unit BG5 DC BG5) or left (from ServoOne DC BG6a) sorted in descending order by power rating to minimise thermal interaction.
  • Page 21 20 mm 28 mm ServoOne DC BG6a ServoOne with liquid cooling Supply unit BG7 with liquid cooling ≥ 40 mm Figure 3.10 Butt mounting axis group with liquid cooling and supply unit BG7 Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Mechanical installation...

  • Page 22: Dimensions, Liquid Cooling Housing Variant

    Mechanical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 3.4.1 Dimensions, liquid cooling housing variant Size BG6a SO84.040.Sxxx.8 SO84.115.Sxxx.8 SO84.375.Sxxx.8 Device SO84.076.Sxxx.8 SO84.170.Sxxx.8 SO84.540.Sxxx.8 Weight [kg] B (width) H (height) T (depth) 406.5 418.5 979/ 995 Figure 3.11 Dimensional drawing, liquid cooling housing variant BG5 + BG6a (symb. depiction) Mounting screws 4 x M6 4 x M8...
  • Page 23 NOTe: On butt mounting devices with different drive powers you should arrange the devices in descending order by power rating (e.g., viewed from the left, BG4-BG3-BG2-BG1). This arrangement will minimise the thermal interaction. The supply unit must always be fitted beside the axis controller with the highest power.

  • Page 24: Cooling Circuit Connection

    Mechanical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Cooling circuit connection Mounting step-up choke NOTe: Arrange the components and cables from the LCL set at a distance >100 mm from the step-up choke to minimise interaction due to stray magnetic flux and to ensure Connect the flow from the liquid cooling to the connection marked.

  • Page 25: Cooling The Step-Up Choke

    3.6.2 Cooling the step-up choke The step-up choke is a primary source of heat and is to be treated as a hotspot component. This component is cooled by natural air convection (gravity circulation). To exploit effectively this physical effect, this component should be mounted in the lower plinth area of the switch cabinet on robust mounting rails (that permit unhindered air flow from below).

  • Page 26: Mounting Input Choke With Film Capacitor

    Mechanical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Mounting input choke with film capacitor Arrange the components such that adequate air circulation is ensured for heat dissipation. As the film capacitor has a viscous filling, the input choke must be installed with the film capacitor upright.

  • Page 27: Mounting Mains Filter

    Mounting mains filter Arrange the components such that adequate air circulation and heat dissipation is ensured. Pay attention to the bending radius of the connection cables. For dimensional drawings/hole spacing see Figure 3.20 and Table 3.5. Mount the mains filter on the backing plate. The thread surface area will provide good contact.
  • Page 28 Mechanical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 NOTe: If the axis controllers are supplied by the PSU, situations may occur which render the mains input filter ineffective. The use of a common-mode filter in the DC link supply of the axis controllers is an effective remedy here. For detailed information on the use of common-mode filters, see Chapter 4.2.5 or refer to the Mounting instruction Common Mode Filter CMR (ID no.: 1101.13B.x).

  • Page 29: Electrical Installation

    Electrical installation WARNING! Risk of injury due to hot surfaces on the device! • Carelessness may result in serious burns. The device and especially the heat sink heat up significantly during operation and can reach temperatures of up to 100 °C. The chokes connected also heat up during operation and can Before you start reach temperatures of up to 145 °C. Prior to starting work, make sure the device has cooled down. On touching there is a risk of burns to the skin. For this reason provide protection against It is imperative you pay attention to the following warnings and safety instructions prior to touching.

  • Page 30: Effective Emc Installation

    Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Effective EMC installation 4.2.3 Earthing measures All earthed points and components must be routed directly to the central earthing point (e.g. PE rail, main earth) with as low an impedance as possible and with good 4.2.1 Cable type conductivity.

  • Page 31: Shielding Measures

    4.2.4 Shielding measures You should take into account the following points for the shielding measures: Use only shielded mains, motor and signal cables as shown in Figure 4.7, p. 35. For all shielded connections, use cables with double copper braiding with 60 to 70% coverage. Connect the shield at both ends using a large area connection.
  • Page 32 Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 4.2.5 Use of common mode filters NOTe: Further information and technical data on the use of common mode filters If the axis controllers are supplied by the PSU, situations may occur which render the can be found in the Mounting instruction Common Mode Filter CMR (ID no.: mains input filter ineffective.

  • Page 33: Overview Of The Connections

    Overview of the connections 4.3.2 Layout, BG6a (SO84.115.S and SO84.170.S) In the following you can see the layout where you can find the corresponding positions of the connectors and terminals. For improved clarity we have added an abbreviation to the designation for the connectors and terminals.

  • Page 34: Overview Of Connections, Bg5 And Bg6A

    Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 4.3.3 Overview of connections, BG5 and BG6a Designation Function Page D1, D2 7-segment display Device state indication p. 67 T1, T2 Button Service functions p. 66 Optional module for field bus e.g. DC-link −...

  • Page 35: Connection Diagram, Bg5

    4.3.4 Connection diagram, BG5 L1.1 Mains fuses F1 L1.1 L2.1 L2.1 Mains supply/emergency stop L3.1 L3.1 Shield plates (grey) Step-up choke with KTY temperature sensor Shielded cables should be used from >500 mm cable 24 V DC length Input choke with film capacitor Mains contactor (after precharging via HREL) Mains filter Short circuit proof cables...

  • Page 36: Connection Diagram, Bg6A

    Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 4.3.5 Connection diagram, BG6a L1.1 Mains fuses F1 L1.1 L2.1 L2.1 Mains supply/emergency stop L3.1 L3.1 Shield plates (grey) Step-up choke with KTY temperature sensor Shielded cables should be used from >500 mm cable length 24 V DC Input choke with film capacitor Mains contactor (after precharging via HREL)

  • Page 37: Layout, Bg7 (So84.375.S And So84.540.S)

    4.3.6 Layout, BG7 (SO84.375.S and SO84.540.S) 4.3.7 Overview of connections, BG7 ZK− ZK− ZK− ZK− DC-link Danger! Pre-charging Service USB 1.1 interface Danger! Service Ethe rnet Mains synchronization interface Control 24 V DC Supply for – D1, D2 control electronic (U ISA00+ T1, T2 ISA00-...
  • Page 38 Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Designation Function Page D1, D2 7-segment display Device state indication p. 67 T1, T2 Button Service functions p. 66 Option 1 Communication Optional module, no function p. 54 Service interface, Plug & Play connection to USB 1.1 interface p. 54 Service interface, fast TCP/IP connection...

  • Page 39: Connection Diagram And Precharging, Bg7

    4.3.8 Connection diagram and precharging, BG7 13) Mains supply/emergency stop Key: Braking resistor with temperature sensor 14) Mains filter Short circuit proof cables 15) Input choke ( including film capacitor) ServoOne supply unit BG7 16) Power supply, DC axis controller 17) Step-up choke with KTY temperature sensor Connection for DC power supply for DC axis controller Connection for DC link precharging...

  • Page 40: Mains On/Off Control Process

    Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Connection of the protective earth Mains On/Off control process conductor Precharging the DC link The leakage current is > 3.5 mA. This situation results in the following minimum Switch S1 "Mains supply On" is switched on. The precharging contactor K2 closes and requirements for the protective earth conductor cross-section as a function of the phase the DC link is precharged via precharging resistors on terminal X45.

  • Page 41: Protective Earth Conductor (X11), Supply Unit Bg6A

    4.5.2 Protective earth conductor (X11), supply unit BG6a Earth the supply unit BG6a and each DC axis controller BG6a separately. Connect the PE connection X11/PE on the supply unit to the PE rail (main earth) in the switch cabinet. For this purpose use a dedicated protective earth conductor Select the protective earth conductor cross-section according to chap. 4.5.

  • Page 42: Protective Earth Conductor (X11) Supply Unit Bg7

    Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 ServoOne DC BG6a ServoOne with liquid cooling Supply unit BG7 with liquid cooling Figure 4.15 Detail: connection of the protective earth conductor 4.5.3 Protective earth conductor (X11) supply unit BG7 Earth the supply unit and each DC axis controller BG7 and BG6a separately! Connect the PE connection X11/PE on the supply unit to the PE rail (main earth) in the switch cabinet.

  • Page 43: Electrical Isolation Concept

    Electrical isolation concept USB1.1 µP Ethernet The control electronics with their logic (µP), the inputs and outputs, are electrically GNDµP X4/15 isolated from the power section (power supply/DC link). All control connections are ISD00 ISD01 designed as safety extra low voltage/protective extra low voltage (SELV/PELV) circuits ISD02 ISD03 Mains synchronization...

  • Page 44: Connection Of The Supply Voltages

    Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Connection of the supply voltages USB1.1 µP Ethernet The supply of power to the ServoOne is separate for the control section and power GNDµP X4/15 section. The control supply is always to be connected first in the sequence so that the GNDµP ISD00 ISD01...

  • Page 45: Control Supply 24 V Dc (X44) For Bg7

    drawn by all axis controllers on starting and in operation. See chap. A.2, 4.7.3 Precharging and mains synchronisation (X21) for BG5 and p. 79. BG6a NOTe: The DC link is precharged via the terminal X21/L1,L2,L3 (see Figure 4.7 and Figure 4.8). Do not use the connector as a "switch" for a reset. At a defined DC link voltage the contact on the internal relay on terminal X21/HREL is closed.

  • Page 46: Precharging (X44) And Mains Synchronisation (X45) For Bg7

    Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 4.7.4 Precharging (X44) and mains synchronisation (X45) for 4.7.5 Connection, mains 400/480 V AC (X12) Note the following points: The regenerative unit is synchronised with the mains via the terminals X45/S1,S2,S3,SN. Switching the mains power: The regenerative unit in the BG7 is pre-charged via the terminals X45/ P1, P2, P3.
  • Page 47 Procedure: Mains connection conditions So that the trouble-free operation of a ServoOne supply unit on the supply system Define the cable cross-section according to local regulations and conditions. is ensured, there is a minimum requirement on the short circuit power on the mains Use shielded cables where necessary and as shown in the connection diagrams.

  • Page 48: Connection Of The Dc Power Supply

    Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Connection of the DC power supply – – – – – DANGeR! Risk of injury due to electrical power! • Carelessness will result in serious injuries or death. The cover for terminal X11 (DC connection) on sizes BG1 to BG5 is to be closed after fitting the pre-assembled connection cables. Operation without a cover is not allowed.

  • Page 49: Connection, Dc Power Supply Bg6A And Bg7

    NOTe: You will find the permissible connection cross-sections and tightening torques in chap. A.3 4.8.2 Connection, DC power supply BG6a and BG7 – – – – – – Connect the DC link terminals ZK+ and ZK- on the supply unit BG6a or BG7 to the corresponding terminal on the next DC axis controller in the row.
  • Page 50 Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 On a supply unit BG7 the DC connection X11/ZK is not protected internally. – – – – – – – – – – – PE PE PE PE ServoOne ServoOne DC BG6a ServoOne DC BG7 Versorgungseinheit BG7...

  • Page 51: Control Connections (X4)

    Control connections (X4) 4.9.1 Specification, control connections Des. Term. Specification Electrical isolation Check whether a complete device setup is already available, i.e. whether the drive Analogue inputs has already been configured. ISA0+ X4/3 ISA0- X4/4 If so, a special control terminal assignment applies. No function ISA1+ X4/5...

  • Page 52: Standard Terminal Assignment

    Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 4.9.2 Standard terminal assignment Des. Term. Specification Electrical isolation Relay outputs Terminal assignment with the factory setting • Relay, 1 NO contact • Functions can be selected as for Des.

  • Page 53: 4.10 Functions Of The Digital Inputs

    4.10 Functions of the digital inputs Value Value name Description OUTPUT_FS_UDC_LIM_AC- Setpoint limiting for the DC link voltage active (the voltage is outside the defined range.) The following functions can be selected for the digital inputs ISD00 to ISD06: OUTPUT_FS_I_LIM_ACTIV No function Value Value name...

  • Page 54: Specification, Usb Interface (X2)

    Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 4.12 Specification, USB interface (X2) 4.15 Braking resistor (X12/RB) The service and diagnostic interface X2 is designed as a USB V1.1 interface. It is only In regenerative operation, e.g. when braking the motors, energy is fed to the DC link in suitable for connecting a PC for commissioning, service and diagnostics using the the multi-axis system and fed back to the mains via the supply unit.

  • Page 55: Overview Of The Step-Up Choke Connections

    NOTe: y The external braking resistor is only allowed to be installed with a supply unit that does not have an internal braking resistor. y Be sure to follow the installation instructions for the external braking resistor. y The minimum permissible connection resistance for the supply unit must not be infringed.

  • Page 56: 4.17 Overview Of The Input Choke Connections

    Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 4.17 Overview of the input choke connections In the following you will find the layout with the corresponding positions and labels on the terminals. For technical data on the input choke, see chap. A.8, p. 83 DANGeR! Risk of injury due to electrical power! • Carelessness will result in serious injuries or death.
  • Page 57 BG6a - 115 A BG6a - 170 A Figure 4.28 Connections, input choke for BG5 and BG6a Figure 4.29 Connections, input choke for BG7 Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Electrical installation...

  • Page 58: 4.18 Overview Of The Mains Filter Connections

    Electrical installation Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 4.18 Overview of the mains filter connections PE L3 In the following you will find the layout with the corresponding positions and labels on the terminals. For technical data on the mains filter, see chap. A.9, p. 84. L1.1 L2.1 L3.1 L1.1 L2.1 L3.1 L1 L2 L3...

  • Page 59: Commissioning

    Commissioning Wiring the components See chap. 4.3, p. 33 and subsequent information. Switch on control voltage Notes for operation External 24-V supply voltage See chap. 4.7.1, p. 44 BG5 and BG6a. See chap. 4.7.2, p. 45 BG7. CAUTION! Damage to the device due to incorrect installation conditions! Establish communication with DriveManager 5 The device may be irreparably damaged due to detrimental ambient You will find information on installation in the Installation Manual DriveManager...

  • Page 60: System Requirements

    Commissioning Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 5.2.1 System requirements = selected setting/component Supply unit installed. Connections Terminals Terminal identifier Cable type You will find details on initial commissioning in chap. 5.2.2, p. 60 Control supply X9/10 +24 V DC / pin 1 = + , pin 2 = – Standard Completion of the work in chap. 4 "Electrical installation"...

  • Page 61: Switching On Control Voltage (24 Vdc)

    5.2.3 Switching on control voltage (24 VDC) 5.2.4 Communication with DriveManager 5 To initialise the supply unit and to configure the parameters, it is necessary initially The user software DriveManager 5 must be installed on a PC. The PC can be to apply only the 24 V DC control supply to X9 or X10. Pay attention to correct connected to the drive controller via USB or Ethernet (TCP/IP).

  • Page 62: Setting Mains Voltage And Mains Frequency Of The Supply System

    Commissioning Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 5.2.5 Setting mains voltage and mains frequency of the supply Set the mains frequency P-0452. system Set automatic mains frequency detection parameter 0449 to 1. The supply unit parameters are configured in the factory for a system with 3 x 400 V AC (50 Hz).

  • Page 63: Automatic Identification Of The Dc Link Capacitance And The Equivalent Time Constant For The Current Regulation

    5.2.6 Automatic identification of the DC link capacitance and 5.2.7 Setting DC link capacitance the equivalent time constant for the current regulation The settings for the DC voltage regulator depend on the DC link capacitance of the entire multi-axis system. You will find the DC link capacitances in the operation The DC voltage regulator in the supply unit regulates the DC link voltage to an manuals for the supply unit and the DC axis controller in the technical data in the internally specified fixed setpoint.

  • Page 64: Setting Dc Link Voltage

    Commissioning Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 5.2.9 Setting monitoring of the braking resistor NOTe: So that the parameters are also effective after a restart, the modified settings must be saved in the device in non-volatile memory and a 24-V reset Set the braking resistor.

  • Page 65: 5.2.10 Switching On Mains Supply Voltage

    Diagnostics If the brake chopper is operated (DC link voltage ≥820 V) the power converted in the braking resistor is integrated. (820 V) 5.3.1 Malfunctions and warnings in DriveManager 5 MON_BrcR If the brake chopper is not operated, the power is integrated using the value configured The parameters P-0031 ErrorStack and P-0033 ActualError contain additional in the parameters for the brake chopper rated power (MON_BrcPnom).

  • Page 66: Integrated Control Unit

    Commissioning Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Integrated control unit The following functions and displays are available: Indication of the device status (see chap. 6.1, p. 71) The device status is indicated after switching on the control supply. If no input The integrated control unit permits diagnostics on the drive controller.

  • Page 67: Function Of Buttons T1 And T2

    5.4.1 Function of buttons T1 and T2 5.4.2 Display These buttons are used to activate the different menus and to control the corresponding The following table defines various indications and items of status information provided functions. via the display. Button Function Comment Display...

  • Page 68: Parameter Menu (Pa)

    Commissioning Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 5.4.3 Parameter menu (PA) 5.4.4 Ethernet IP address menu (IP) The following functions are available on the Parameter menu: An Ethernet TCP/IP port is available as a service and diagnostics interface. The IP address is set in the factory to 192.168.39.5.

  • Page 69: Field Bus Address Menu (Fb)

    Example configuration of the subnet mask NOTe: y During the flashing phase after step 7 the save procedure can still be In this example the subnet mask is changed from 255.255.255.0 to 122.255.255.0. aborted by pressing any button, without applying the value set. Otherwise the new value will be saved after five seconds.
  • Page 70 Commissioning Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Example configuration of the field bus address In this example the field bus address is changed from 1 to 23. several actuations of buttonTx (X = 1, 2) until the desired menu appears in the display single actuation T1 T2...

  • Page 71: Diagnostics

    Diagnostics NOTe: The safety function STO (Safe Torque OFF) is not required for the ServoOne supply unit, as no motors are connected. To be able to start the supply unit, a jumper must be placed between X4/14 and X4/22. If this jumper is forgotten, there is a flashing point on the device display. The Device states safety function STO is used for ServoOne DC axis controllers.

  • Page 72: Error List

    Diagnostics Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Error list Error Error Error text number location Overtemperature PTC Error messages (error number, error location, error text) for the supply unit are listed in the following table. In there is an error, the display on the supply unit changes cyclically Unknown error between the indications "Er", ">Error number<", ">Error location<".
  • Page 73 Error Error Error Error Error text Error text number location number location CAN option: Message transmit failed Drive initialization: Unexpected error during drive initialization CAN option: Heartbeat error DC voltage tracking error CAN option: Illegal address Unknown VoltageDiff error CAN option: mapping error Max.
  • Page 74 Diagnostics Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Error Error Error text number location User defined error in the PLC program detected. Error in PROFIBUS option PROFIBUS option: Unknown error PROFIBUS option: process data timeout Task overload Internal timing error Internal timing error Internal timing error Power fail detected...

  • Page 75: Appendix

    Appendix Size Device SO84.040.Sxxx.x SO84.076.Sxxx.x Brake chopper power electronics Response threshold [VDC] Technical data, supply unit Peak braking power [kW] 90/99 software/hardware-side Minimum ohmic resistance of an exter- 7.5 Ω Size nally installed braking resistor Device SO84.040.Sxxx.x SO84.076.Sxxx.x Continuous chopper power [kW] Mains input voltage 460 / 480 460 / 480 Optional for liquid cooling: internal braking resistor (mounted on the base of the cooler) on request (±10 %) [V AC] Minimum switch-on time 250 µs Regulated DC link voltage...
  • Page 76 Appendix Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Size BG6a Size BG6a Device SO84.115.Sxxx.x SO84.170.Sxxx.x Device SO84.115.Sxxx.x SO84.170.Sxxx.x Brake chopper power electronics Mains input voltage 460 / 480 460 / 480 (±10 %) [V AC] Response threshold Regulated DC link voltage Peak braking power [kW] [V DC] 143/157 software/hardware-side Input, mains side Minimum ohmic resistance of an external- 4.7 Ω ly installed braking resistor Continuous current [A AC eff Peak current...
  • Page 77 Size BG6a Size Connection Device SO84.115 SO84.170 Device SO84.375.S SO84.540.S Mains input voltage (±10%) 460 / 460 / Use the pre-assembled connection cables supplied or [VAC] Cable cross-section 35...95 mm X11/L+, L- (AWG 2...AWG 3/0) Regulated DC link voltage [VDC] Tightening torque 25...30 Nm (221...265 lb-in) Input, mains side Continuous current [AAC Screw size for ring eff cable lug Peak current [AAC] X11/PE Tightening torque 10...12 Nm (88...106 lb-in) Switching frequency [kHz] Continuous power [kW] 50...150 mm 50...150 mm Power dissipation [W] 3300 4100 Cable cross-section...
  • Page 78 Appendix Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Size Size Connection Device SO84.375.S SO84.540.S Device SO84.375.S SO84.540.S Brake chopper power electronics Screw size for ring cable lug Response threshold [VDC] X11/ZK+, ZK- Tightening torque 25...30 Nm (221...265 lb-in) Peak braking power [kW] 210/- software/hardware-side Screw size for ring cable lug Minimum ohmic resistance of an exter- 3.2 Ω X11/PE nally installed braking resistor Tightening torque 20...25 Nm (177...221 lb-in) Continuous chopper power [kW] Internal braking resistor (mounted on the base of the cooler) on request Screw size for ring cable lug X12/L1, L2, L3...

  • Page 79: Current Required For The Control Supply

    Current required for the control supply Pre-assembled connection cables Size BG6a For devices of size BG5, pre-assembled connection cables are available for the DC link SO84.040 SO84.115 SO84.375 coupling. For devices of sizes BG6a and BG7, connection cables must be specified by Device SO84.076 SO84.170...

  • Page 80: Hydrological Data For The Liquid Cooling

    Appendix Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Hydrological data for the liquid cooling NOTe: Do not use material combinations with contact corrosion in the cooling circuit, such as aluminium and copper. This can lead to leaks and blockages of the CAUTION! Damage to the device due to condensation on the cooling plate cooling lines.

  • Page 81: Dynamic Temperature Monitoring

    Ambient conditions Dynamic temperature monitoring Should the coolant flow rate collapse or not become established, the power stage could Ambient conditions ServoOne overheat. For this reason the drive controllers BG5 and BG6a are equipped with dynamic Protection IP20 except terminals (IP00) monitoring of the heat sink temperature and drive controller BG7 is equipped with static Accident prevention reg- As per the local regulations (in Germany e.g.

  • Page 82: Technical Data, Step-Up Choke

    Appendix Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Technical data, step-up choke Mechanical conditions ServoOne As per EN 61800-2, IEC 60721-3-2 class 2M1 Frequency [Hz] Amplitude [mm] Acceleration [m/s²] For size BG6a Vibration limit in transit 2 ≤ f < 9 Not applicable For device SO84.040 SO84.076 SO84.115...

  • Page 83: Technical Data, Input Choke

    Technical data, input choke For size For device SO84.375.S SO84.540.S Rated AC current 3 x 375 A 3 x 540 A For size BG6a Supply voltage 3 x 400 VAC ... 3 x 480 VAC 3 x 400 VAC ... 3 x 480 VAC For device SO84.040 SO84.076 SO84.115 SO84.170 Designed for active power (step-up Rated AC current 3 x 40 A 3 x 76 A 3 x 115 A 3 x 170 A 250 kW 360 kW operation 650 VDC/770 VDC) Supply voltage 3 x 400 VAC ... 3 x 480 VAC Power dissipation at 100 % duty factor 714 W 1050 W Power dissipation 120 W 144 W 180 W...

  • Page 84: Technical Data, Mains Filter

    Appendix Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 Technical data, mains filter For size For device SO84.375.S SO84.540.S Rated AC current 3 x 375 A 3 x 540 A For size BG6a Supply voltage 3 x 400 VAC ... 3 x 480 VAC 3 x 400 VAC ... 3 x 480 VAC For device SO84.040.S SO84.076.S SO84.115.S SO84.170.S Power dissipation at 100 % duty factor 280 W 525 W Type FFU 3 x 56 K FFU 3 x 80 K FFU 3 x 130 K FFU 3 x 180 K...

  • Page 85: A.10 Technical Data, Mains Fuse

    A.11 Technical data, mains contactor For size For device SO84.375.S SO84.540.S Thread We recommend the utilisation of the following mains contactors. Alternative products The screw size and tightening torque depend on the ring must be technically equivalent! Tightening torque cable lug used. For size BG6a Rated AC current at 40 °C ambient temperature...

  • Page 86: A.12 Technical Data, Circuit Breaker

    Appendix Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020 A.12 Technical data, circuit breaker A.13 UL certification We recommend the following circuit breakers for system protection. Alternative products The description of all measures to maintain UL approval is to be found in the document must be technically equivalent! "UL-Certification"...
  • Page 87 Glossary Cooling Liquid cooling ....................... 80 Cooling circuit ......................24 Date of manufacture ..................... 8 Ambient conditions ....................81 DC power supply ......................47 Ambient temperature ....................81 Connection BG5 ....................47 Axis group mounting ....................20 Connection BG6a....................48 Supply unit BG5 ....................
  • Page 88 Glossary Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: Date: 04-2020 Measures for your safety ..................... 11 Mechanical conditions ....................81 Firmware ........................61 Mechanical installation ....................15 Mounting ........................15 Input choke ......................26 Mains filter ......................27 Hydrological data for the liquid cooling............... 80 Liquid cooling housing variant ................
  • Page 89 Rating plate ........................8 X2 ..........................53 Residual current device ....................46 X3 ..........................53 Responsibility ......................13 X4 ..........................50 Routing of cables ......................30 X9 ..........................43 X10 ..........................43 X11 ......................39, 40, 41, 47 X21 ........................... 44 Safety instructions and warnings ................
  • Page 90 Glossary Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: Date: 04-2020...
  • Page 91 Operation Manual ServoOne Supply Unit ID no.: 1101.21B.6-00 Date: 04/2020...
  • Page 92 Czech Republic • Turkey • USA Copyright © 2020 KeBA All rights reserved. All content of the documentation, in particular the text, photographs and graphics it contains are protected by copyright. The copyright lies, unless otherwise expressly stated, with KEBA Industrial Automation Germany GmbH.

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