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Kollmorgen EB-9207 Installation & Service Manual

Brushless motor amplifier eb-60x series motors
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Kollmorgen Brushless Motor Amplifier
EB-60X Series Motors
Installation and Service Manual
Edition: September 2020, Revision B
Part Number: EB-9207
Original Document
For safe and proper use, follow these instructions. Keep for future use.

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  • Page 1 Kollmorgen Brushless Motor Amplifier EB-60X Series Motors Installation and Service Manual Edition: September 2020, Revision B Part Number: EB-9207 Original Document For safe and proper use, follow these instructions. Keep for future use.
  • Page 2 Technical changes which improve the performance of the device may be made without prior notice! This document is the intellectual property of Kollmorgen. 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.

  • Page 3: Table Of Contents

    Performance Curves ................38 EB-60x Typical Current and Voltage (Wave forms at Motor)....42 3.6.1 Current Phase C ................... 42 3.6.2 Voltage line A-C ..................42 EB-60x Intermittent Duty Operation ............42 INDEX ......................... 46 Kollmorgen | kdn.kollmorgen.com | January 2020...

  • Page 4: Introduction

    An unregulated 300 VDC bus, derived from full-wave rectification of a 3-phase 230 AC line by the power supply unit, is used to power the motor amplifier. Kollmorgen brushless motors feature the latest in permanent magnet technology; utilizing high energy Samarium-Cobalt and Neodymium-Iron-Boron alloys. These brushless motors consist of permanent magnet rotors and 3-phase Y-stator windings.

  • Page 5: Amplifier And Power Supply Ratings

    EB-60X Installation & Service Manual | Introduction Amplifier and Power Supply Ratings Ratings 235 V (L-L) 3-phase (±10%); isolation transformer not required – Input Power: provided short circuit (inrush) current remains limited to less than 1000 amps.115 VAC 1-phase control power. Power Supply DC Bus 325 VDC nominal, no load Amplifier: at rated load...

  • Page 6: Wiring

    3. Minimize lead lengths as much as practical. 4. Double-check all interface wiring. Carefully inspect all connections. 5. Do not use main contactor for control functions. Motor and resolver phasing are critical for proper operation. Kollmorgen | kdn.kollmorgen.com | January 2020...

  • Page 7: Typical Amplifier

    EB-60X Installation & Service Manual | Wiring Typical Amplifier 2.1.1 Front View STABILITY CURRENT LIMIT COMMAND SCALE BALANCE CONTROL VOLTS ENABLE STABILITY DRIVE READY CURRENT LIMIT DRIVE ADJUSTMENTS FOLDBACK COMMAND SCALE BALANCE OVERTEMP CONTROL VOLTS OVERCURRENT ENABLE DRIVE READY OVERVOLTS FOLDBACK DRIVE INDICATORS UNDERVOLTS...

  • Page 8: Typical Power Supply

    EB-60X Installation & Service Manual | Wiring Typical Power Supply 2.2.1 Front View EXTERNAL REGENERATION POWER RESISTOR TERMINAL BLOCK EXTERNAL REGEN RESISTOR D.C. BUS D.C. BUS REGEN REGEN FAULT FAULT FAULT OUTPUT & 115 VAC CONTROL POWER INPUT 18 & +10 VOLT CONTROL VOLTAGE OUTPUT INDUSTRIAL DRIVES...

  • Page 9: Psr4/5 & Motor Wiring

    EB-60X Installation & Service Manual | Wiring PSR4/5 & Motor Wiring *Notes are on the following pages.
  • Page 10 EB-60X Installation & Service Manual | Wiring (ALL WIRES TO BE COPPER WITH MIN. TEMP. RATING OF 60° C) The motor thermostat automatically resets when the motor cools. You are responsible for latching this signal to inhibit operation after a motor thermostat fault.
  • Page 11 EB-60X Installation & Service Manual | Wiring The total number of axes allowed, per PSR4/5, depends on the PSR4/5 model and the combination of BDS4s and/or BDS5s: • PSR4/5-X12: a max of 4 BDS4’s or 3 BDS5s. • PSR4/5-X20: a max of 4 BDS4’s or 3 BDS5s. •...
  • Page 12 EB-60X Installation & Service Manual | Wiring Use a Corcom 5R1 single phase filter or equivalent (for CE requirements). Use a Shaffner three phase filter or equivalent • Model No. 258-16/07 for PSR4/5A-112 & 212. • Model No. 258-30/77 for PSR4/5A-120 & 220. •...

  • Page 13: Bds4 Wiring

    EB-60X Installation & Service Manual | Wiring BDS4 Wiring...
  • Page 14 EB-60X Installation & Service Manual | Wiring MASTER BDS4 SLAVE BDS5 CONNECTOR C1 CONNECTOR C1 - DIFF HI - DIFF LO SPEED COMMAND INPUT: PINN 11 POSITIVE WITH CONNECTION SHOWN IS RESPECT TO PIN 1 FOR MASTER AND SLAVE WILL CAUSE MASTER TO ROTATE IN SAME TO ROTATE DIRECTION.
  • Page 15 EB-60X Installation & Service Manual | Wiring MASTER BDS4 SLAVE BDS5 CONNECTOR C1 CONNECTOR C1 - DIFF HI - DIFF LO TACH A-96170 CABLE SPEED COMMAND ASSEMBLY INPUT: PINN 11 POSITIVE WITH RESPECT TO PIN 1 WILL CAUSE MASTER TO ROTATE CLOCKWISE VIEWING FROM SHAFT END.
  • Page 16 EB-60X Installation & Service Manual | Wiring CONNECTOR C1 MASTER BDS4 AND SLAVE BDS5 SEE NOTE C ON FILTER KITS IN B IN B CONNECTOR 32 (OPTIONAL) (OPTIONAL) BDS4-OPT2/3A-01 IN A IN A OUT A OUT A (OPTIONAL) (OPTIONAL) OUT B OUT B SLAVE BDS5 OUT Z...

  • Page 17: System Wiring

    EB-60X Installation & Service Manual | Wiring System Wiring *Notes are shown on the next page.
  • Page 18 EB-60X Installation & Service Manual | Wiring Notes for System Wiring: 1. All signal and control wire to be 22-18 AWG wire. If 16 AWG is desired, then use Molex #39-00-0078 crimp pins (not supplied) instead of the parts supplied. 2.

  • Page 19: Typical Motor Connections

    EB-60X Installation & Service Manual | Wiring Typical Motor Connections Notes are found on following page.

  • Page 20: Grounding

    EB-60X Installation & Service Manual | Wiring Notes for previous diagram: 1. The motor thermostat is an automatic resetting device and should be connected into a latched (lock-out) power down type circuit. 2. Thermostat to be wired with twisted pair. 3.

  • Page 21: Preliminary Checks

    EB-60X Installation & Service Manual | Wiring Preliminary Checks Once the typical amplifier system has been installed and wired in, follow the steps below to ensure proper operation before the main power is applied. 2.9.1 Checking AC Input Voltage Open the circuit breaker or remove the fuses in the secondary of the large 3-phase isolation transformer.

  • Page 22: Motor Data Package

    EB-60X Installation & Service Manual | Motor Data Package MOTOR DATA PACKAGE This product's features and benefits are: UL-listed explosion-proof for Class I, Groups C & D hazardous locations  Neodymium-Iron-Boron magnets  Aluminum end bells  Frameless, shaft-mounted resolver ...

  • Page 23: Outline Drawing

    EB-60X Installation & Service Manual | Motor Data Package Outline Drawing 3.2.1 EB-606-11-BXR102 A-62908...

  • Page 24: Specifications Cd-27026

    EB-60X Installation & Service Manual | Motor Data Package EB-602 3.3.1 Specifications CD-27026 Specification Symbol Units *Continuous Torque lb-ft 13.0 12.8 12.8 Nom. (stall) at 40° C Ambient 17.63 17.36 17.36 Cont. Line Current Nom. 10.0 20.0 15.0 †Max. Speed Nom.
  • Page 25 EB-60X Installation & Service Manual | Motor Data Package † Symbol Units Value Rotor Inertia lb ft sec 0.000758 kg m 0.001028 Weight kg (f) 16.8 Static Friction lb-ft 0.360 0.490 Thermal Time Constant Peak TCTP Minutes Viscous Damping Z Source lb-ft/krpm 0.053 ∞...

  • Page 26: Performance Curves

    EB-60X Installation & Service Manual | Motor Data Package 3.3.2 Performance Curves 3.3.2.1 EB-602-A PC-26614 Do not operate this motor outside the parameters shown on this performance curve. Motor B-602-A Drive BDS4-210 Test T3-1443 SPEED (rpm)
  • Page 27 EB-60X Installation & Service Manual | Motor Data Package 3.3.2.2 EB-602-A PC-26614 Do not operate this motor outside the parameters shown on this performance curve. Motor EB-602-A Drive BDS4-210 Test T3-1443 SPEED (rpm)
  • Page 28 EB-60X Installation & Service Manual | Motor Data Package 3.3.2.3 EB-602-B PC-26615 Do not operate this motor outside the parameters shown on this performance curve. Motor EB-602-B Drive BDS4-220 Test T3-1441 SPEED (rpm)
  • Page 29 EB-60X Installation & Service Manual | Motor Data Package 3.3.2.3 EB-602-C PC-26804 (Q) Do not operate this motor outside the parameters shown on this performance curve. Motor EB-602-C Drive 15-amp continuous/45 amp peak Test Calculated SPEED (rpm)

  • Page 30: Specifications Cd 27027

    EB-60X Installation & Service Manual | Motor Data Package EB-604 3.4.1 Specifications CD-27027 Specification Symbol Units *Continuous Torque lb-ft 22.2 22.2 23.0 22.8 Nom. (stall) at 40° C Ambient 30.1 30.1 31.2 30.9 Cont. Line Current Nom. 27.7 39.4 †Max. Speed Nom.
  • Page 31 EB-60X Installation & Service Manual | Motor Data Package † Symbol Units Value Rotor Inertia lb ft sec 0.001500 kg m 0.002034 Weight kg (f) 23.1 Static Friction lb-ft 0.38 0.52 Thermal Time Constant Peak TCTP Minutes Viscous Damping Z Source lb-ft/krpm 0.080 ∞...

  • Page 32: Performance Curves

    EB-60X Installation & Service Manual | Motor Data Package 3.4.2 Performance Curves 3.4.2.1 EB-604-A PC-26616 Do not operate this motor outside the parameters shown on this performance curve. Motor EB-604-A Drive BDS4-230/20 Test T3-1433 SPEED (rpm)
  • Page 33 EB-60X Installation & Service Manual | Motor Data Package 3.4.2.2 EB-604-B PC-26951 Do not operate this motor outside the parameters shown on this performance curve. Motor EB-604-B Drive BDS4-230 Test T3-1633 SPEED (rpm)
  • Page 34 EB-60X Installation & Service Manual | Motor Data Package 3.4.2.3 EB-604-C PC-26952 Do not operate this motor outside the parameters shown on this performance curve. Motor EB-604-C Drive BDS4-240 Test T3-1635 SPEED (rpm)
  • Page 35 EB-60X Installation & Service Manual | Motor Data Package 3.4.2.4 EB-604-D PC-26805 (Q) This motor is not to be operated outside the parameters shown on the respective performance curve. Motor EB-604-D Drive 15-amp continuous/45-amp peak Test Calculated SPEED (rpm)

  • Page 36: Specifications Cd 27028

    EB-60X Installation & Service Manual | Motor Data Package EB-606 3.5.1 Specifications CD-27028 Specification Symbol Units *Continuous Torque lb-ft Nom. (stall) at 40° C Ambient 44.8 44.8 44.8 Cont. Line Current Nom. 54.8 †Max. Speed Nom. N max. 1550 3050 4150 2300 *Peak Torque...
  • Page 37 EB-60X Installation & Service Manual | Motor Data Package † Symbol Units Value Rotor Inertia lb ft sec 0.00224 kg m 0.00304 Weight kg (f) 29.9 Static Friction lb-ft 0.694 0.941 Thermal Time Constant Peak TCTP Minutes Viscous Damping Z Source lb-ft/krpm 0.108 ∞...

  • Page 38: Performance Curves

    EB-60X Installation & Service Manual | Motor Data Package 3.5.2 Performance Curves 3.5.2.1 EB-606-A PC-26618 This motor is not to be operated outside the parameters shown on the respective performance curve. Motor EB-606-A Drive BDS4-230/20 Test T3-1432 SPEED (rpm)
  • Page 39 EB-60X Installation & Service Manual | Motor Data Package 3.5.2.2 EB-606-B PC- 26619 This motor is not to be operated outside the parameters shown on the respective performance curve. Motor EB-606-B Drive BDS4-230/40 Test T3-1422 SPEED (rpm)
  • Page 40 EB-60X Installation & Service Manual | Motor Data Package 3.5.2.3 EB-606-C PC- 26954 This motor is not to be operated outside the parameters shown on the respective performance curve. Motor EB-606-C Drive BDS4-255 Test T3-1637 SPEED (rpm)
  • Page 41 EB-60X Installation & Service Manual | Motor Data Package 3.5.2.4 EB-606-D PC- 26955 This motor is not to be operated outside the parameters shown on the respective performance curve. Motor EB-606-D Drive BDS3-230 Test T3-1634 SPEED (rpm)

  • Page 42: Eb-60X Typical Current And Voltage (Wave Forms At Motor)

    EB-60X Installation & Service Manual | Motor Data Package EB-60x Typical Current and Voltage (Wave forms at Motor) 3.6.1 Current Phase C 2 ms DSW2 10 mV TPOS 4 2 ms VZR 0.0 10 mV CSW2 V = 40.8 mV T = 20.46 ms EB-606-C–...
  • Page 43 EB-60X Installation & Service Manual | Motor Data Package T OUT 1 - e -ton / Duty cycle X TCTP -ton / TCTP 1 - e where, duty cycle = ton/(ton + t = output torque = continuous torque at operating speed = time on TCTP = thermal time constant for peak power of motor This equation expresses operating torque as a function of ON time.
  • Page 44 EB-60X Installation & Service Manual | Motor Data Package (EQ-5) t max - TCTP 1n T OUT where: t = max on time TCTP = thermal time constant of motor = continuous torque of the motor at the particular operating speed = operating torque This gives the maximum ON time for a given operating torque beginning at ambient temperature.
  • Page 45 EB-60X Installation & Service Manual | Motor Data Package b) The required OFF time for a given ON time is found from (EQ-2). -ton / TCTP 1 - e T OUT -ton toff = - TCTP 1n 1 - = 4 sec TCTP = 16 min.
  • Page 46 Using EQ-2 and known values: = 14.1 seconds The applications engineers at Kollmorgen can assist in the proper sizing of the motor and amplifier based on the applications’ duty cycle. Contact them if any questions arise in the derivation of t...
  • Page 47 EB-60X Installation & Service Manual | Motor Data Package TYPICAL AMPLIFER DATA APACKAGE Typical Amplifier Specifications Ratings 235 V (L-L) 3-phase (±10%); isolation transformer not required – Input Power: provided short circuit (inrush) current remains limited to less than 1000 amps.115 VAC 1-phase control power. Power Supply DC Bus 325 VDC nominal, no load Amplifier: at rated load...

  • Page 48: Index

    EB-60X Installation & Service Manual | Index INDEX Amplifier EB 604-D power supply settings ........6 performance curve ........39 Preliminary Checks ........23 EB 606 Ratings ............6 typical.............. 5 SPECIFICATIONS ........41 Axes EB 606-B total number allowed ........13 performance curve ........
  • Page 49 EB-606-D............47 PC-26804 ............32 performance curve ........47 PC-26805 ............39 Equation 1 ............48 PC-26951 ............37 Equation 2 ............49 PC-26952 ............38 Equation 3 ............49 PC-26954 ............46 Equation 4 ............49 PC-26955 ............47 Equation 5 ............
  • Page 50 EB-60X Installation & Service Manual | Index Thermostat ............22 Wire Torque control ............20 gauge ............20 recommended ..........13 signal ............20 Wave Forms Wiring ..............7 A-C voltage ........... 48 AC lines ............13 current............48 control ............12 motor.............
  • Page 51 About Kollmorgen Kollmorgen is a leading provider of motion systems and components for machine builders. Through world-class knowledge in motion, industry-leading quality and deep expertise in linking and integrating standard and custom products, Kollmorgen delivers breakthrough solutions that are unmatched in performance, reliability and ease-of- use, giving machine builders an irrefutable marketplace advantage.

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