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Kollmorgen Essentials KED6V03 Installation Manual

3, 6, 12 amp single-axis servo drive with functional safety option 1,sto - sil2
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Kollmorgen Essentials Drive
3, 6, 12 Amp Single-Axis Servo Drive with Functional Safety
Option 1, STO - SIL2
Installation Manual
Manual Edition: A (BETA VERSION), March 2025
Safety Edition: BETA VERSION, March 2025
Valid for Kollmorgen Essentials Drive Hardware Revision A (BETA VERSION)
Part Number XX
Original Document
For safe and proper use, follow these instructions.
Keep for future use.
, English
Kollmorgen Essentials Drive |
Kollmorgen® | kdn.kollmorgen.com | March 2025
1

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Summary of Contents for Kollmorgen Essentials KED6V03

  • Page 1 Installation Manual , English Manual Edition: A (BETA VERSION), March 2025 Safety Edition: BETA VERSION, March 2025 Valid for Kollmorgen Essentials Drive Hardware Revision A (BETA VERSION) Part Number XX Original Document For safe and proper use, follow these instructions. Keep for future use.
  • Page 2 Kollmorgen. The information in this document is believed to be accurate and reliable at the time of its release. Kollmorgen assumes no responsibility for any damage or loss resulting from the use of this help, and expressly disclaims any liability or damages for loss of data, loss of use, and property damage of any kind, direct, incidental or consequential, in regard to or arising out of the performance or form of the materials presented herein or in any software programs that accompany this document.

  • Page 3: Table Of Contents

    Kollmorgen Essentials Drive | Table of Contents Table of Contents Table of Contents 1 Welcome to Kollmorgen Essentials 2 General 2.1 About this Installation Manual 2.2 Symbols Used 2.2.1 Warning Symbols 2.2.2 Drawing Symbols 2.3 Abbreviations Used 3 Product Safety 3.1 You should pay attention to this 3.2 Use as Directed...
  • Page 4 Kollmorgen Essentials Drive | Table of Contents 6.6.1 Drive dynamic braking 6.6.2 Regeneration braking 6.6.2.1 Functional description 6.6.2.2 Technical data – 240V drives 6.6.2.3 Technical data – 480V drives 6.7 LED and Push-button B1 7 Mechanical Installation 7.1 Important Notes 7.2 Guide to Mechanical Installation...
  • Page 5 Kollmorgen Essentials Drive | Table of Contents 8.9 Motor Power, Brake, and Feedback Connection 8.9.1 Motor Connectivity Example 8.9.2 Motor Cable Connection 8.9.2.1 Motor power and brake connector X1 8.9.2.2 Motor Leads to X1 Drive Connector 8.9.2.3 Motor Feedback Cable Connector to X23 Drive Connector 8.9.3 Motor Holding Brake Connection...
  • Page 6 Kollmorgen Essentials Drive | Table of Contents 10.3 Safety Function Option 1 (I/O, SIL2 PLd) 10.3.1 Safety Properties Overview 10.3.2 Technical Data 10.3.3 STO (Safe Torque Off) 10.3.3.1 Important Notes 10.3.3.2 Activation 10.3.3.3 Restart 10.3.3.4 Timing 10.3.3.5 Safety Diagnostic view in WorkBench 10.3.3.6 Fault Reaction / Failure Messages...

  • Page 7: Welcome To Kollmorgen Essentials

    Kollmorgen Essentials Drive | 1   Welcome to Kollmorgen Essentials 1 Welcome to Kollmorgen Essentials This section should provide an overview of what Kollmorgen Essentials is, Ease of use Components Compliance when the drive is used in the system with an Essentials motor and cable.

  • Page 8: General

    Kollmorgen Essentials Drive | 2   General 2 General 2.1 About this Installation Manual 2.2 Symbols Used 2.3 Abbreviations Used Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 9: About This Installation Manual

    Kollmorgen Essentials Drive | 2   General 2.1 About this Installation Manual This Installation Manual describes the Kollmorgen Essentials Drive series of digital drives and includes information to safely install the product. Manual updates can be downloaded from the Kollmorgen website (www.kollmorgen.com). Product information for use consists of: Safety Notes : Multilingual document with safety information, part of product delivery in Europe, printed on paper DIN A5.

  • Page 10: Symbols Used

    Kollmorgen Essentials Drive | 2   General 2.2 Symbols Used 2.2.1 Warning Symbols Symbol Indication DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

  • Page 11: Drawing Symbols

    Kollmorgen Essentials Drive | 2   General 2.2.2 Drawing Symbols Symbol Description Symbol Description Signal ground Diode Chassis ground Relay Protective earth Relay switch off delayed Resistor Normally open contact Fuse Normally closed contact State-of-the-art firewall EMC filter 2.3 Abbreviations Used Abbreviations related to functional safety (➜...
  • Page 12 Functional Safety Option 1, 2, 3 FSoE Fail safe over EtherCAT Kollmorgen Automation Suite KAS IDE Setup software (Kollmorgen Automation Suite Integrated Development Environment) Kollmorgen Developer Network Light-emitting diode Low significant byte (or bit) Most significant byte (or bit) Zero pulse...

  • Page 13: Product Safety

    Kollmorgen Essentials Drive | 3   Product Safety 3 Product Safety To avoid possible damage, read and follow the instructions. 3.1 You should pay attention to this 3.2 Use as Directed 3.3 Prohibited Use 3.4 Warning Note Labels 3.5 Shock-hazard Protection 3.6 Stop / Emergency Stop / Emergency Off...

  • Page 14: You Should Pay Attention To This

    Kollmorgen Essentials Drive | 3   Product Safety 3.1 You should pay attention to this This section helps to recognize risks and avoid dangers to people and objects. Specialist staff required! The devices are intended for industrial applications. Machine builders must employ qualified personnel. Qualified personnel are people who have been trained to transport, install, commission, and operate electrical drives.
  • Page 15 Therefore, the drive may only be opened by authorized specialist personnel. Kollmorgen can't be held accountable for any defects, malfunctions or degradations resulting from users opening up the device. In case of damage or malfunction, send the drive for repair or replacement.

  • Page 16: Use As Directed

    The operator must provide ear protection and monitor its use depending on the daily noise exposure level determined. 3.2 Use as Directed Use your Kollmorgen Essentials Drive exclusively with the Kollmorgen Essentials Motor and Cables. The Kollmorgen Essentials Drives are exclusively intended for driving suitable synchronous servomotors with closed-loop control of torque, speed, and/or position.

  • Page 17: Prohibited Use

    Kollmorgen Essentials Drive | 3   Product Safety 3.3 Prohibited Use Other use than that described in the previous “Use as Directed” section is not intended and can lead to personnel injuries and equipment damage. The drive may not be used with a machine that does not comply with appropriate...

  • Page 18: Residual Current Protective Device (Rcd)

    Kollmorgen Essentials Drive | 3   Product Safety Since the leakage current to PE is more than 3.5mA, in compliance with IEC 61800-5-1 the PE NOTE connection must either be doubled or a connecting cable with a cross-section >10mm² must be used.

  • Page 19: Stop / Emergency Stop / Emergency Off

    Kollmorgen Essentials Drive | 3   Product Safety 3.6 Stop / Emergency Stop / Emergency Off The control functions Stop, Emergency Stop, and Emergency Off are defined by IEC 60204. Notes for functional safety aspects of these functions can be found in ISO 13849 and IEC 62061.

  • Page 20: Emergency Stop

    Kollmorgen Essentials Drive | 3   Product Safety 3.6.2 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. Principles of emergency stop devices and functional aspects are defined in ISO 13850.

  • Page 21: Product Life Cycle Handling

    Kollmorgen Essentials Drive | 4   Product Life Cycle Handling 4 Product Life Cycle Handling 4.1 Transport 4.2 Packaging 4.3 Storage 4.4 Installation, Setup, and Normal operation 4.5 Decommissioning 4.6 Maintenance and Cleaning 4.7 Disassembly 4.8 System Repair 4.9 Disposal Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 22: Transport

    If the packaging is damaged, check the unit for visible damage. Inform the shipper and the manufacturer of any damage to the package or product. 4.2 Packaging The Kollmorgen Essentials Drive packaging consists of recyclable cardboard with inserts and a label on the outside of the box. Model...

  • Page 23: Installation, Setup, And Normal Operation

    Kollmorgen Essentials Drive | 4   Product Life Cycle Handling 4.4 Installation, Setup, and Normal operation Mechanical installation (➜ # 41) Electrical installation (➜ # 44) Setup (➜ # 86) Normal operation tested for environmental class 3K3 according to EN 61800-2 (➜ # 33).
  • Page 24 Kollmorgen Essentials Drive | 4   Product Life Cycle Handling 4. Demount: Loosen the fastening screws. Remove the device. Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 25: System Repair

    Kollmorgen Essentials Drive | 4   Product Life Cycle Handling 4.8 System Repair Only professional staff who are qualified in electrical engineering are allowed to exchange parts of the NOTICE drive system. CAUTION : Automatic Start! During replacement work a combination of hazards and multiple episodes may occur.

  • Page 26: Package

    Kollmorgen Essentials Drive | 5   Package 5 Package 5.1 Package Supplied 5.2 Nameplate 5.3 Part Number Scheme Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 27: Package Supplied

    Other connectors and cables need to be provided by the user. Accessories sold separately Accessories may be ordered separately if required, see (➜ Accessories for Kollmorgen Essentials # 123). EMC filters for mains supply voltage, categories C2 or C3 External regen resistor...

  • Page 28: Part Number Scheme

    Kollmorgen Essentials Drive | 5   Package 5.3 Part Number Scheme Use the part number scheme for product identification only. Mating connectors NOTE X10 (DC Input) and X3 (AC Input) are included with the "-A" at the end of the model number.
  • Page 29 Kollmorgen Essentials Drive | 5   Package Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 30: Technical Description And Data

    Kollmorgen Essentials Drive | 6   Technical Description and Data 6 Technical Description and Data 6.1 The Family of Kollmorgen Essentials Drives 6.2 Ambient Conditions, Ventilation and Mounting Position 6.3 Mechanical Data 6.4 Performance Data 6.5 Electrical Data 6.6 Electrical Motor Braking 6.7 LED and Push-button B1...

  • Page 31: The Family Of Kollmorgen Essentials Drives

    Kollmorgen Essentials Drive | 6   Technical Description and Data 6.1 The Family of Kollmorgen Essentials Drives Available Kollmorgen Essentials Drive versions Connectivity Rated Voltages Current Axis Funct. Safety M: Multi-Ethernet 03: 3A S: Single 1:SIL2 STO 120/240VAC 1~ (EtherNet/IP, EtherCAT, 06: 6A Axis 240VAC 3~...
  • Page 32 Digital Inputs/Outputs (➜ # 1) Service Interface (➜ # 81) Industrial Ethernet interface (➜ # 78) Accessories Connector kit with mating connectors X3 and X10 For accessories refer to the (➜ Accessories for Kollmorgen Essentials # 123). Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 33: Ambient Conditions, Ventilation And Mounting Position

    Kollmorgen Essentials Drive | 6   Technical Description and Data 6.2 Ambient Conditions, Ventilation and Mounting Position Storage, Transport (➜ # 22) Normal operation vironmental class 3K3 according to IEC 61800-2 Surrounding 0 to +40°C under rated temperature in operation +40°C to +55°C with output current derating 2% per Kelvin...

  • Page 34: Performance Data

    Kollmorgen Essentials Drive | 6   Technical Description and Data 6.4 Performance Data Kollmorgen Essentials Drive Performance Data Units 6V03/ 6V12/ 7V06/ 6V06 7V03 7V12 High/Quiet PWM Switching Frequency (optional setting)(dynamic) Nominal/High Load PWM Switching Frequency (dynamic) High Load Stalled PWM Switching Frequency (dynamic) Max.

  • Page 35: Mains Supply Data, Dc

    Kollmorgen Essentials Drive | 6   Technical Description and Data 6.5.3 Mains supply data, DC Input data Units 6V03 6V06 6V12 7V03 7V06 7V12 Operational supply voltage (DC+ to DC-) to 370 34 to 740 Rated supply voltage 100 to 340...

  • Page 36: Output Data

    Kollmorgen Essentials Drive | 6   Technical Description and Data 6.5.4 Output data Units 6V03 6V06 6V12 7V03 7V06 7V12 Continuous output current ( ± 3%) Arms Peak output current (for 5s, ±3%) Arms Continuous motor shaft output power at rated input current at 1 x 120 VAC 0.22...

  • Page 37: Steady State Control Current Per Brake Option

    (also called regenerative resistor or brake resistor). The drive supports the ability to connect an external resistor depending on the application requirements. For more information on external regen resistors, see the (➜ Accessories for Kollmorgen NOTE Essentials # 123).

  • Page 38: Technical Data - 240V Drives

    Brake circuit * depends on connected regen resistor power. 6.7 LED and Push-button B1 The Kollmorgen Essentials Drive has an LED on its front side that indicates the status by a bi-color red-green light. Status LED Kollmorgen® | kdn.kollmorgen.com | March 2025...
  • Page 39 Kollmorgen Essentials Drive | 6   Technical Description and Data Color State Dark Control board unpowered Dark, yellow flash Control board powered, disabled, no faults, warnings Dark, green flash Control board powered, disabled, no faults, no warnings Dimly green Control board powered but still booting up...
  • Page 40 Kollmorgen Essentials Drive | 6   Technical Description and Data Push button B1 The Kollmorgen Essentials Drive has a push-button B1 on its top side. B1 Button Description Functions "Fall back" Press this button during power up to run in recovery mode. mode This mode allows for a firmware file to be downloaded through WorkBench in case the firmware in the drive has been corrupted.

  • Page 41: Mechanical Installation

    Kollmorgen Essentials Drive | 7   Mechanical Installation 7 Mechanical Installation 7.1 Important Notes 7.2 Guide to Mechanical Installation 7.3 Dimensions Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 42: Important Notes

    Kollmorgen Essentials Drive | 7   Mechanical Installation 7.1 Important Notes CAUTION High EMC Voltage Level! Risk of electrical shock, if the servo amplifier (or the motor) is not properly EMC-grounded. Use electrically conductive mounting plates, e. g. made of aluminum or galvanized steel.
  • Page 43 Kollmorgen Essentials Drive | 7   Mechanical Installation Kollmorgen Essentials Drive Parameter Unit 6V03 6V06 6V12 Weight (without mating <1.1 <1.1 <2.0 connectors) Outline width and height dimensions are measured on footprint level (mounting plate). Dimensions on the NOTE front plate are slightly smaller.

  • Page 44: Electrical Installation

    Kollmorgen Essentials Drive | 8   Electrical Installation 8 Electrical Installation 8.1 Important Notes 8.2 Guide to electrical installation 8.3 Wiring 8.4 EMI Noise Reduction 8.5 Connection Overview 8.6 Power and Logic Voltage Supply (X3/X10) 8.7 DC Bus Link Connector X3 8.8 Regen Resistor Connector X3...

  • Page 45: Important Notes

    NOTE invalidate the warranty. 8.2 Guide to electrical installation Kollmorgen recommends to install the drive electrical system as follows: 1. Select cables in accordance with IEC 60204 (➜ # 1). 2. Install shielding and ground the drive. For EMC-compliant shielding and grounding, see (➜ # 49).
  • Page 46 Kollmorgen Essentials Drive | 8   Electrical Installation Wire the Safe Torque Off (STO) inputs into the emergency off circuit of the system. Connect the digital control inputs and outputs. Connect the motor hybrid cable Connect shielding at both ends and ground cable to drive via cable clamp.

  • Page 47: Wiring

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.3 Wiring Only professional staff who is qualified in electrical engineering are allowed to install the drive. NOTICE Wires with color green with one or more yellow stripes must not be used other than for protective earth (PE) wiring.

  • Page 48: Cable And Wire Requirements

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.3.3 Cable and Wire Requirements The Kollmorgen Essentials Drive has one motor cable (X1) which you can use for all motors. For information on the chemical, mechanical, and electrical characteristics of the cable please refer to the Kollmorgen 2G Cable Guide or contact our customer support.

  • Page 49: Protective Earth Connection

    (neutral point connection). The leakage current from Kollmorgen Essentials Drive against PE is more than 3.5 mA. In accordance with EN 61800-5-1, the PE connection must therefore either be double implemented or a connection cable with >10 mm²...

  • Page 50: Shielding With External Shielding Busbar

    (➜ # 1). Use Kollmorgen cables. Route power and control cables separately, Kollmorgen recommends a distance of at least 200mm to improve interference immunity.

  • Page 51: Shielding Busbar - Tbd

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.4.2.2 Shielding Busbar - TBD The power cable shields (line in, motor cable, external regen resistor) can be routed to an additional busbar via shield clamps. Kollmorgen recommends using Weidmüller KLBÜ shield clamps.
  • Page 52 Kollmorgen Essentials Drive | 8   Electrical Installation Æ 6.2 1. Cut a busbar of the required length from a brass rail Brass, 3mm thick (cross-section 10 x 3 mm) and drill holes in it as indicated. All shield clamps required must fit between the drill holes.

  • Page 53: Shielding Connection To The Drive

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.4.3 Shielding Connection to the Drive 8.4.3.1 Shielding Concept 24 VDC Cabinet Power Supply as short as possible L 1 L 2 L 3 24 VD C O U < 3 m Mains...

  • Page 54: Grounding Shield Connection Clamp

    8.4.3.2 Grounding Shield Connection Clamp A grounding shield clamp is mounted to the drive. Kollmorgen Essentials Cables are supplied with the shield connection clamp. Push the cable into the spring clamp so that the exposed cable shield makes good contact with the shield clamp.

  • Page 55: Connector Position - Kollmorgen Essentials Drive 6V12/7V03

    Kollmorgen Essentials Drive | 8   Electrical Installation Top View X20 Service Port Workbench Connection USB-C B1 Button Status LED Front View X11, X12 RJ45 Ethernet EtherCAT, EtherNET/IP PROFINET 24V, STO Input X21 DIO Digital Input/Output Motor Power and Brake X23 Feedback...

  • Page 56: X1: Motor Power And Brake

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.5.4.1 X1: Motor power and brake X1 specifications Pinout diagram Specifications 6 pin, pitch 5.08 / 7.62mm 6 slotted conductor screws, tightening torque: 0.5-0.6 Nm 2 locking screws: 0.3Nm Motor power, motor brake X1 pinout...

  • Page 57: X10: 24 Vdc And Sto Input

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.5.4.3 X10: 24 VDC and STO input X10 specifications Pinout diagram Specifications 4x2 pin, pitch 3.5mm Spring clamps 24 VDC supply voltage, STO inputs X10 pinout Signal GND_24V +24V +24V STO-A GND_24V +24V...

  • Page 58: X20: Service

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.5.4.5 X20: Service X20 specifications Connector at Connector at Length Image Right-angle Spec Type computer drive connector at drive A male C male < 3m Data transfer and charge < 3m Data transfer and charge 8.5.4.6 X21: I/O...

  • Page 59: Power And Logic Voltage Supply (X3/X10)

    Kollmorgen Essentials Drive | 8   Electrical Installation X23 pinout Signal Description Data+ with +12V Data- with 0V 8.6 Power and Logic Voltage Supply (X3/X10) 8.6.1 Electrical Supply Connection 8.6.1.1 Connection to various mains supply networks – 240V drive An isolating transformer is required for 400 to 480V networks to get a maximum voltage of 240V NOTICE +10%.

  • Page 60: Mains Power Supply Connector X3

    Isolating transformer 8.6.2 Mains Power Supply Connector X3 Drives in the Kollmorgen Essentials Drive series can be supplied as follows: 240V drive with 3 and 6A 1, 2 or 3 phase industrial AC supply networks (TN-S or TT, see KDN): (➜ # 34) DC supply networks: (➜...

  • Page 61: Wiring Examples Mains Power Supply

    For complete information refer to WorkBench Help. You need to provide AC line filtering. Use filter type FN2090 and refer to the (➜ Accessories for Kollmorgen Essentials # 123) for more information. Use a shielded cable between filter and drive.
  • Page 62 For complete information refer to WorkBench Help. You need to provide AC line filtering. Use filter type FN2090 and refer to the (➜ Accessories for Kollmorgen Essentials # 123) for more information. Use a shielded cable between filter and drive.
  • Page 63 Kollmorgen Essentials Drive | 8   Electrical Installation DC supply Activate DC supply (VBUS.DCOPERATION = 1) and set VBUS.DCNOMINAL. You need to provide DC supply filtering. DC supply to mains lines R/T (L1/L3) DC power source is connected to the drive AC line inputs. This wiring provides soft start of the energy storage capacitors inside the drive and the AC rectifier diodes prevents motor regeneration energy from returning to the dc power source.
  • Page 64 Kollmorgen Essentials Drive | 8   Electrical Installation DC Supply to DC Bus line X3 As a user you are responsible for current and power management when NOTICE using additional external devices and when wiring DC power supply to the drive DC Bus terminal X3. For more information refer to (LINK).

  • Page 65: Fusing

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.6.2.2 Fusing Fuse types Description US fuses Class J, 600VAC, 200kA SCCR, time-delay must be UL and CSA listed Alternate fuses and breakers to Class J must have similar or better Ip and I²T performance per UL 508A SB4.2 at max.
  • Page 66 Kollmorgen Essentials Drive | 8   Electrical Installation Drive FN1, FN2, FN3: Ampere rating Example class J Example class J Model Eaton Bussmann Mersen Drive FN1, FN2, FN3: Ampere rating Semi-conductor Semi-conductor Model Eaton/Bussmann Mersen Kollmorgen® | kdn.kollmorgen.com | March 2025...
  • Page 67 Kollmorgen Essentials Drive | 8   Electrical Installation AC supply, group of drives, line fusing F1, F2, F3: depends on sum of application's required input currents and cabinet requirements. Filters for special EMC requirements only (➜ # 124). FN1, FN2, FN3 maximum rating: fuse size for group installation is limited to 30A max. and 32A max. for Semiconductor fuses.
  • Page 68 Kollmorgen Essentials Drive | 8   Electrical Installation AC supply, single drives, automatic circuit breakers F1, F2, F3: depends on the sum of application's required input currents and cabinet requirements. Filters for special EMC requirements only (➜ # 124). FN maximum rating: 30 A...
  • Page 69 Kollmorgen Essentials Drive | 8   Electrical Installation AC supply, group of drives, automatic circuit breakers F1, F2, F3: depends on sum of application's required input currents and cabinet requirements. Filters for special EMC requirements only (➜ # 124). FN maximum rating: circuit breaker size for group installation is limited to 30 A max.

  • Page 70: Auxiliary Voltage Power Supply Connector X10

    Kollmorgen Essentials Drive | 8   Electrical Installation DC supply, single drives, line fusing F1, F2, F3: depends on sum of application's required input currents and cabinet requirements. Filters for special EMC requirements only (➜ # 124). FN1, FN2 maximum rating 30A...

  • Page 71: Wiring Example 24 Vdc Supply

    (identical mains supply voltage) may have the DC bus links interconnected. Interconnection of DC bus links works best in systems powered by 3-phase AC or DC power. Consult Kollmorgen for DC bus linking with single phase AC power input. The sum of the application currents in the connected in parallel DC bus wires must NOTE not exceed 48 A.
  • Page 72 Kollmorgen Essentials Drive | 8   Electrical Installation In addition to the sum of the axes currents (I 1...n ) in parallel DC bus groupings being less than NOTE 48 A, the sum of the AC input currents (A 1...n ) must be less than 30 A (32 A when semiconductor fuses are used).

  • Page 73: Fusing

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.7.1 Fusing External regen fusing FB1/FB2 (➜ # 74). DC bus link fusing depends on topology (see (➜ # 71)). Wiring Ampere Ampere Example Eaton: Example Mersen: topology rating@240V rating@480V 240V Kollmorgen Essentials Drive Group: Fgroup max.

  • Page 74: Wiring Example With Busbar

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.7.2 Wiring example with busbar If a device fails in this system due to a short-circuit, only its fuses (Fbus) are tripped and the rest of the network continues uninterrupted. The solid busbars can conduct significantly larger currents than T connectors, because the compensating current does not flow through the connector as above.

  • Page 75: Motor Power, Brake, And Feedback Connection

    The drive is able to protect the connected motor from overloading, if the parameters are set correctly and the thermal protection sensor is connected and supervised. With Kollmorgen motors the valid data are automatically set by the WorkBench motor database. Refer to parameter AXIS#.MOTOR.RTYPE for supported thermal sensors.

  • Page 76: Motor Leads To X1 Drive Connector

    Set parameter AXISx.MOTOR.BRAKEIMM to 1 with vertical axes, to apply the brake immediately after faults or Hardware Disable. Pinout X1 Signal Description Brake positive line Brake negative line Wiring Usually the brake line is part of Kollmorgen cable connection to X1 (➜ # 1). Drive Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 77: Feedback Connector X23

    Kollmorgen Essentials Drive | 8   Electrical Installation Functionality The brake function must be enabled through a parameter. The diagram below shows the timing and functional relationships between the controlled stop signal, speed, and braking force. All values can be adjusted with parameters;...

  • Page 78: Industrial Ethernet Interface Connector

    Kollmorgen Essentials Drive | 8   Electrical Installation Feedback Type Max. cable length SFD-M 25m / 50m* SFD-3 25m / 50m* *with choke Specifications 2-wire connection with 12V signal SFD3, SFD-M and HIPERFACE DSL are supported Up to 350mA available from 11V...12V at the drive Wiring diagram The diagram below shows the connection of the two-wire SFD3/SFD-M feedback system.

  • Page 79: Ethercat

    Activity Static off: No link. Bus topology example (EtherCAT®) We suggest to use Kollmorgen ENCP cables. For more possible system solutions refer to the WorkBench Online Help. Communication profile For EtherCAT® communication profile description refer to the manual AKD2G EtherCAT® Communication .

  • Page 80: Profinet

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.11.2 PROFINET The Kollmorgen Essentials Drive can be connected as a slave to a PROFINET network by using RJ45 connectors X11 (Port 2) and X12 (Port 1). PROFINET RT or IRT protocols can be used.

  • Page 81: Service Interface Connector X20

    Link/Activity No Ethernet Connection Bus topology example (EtherNet/IP) We suggest to use Kollmorgen ENCP cables. For more possible system solutions refer to the WorkBench Online Help. 8.12 Service Interface Connector X20 The Service Interface X20 provides USB connection to a PC running WorkBench software for configuration, firmware updates and diagnostics.

  • Page 82: Network Configuration

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.12.3 Network Configuration Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 83: Connection Examples

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.12.4 Connection Examples Standard USB-C to USB-C or USB-A cable (up to 2m) d 2m Servo Drive (X20 USB-C) (USB-C or USB-A) USB Hub for connections up to 4m USB Hub Servo Drive...

  • Page 84: Digital I/O - X21

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.13 Digital I/O – X21 The drive provides 4 digital inputs and 2 digital outputs on the X21 DB9 (9-pin D-sub) port. All inputs and outputs can be used to initiate pre-programmed actions. A list of actions is included in WorkBench. If an input, or output is programmed, it must be saved to the drive.

  • Page 85: X21 Connector Pinout

    Kollmorgen Essentials Drive | 8   Electrical Installation 8.13.1 X21 Connector Pinout Control Essentials Drive +24V referred to I/O GND DIGITAL-IN1 DIGITAL-IN2 DIGITAL-IN3 DIGITAL-IN4 GND_IO I/O-GND DIGITAL-OUT1+ DIGITAL-OUT1– DIGITAL-OUT2+ DIGITAL-OUT2– Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 86: Setup

    Kollmorgen Essentials Drive | 9   Setup 9 Setup 9.1 Important Notes 9.2 Guide to Drive Setup 9.3 Switch-On and Switch-Off Behavior 9.4 Fault and Warning Messages 9.5 Troubleshooting Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 87: Important Notes

    Kollmorgen Essentials Drive | 9   Setup 9.1 Important Notes Only professional personnel with extensive knowledge in the fields of electrical engineering and drive NOTICE technology are allowed to test and set up the drive. DANGER Lethal Voltage! There is a danger of serious personal injury or death by electrical shock. Lethal danger exists at live parts of the device.

  • Page 88: Guide To Drive Setup

    I/Os) is well parameterized, then proceed with step 2. 2. Functional Safety setup (➜ # 114) . 9.2.1 Initial Drive Test Procedure 9.2.1.1 Unpacking, mounting, and wiring the Kollmorgen Essentials Drive 1. Unpack the drive and accessories. 2. Mount the drive.

  • Page 89: Confirm Connections (Example: Directly To Pc)

    Set the IP address for EtherNet/IP from the Industrial Ethernet view in WorkBench. 9.2.1.5 Install and start WorkBench WorkBench is available on the Kollmorgen website. Select the install file and follow the instructions given by the installer. Once the installation is complete, click the WorkBench icon to start the program.

  • Page 90: Enable The Axis (Hardware)

    4. Select Start. 9.2.1.9 Tune the axis Details see WorkBench Online Help 9.2.2 WorkBench Installation This chapter describes the installation of the WorkBench software for the Kollmorgen Essentials Drive. Kollmorgen offers training and familiarization courses on request. Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 91: Use As Directed

    With the software to set up your drive you can alter and save the operating parameters for the Kollmorgen Essentials Drive series. The attached drive can be set up with the help of this software. During this procedure the drive can be controlled directly by the service functions.

  • Page 92: Software Description

    An Ethernet cable connects the PC with the drive (➜ # 1), WorkBench establishes the communication between PC and drive. Please find the software to set up your drive in the download area of the Kollmorgen website. With WorkBench you can...

  • Page 93: Installation Under Windows 7/8/10/11

    Kollmorgen Essentials Drive | 9   Setup 9.2.2.5 Installation under Windows 7/8/10/11 Use WorkBench to setup your drive. You can download the latest version from the Kollmorgen website. Install the WorkBench as follows: 1. Download one of the following installation packages from www.kollmorgen.com: Standard installation: Contains the application with complete help files.
  • Page 94 Kollmorgen Essentials Drive | 9   Setup Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 95: Switch-Off Behavior

    Kollmorgen Essentials Drive | 9   Setup 9.3.2 Switch-off Behavior The drive’s 24V supply must remain constant. STO disables the power stage immediately. Configured NOTE digital inputs and fieldbus commands can be used to perform controlled stops. 9.3.2.1 Switch-off behavior using the AXIS#.DIS command The enable/disable button in WorkBench issues a AXIS#.DIS command internally to the drive.

  • Page 96: Switch-Off Behavior Using A Digital Input (Controlled Stop)

    Kollmorgen Essentials Drive | 9   Setup 9.3.2.2 Switch-off behavior using a digital input (controlled stop) This is a category 1 stop according to IEC 60204 (➜ # 19). A digital input can be configured to bring the motor to a controlled stop and then disable the drive and apply the holding brake (if present).

  • Page 97: Switch-Off Behavior In The Event Of A Fault

    Kollmorgen Essentials Drive | 9   Setup 9.3.2.4 Switch-off behavior in the event of a fault The behavior of the drive always depends on the fault type and the setting of a number of different parameters (AXIS#.DISMODE, VBUS.UVFTHRESH, AXIS#.ZEROV, and others; see the WorkBench Online Help for more details).
  • Page 98 Kollmorgen Essentials Drive | 9   Setup Switch-off behavior for faults that cause dynamic braking This is a category 2 stop according to IEC 60204 (➜ # 19). If the drive detects the motor to be at zero velocity (AXIS#.ZEROV) or timeout occurs (AXIS#.ZEROT), the motor brake is applied (➜...

  • Page 99: Fault And Warning Messages

    Kollmorgen Essentials Drive | 9   Setup Switch-off behavior for faults that cause a controlled stop This is a category 2 stop according to IEC 60204 (➜ # 19). If the drive detects the motor to be at zero velocity (AXIS#.ZEROV) or timeout occurs (AXIS#.ZEROT), the motor brake is applied (➜...

  • Page 100: Troubleshooting

    Kollmorgen Essentials Drive | 9   Setup Group Group System Feedback (# indicates feedback number) File Motor Hardware Wake and Shake Power Motion Temperature Fieldbus Software Safety The following ways will help you identify a system failure: 1. Visible inspection: See status LED on the front side of the drive (➜ # 38).
  • Page 101 Kollmorgen Essentials Drive | 9   Setup Problem Possible Causes Remedy 1. wrong cable used, cable plugged 1. plug cable into the correct sockets on the drive HMI message: into wrong position on drive or PC and PC Communication fault 2. wrong PC interface selected 2.

  • Page 102: Safety Manual For Fs1

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10 Safety Manual for FS1 Revision History for Safety Manual Revision Remarks S101, ??/2025 Functional Safety Option 1 The Safety Manual is valid for: Kollmorgen Essentials Drive with Functional Safety Option 1 (FS1) KED - xxx - xxxxx - x1xx - xxxx Safety Functions: STO;...
  • Page 103 Kollmorgen Essentials Drive | 10   Safety Manual for FS1 Contents: 10.1 General Notes 10.2 Verification 10.3 Safety Function Option 1 (I/O, SIL2 PLd) 10.4 Settings 10.5 Safety Faults, Safety Warnings 10.6 Functional Safety Parameter Reference Kollmorgen | kdn.kollmorgen.com | BETA VERSION,...

  • Page 104: General Notes

    The safety properties listed in this chapter can be reached with Kollmorgen components. Ensure the compliance of the application with all relevant directives and local electrical code. NOTICE You are responsible for implementation and validation of the drive system and safety system.

  • Page 105: Use As Directed

    Therefore, the drive may only be opened by authorized specialist personnel. Kollmorgen can't be held accountable for any defects, malfunctions or degradations resulting from users opening up the device. In case of damage or malfunction, send the drive for repair or replacement.

  • Page 106: Abbreviations Used For Functional Safety

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.1.3 Abbreviations used for functional safety More abbreviations see (➜ # 11). Abbreviation Meaning A# or AXIS# are placeholders for the axis number. Used with parameters A#, AXIS# (AXIS#.SAFE.STO.ACTIVE) or signal names (STO-A-A#) (➜...

  • Page 107: Enclosure, Wiring

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.1.4 Enclosure, wiring Enclosure Since the drive meets IP20, you must select an enclosure that permits safe operation of the drive. The enclosure must at least meet IP54 . Transport in accordance with IEC 61800-2 Transport only in the manufacturer’s original recyclable packaging.

  • Page 108: Verification

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.2 Verification Check and verify the STO wiring (examples (➜ # 110)). The installation must be verified by trained personnel after any changes to the installation. The expertise of the personnel must be appropriate to the complexity and safety integrity level of the drive system.

  • Page 109: Safety Function Option 1 (I/O, Sil2 Pld)

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.3 Safety Function Option 1 (I/O, SIL2 PLd) The safety function STO on the Kollmorgen Essentials Drive with functional safety option 1 is certified. The drive is ready to operate with pre-configured STO NOTICE function.

  • Page 110: Sto (Safe Torque Off)

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 For parameter description refer to the Safety Parameters Reference Guide (➜ # NOTE 117). Factory Default Settings The drive is ready to operate with pre-configured STO function. AXIS1.SAFE.STO.REPORTFAULT is set to 1.

  • Page 111: Restart

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.3.3.3 Restart Examples AXIS1.SAFE.STO. AXIS1.SAFE.STO. REPORTFAULT = 1 REPORTFAULT = 0 Example 1: Message W9000 Restart: Axis 1 was disabled, STO is activated Restart: 1. deactivate STO 1. deactivate STO 2. enable axis 1 2.

  • Page 112: Timing

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.3.3.4 Timing Example. Timing Remarks STO channel A enabled (0 V) t1 to t2 STO enable delay (response time) STO active STO channel B enabled (0 V) t1 to t3 accepted delay between dual channel edges...

  • Page 113: Fault Reaction / Failure Messages

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.3.3.6 Fault Reaction / Failure Messages With the dual-channel control of the STO (SIL2/PLd Cat.3) safety function, the switch-off paths STO-A-A# and STO- B-A# are switched separately by two outputs of a safety controller.

  • Page 114: Settings

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.4 Settings Push button B1 The Kollmorgen Essentials Drive has a push-button B1 on its top side. Description Functions "Fall back" Press this button during power up to run in recovery mode. mode This mode allows for a firmware file to be downloaded through WorkBench in case the firmware in the drive has been corrupted.

  • Page 115: Safety Faults, Safety Warnings

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.5 Safety Faults, Safety Warnings The Kollmorgen Essentials Drive with safety option 1 does not have safety failure modes. Kollmorgen | kdn.kollmorgen.com | BETA VERSION, March 2025...

  • Page 116: Drive Safety Faults

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.5.1 Drive Safety Faults More information about drive fault messages, remedy and clearing faults can be found in the WorkBench NOTE User Manual. Fault Description Cause Remedy STO function has been triggered while the axis is See (➜...

  • Page 117: Functional Safety Parameter Reference

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.6 Functional Safety Parameter Reference Abbreviations Acc. = Access: RO = Read Only, RW = Read/Write, WO = Write Only N/A = Not Available, Y = Yes, N = No Parameters are sorted alphanumerically...

  • Page 118: Safety Parameters, Sorted Alphanumeric

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.6.1 Safety Parameters, sorted alphanumeric Kollmorgen | kdn.kollmorgen.com | BETA VERSION, March 2025...

  • Page 119: Axis#.Safe.sto.a

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.6.1.1 AXIS#.SAFE.STO.A Description Indicates the state for STO-A input. Value Description 24V present (STO inactive, allowed to enable) 24V not present (STO active, axis disabled) Context For complete STO information refer to " STO (Safe Torque Off)" (➜ # 110).

  • Page 120: Axis#.Safe.sto.b

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.6.1.2 AXIS#.SAFE.STO.B Description Indicates the state for STO-B input. Value Description 24V present (STO inactive, allowed to enable) 24V not present (STO active, axis disabled) Context For complete STO information refer to " STO (Safe Torque Off)" (➜ # 110).

  • Page 121: Axis#.Safe.sto.active

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.6.1.3 AXIS#.SAFE.STO.ACTIVE Description Indicates the Safe Torque Off (STO) state of the axis. Value Description STO active (inputs +0V) STO inactive (inputs 24V) Context For complete STO information refer to " STO (Safe Torque Off)" (➜ # 110).

  • Page 122: Axis#.Safe.sto.reportfault

    Kollmorgen Essentials Drive | 10   Safety Manual for FS1 10.6.1.4 AXIS#.SAFE.STO.REPORTFAULT Description This parameter controls whether a Safe Torque Off (STO) fault F9000 will be created when STO is activated while the axis is enabled. The STO warning W9000 is always generated if this parameter is 1 and the STO function is active.

  • Page 123: Accessories For Kollmorgen Essentials

    Kollmorgen Essentials Drive | 11   Accessories for Kollmorgen Essentials 11 Accessories for Kollmorgen Essentials This section is in progress. Kollmorgen | kdn.kollmorgen.com | BETA VERSION, March 2025...

  • Page 124: Approvals - Tbd

    Kollmorgen Essentials Drive | 12   Approvals – TBD 12 Approvals – TBD If the drive is labeled Beta, approvals are pending. NOTICE Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 125: Index

    Kollmorgen Essentials Drive | 13   Index Mechanical Software WorkBench 13 Index Installation, Setup, Normal Operation Leakage current Abbreviations 11, 106 Ambient Conditions Aux. supply 24V, interface Mains supply, interface Maintenance Mating Connectors Cable and Wire Requirements Mechanical Data Commissioning Motor Holding Brake Connection...
  • Page 126 Kollmorgen Essentials Drive | 13   Index Shielding Shock-hazard protection Site Stop Function Switch-on, switch-off behavior Symbols used Trouble Shooting Use as directed Drive Functional Safety WorkBench Setup Software Ventilation Verification Warning Messages Warning note labels Wiring Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 127: Record Of Document Revisions

    Kollmorgen Essentials Drive | 14   Record of Document Revisions 14 Record of Document Revisions Edition Remarks A, WIP First edition Table with lifecycle information of this document (➜ # 1) Kollmorgen® | kdn.kollmorgen.com | March 2025...

  • Page 128: Support And Services

    When you need motion and automation systems for your most demanding applications and environments, count on Kollmorgen - the innovation leader for more than 100 years. We deliver the industry’s highest-performing, most reliable motors, drives, AGV control solutions and automation platforms, with over a million standard and easily modifiable products to meet virtually any motion challenge.

This manual is also suitable for:

Essentials ked-6v06Essentials ked-6v12Essentials ked-7v03Essentials ked-7v06Essentials ked-7v12

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